Abstract: Tooth surface waviness of gears is a key excitation source of whining noise in the gear transmission system of new energy vehicle reducers. The control of machined tooth surface waviness was investigated based on the continuous generating grinding process with a worm grinding wheel. Firstly, through a split-plot experimental design, the factors found to significantly affect tooth surface waviness were wheel dressing speed, grinding allowance, and axial grinding feed rate. Secondly, the different effects of grinding process parameters on various characteristics of tooth surface waviness were analyzed based on the experimental results. Thirdly,a linear model was established to describe the relationship between the key process parameters and tooth surface waviness, and the optimal combination of process parameters was obtained. The measurement results of the machined specimens further verified the rationality and effectiveness of the established model. Finally, after process parameter optimization, the overall amplitude of gear tooth surface waviness was reduced by 37.4%, providing a technical basis and practical guidance for optimizing the worm wheel grinding process toward tooth surface waviness control.