At the present, the trial grinding method is mainly used to compensate the error for continuous generating grinding machine which requires dressing the wheel for many times. However, the problems of long trial grinding time, high cost in wheels and limitation of precision remain. To solve these problems, a new error compensation method for continuous generating grinding machine based on virtual-axis is proposed in this paper. Firstly, for the condition that the distribution of the movement error of CNC axes cannot be achieved according to the tooth surface error by measurement, the machine tool errors are divided into generating motion error (motion error of Y-axis, Z-axis, B-axis, and C-axis) and error of X-axis. Then, a corresponding mathematical model is established. Finally, two virtual-axes are established coinciding with C-axis and X-axis respectively and the error compensation of all axes for grinding process is completed. The method can compensate the tooth surface error point-to-point according to the off-line measurement result, which has the advantages of short trial grinding time, low cost, and high precision.
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