Gearing Basic（10）

10．Gear Cutting & Grinding

 10.1 Gear hobbing
 10.2 Gear shaping
 10.3 Gear shaving
 10.4 Gear grinding
 10.5 Gear skiving

Methods of Making Gear Teeth

（*）

(*) Darle W. Dudley, Handbook of Practical Gear Design, 1984, McGraw-Hill Book Company
 Hob Cutter

A hob has a series of rack teeth arranged in a spiral

around the outside of a cylinder, then hob rotation
is transformed to rack translation.

Fig. Vocabulary(*)
(*) http://www.hssforum.com/GearCuttingEN.pdf

Hobbing

Throughout the hobbing

hob
process, the gear blank
cutter
and the hob rotate in
climb continuous coordinated
movement. A linear feed
is also applied.

depth of cut conventional

Fig. Dry hobbing(*)

A hob needs clearance to run-out at the end of the cut. If

the gear teeth come too close to a shoulder or other
obstruction, it may be impossible to cut the part by hobbing.

(*) YouTube
 Conventional & Climb Cut

(*) (*)

Table Merits & demerits(**)

tool wear ○
chip discharge ○
○ cut surface △

(*) http://www.hssforum.com/GearCuttingEN.pdf
(**) Mitsubishi Materials

Variety of Hob Cutters

Fig. Solid hob(*) Fig. Segmented hob(*)

Fig. Normal section of hob tooth profile(*)

(*) http://www.hssforum.com/GearCuttingEN.pdf
 Gear Shaping

The shaper cuts while traversing across the facewidth

and rolling with the gear blank at the same time.

Fig. Gear shaping(**) Fig. Concept of gear shaping(*)

(*) http://www.hssforum.com/GearCuttingEN.pdf
(**) YouTube

Pinion Cutter

Fig. Vocabulary(*)

Fig. Helical gear shaper cutter(*) (*) http://www.hssforum.com/GearCuttingEN.pdf

 Variety of Pinion Cutters

Fig. Disk shaper cutter for shoulder gears(*) Fig. Shank type shaper cutter
for internal gears(*)

Fig. Disk shaper cutter(*) Fig. Shank type shaper cutter(*)

(*) http://www.hssforum.com/GearCuttingEN.pdf

Gear Shaving

Gear shaving is a finishing operation, taking place after

roughing with a hob or a shaper cutter. It uses a serrated gear-
shaped cutter to shave off small amounts of metal.

Fig. Gear shaving(**) Fig. Concept of gear shaving(*)

(*) http://www.hssforum.com/GearCuttingEN.pdf
(**) YouTube
 Shaving Cutter

Fig. Disk shaper cutter(*)

(*) http://www.hssforum.com/GearCuttingEN.pdf

Shaving Methods(*)（I）

(*) https://www.mhi-machinetool.com/en/products/detail/gear_shaving_cutter.html
 Shaving Methods(*)（II）

(*) https://www.mhi-machinetool.com/en/products/detail/gear_shaving_cutter.html

Variety of Gear Grindings（I）

Fig. Reishauer Type(*)

Fig. Maag Type(*)

(*) YouTube
Variety of Gear Grindings（II）

Fig. Kapp Type(*)

Fig. Fässler Type(*)

(*) YouTube

Gear Skiving(*)

(*) YouTube
 Summary

This chapter has introduced the following:

1. gear hobbing and shaping as rough
cutting methods
2. gear shaving as a finishing method
3. various gear grinding methods
4. gear skiving

Gearing Basic（11）

11．Gear Inspection
 11.1 Profile & helix deviations
 11.2 Pitch deviations
 11.3 Measurement of tooth thickness
 11.4 Measurement of runout
 11.5 Radial composite deviation
 11.6 Single flank gear tester
 11.7 Traceability
 i) Design profile: unmodified involute
Actual profile: with minus material deviations in the reduction zone

Involute Profile Measurement

ii) Design profile: modified involute (example)
Actual profile: with minus material deviations in the reduction zone

iii) Design profile: modified involute (example)

Actual profile: with excess of material in the reduction zone

Tip Root Tip Root Tip Root

A E F A F A F
t-t
----------
i I I I + i I

LAE
I- . ==I I
LAF LAF
a - -

A E F A E F A E F

I LAE I
-1

LAF LAF
ii) - w 4 -

A ----- E F A + E F
---7 I

ffα
IS0 1328=1:1995(E)
I I
L AF LAF LAF
iii) fi - - - C

a) Total profile deviation b) Profile form deviation c) Profile slope deviation

(*)
Figure 2 - Profile deviations (**)

-------- : Design helix f : Actual helix ---B-B----------. -

. Mean helix
(*) Yefim Kotlyar, Involute Inspection Methods and Interpretation of Inspection Results, July/August 1997, Gear technology
(**) ISO 1328-1:1995

i) Design helix: unmodified helix

Actual helix: with minus material deviations in the reduction zone

Helix Measurement
ii) Design helix: modified helix (example)
Actual helix: with minus material deviations in the reduction zone

modified helix (example)

iii) Design helix: Actual helix:
with excess of material in the reduction zone

t-t---------
I II I II I II

--l-i
---------

- LB ~
I ’ ’ 1
b b
i)

I II I II
----

t
CT
c
b I( 4

Fig. Concept of helix measurement(*)

b
ii)

I II
ffα

LP
b
iii>

a) Total helix deviation b) Helix form deviation c) Helix slope deviation

Figure 3 - ltielix deviations (**)

(*) JIS B 1752-1989

(**) ISO 1328-1:1995

5
 Measurement of Tooth Spacing
approximately mid-depth
of the teeth

(**)

(*)

total cumulative pitch deviation (Fp)

the number of pitches (k) ranges from 2
Maximum cumulative pitch deviation of to the number nearest to z/8
any sectors (with k = 1 up to k = z)

(*) Darle W. Dudley, Handbook of Practical Gear Design, 1984, McGraw-Hill Book Company
(**) ISO/TR 10064-1:1992

from JIS B 1752-1989

(µm)
indicator cumulative adjacent cumulative cumulative
teeth no. pitch dev.
value value pitch dev. mean dev.
1-2 4 4 2 2 2.33×1! 2 2
2-3 6 10 4 3 2.33×2 ! 5 5
3-4 9 19 7 2 2.33×3 ! 7 12
4-5 7 26 5 7 2.33×4 ! 9 17
5-6 0 26 -2 3 2.33×5 !12 14
6-7 -3 23 -5 6 2.33×6 !14 9
7-8 3 26 1 1 2.33×7 !16 10
8-9 2 28 0 6 2.33×8 !19 9
9 - 10 -4 24 -6 0 2.33×9 ! 21 3
10 - 11 -4 20 -6 3 2.33×10 ! 23 -3
11 - 12 -1 19 -3 8 2.33×11! 26 -7
12 - 13 7 26 5 7 2.33×12 ! 28 -2
13 - 14 0 26 -2 4 2.33×13 ! 30 -4
14 - 15 4 30 2 1 2.33×14 ! 33 -3
15 - 1 5 35 3 1 2.33×15 ! 35 0

35
! 2.33 ! 2 17 −(−7) = 24
15
 Checking Tooth Thickness

(*)

(*)

(*) ISO 21771:2007

Runout & Radial Composite Dev.

(*)

(*)

(*)

(*) ISO/TR 10064-2:1996

Single Flank Gear Tester

(*)

(*) Darle W. Dudley, Handbook of Practical Gear Design, 1984, McGraw-Hill Book Company

Tooth Contact Patterns

(*)
(*)

(*)
(*)

(*) ISO/TR 10064-4:1998

 Traceability

(*)

(*) ISO 18653:2003

Summary

This chapter has introduced the following:

1. measurement of involute profile, helix
and tooth spacing
2. measurement of tooth thickness
3. measurement of runout, radial
composite deviation
4. single flank tester
5. traceability of measurement