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Gear Cutting/Manufacturing
Published in Zainul Huda, Machining Processes and Machines, 2020
It has been learnt in Section 10.2 that gear shaping is a gear generation process that results in the machined part’s geometry dictated by the relative motion of work and cutter. Gear shaping is used for cutting external gears, internal gears (or splines), face gears, worm gears, racks, and the like. In gear shaping, the cutter axis and the work (gear blank) axis are parallel to each other. The shaping cutting tool (cutter) is mounted on a spindle that has three types of motion: (a) axial reciprocating (primary) motion, (b) rotatory generating motion, and (c) feed motion (see Figure 10.7). The work spindle rotates slowly and is synchronized with the cutter spindle. The cutter is fed into the work and moves down for cutting stroke; then it is withdrawn and raised for return stroke. The synchronized rotations of work and tool result in the next tooth cutting, as illustrated in Figure 10.7). In this way, all the teeth on the work (gear blank) are successively cut.
Gear-Cutting Machines and Operations
Published in Helmi Youssef, Hassan El-Hofy, Traditional Machining Technology, 2020
Because tooling cost is relatively low, gear shaping is practical for any production volume. WP design often prevents the use of milling cutters or hobs (e.g., cluster gears), and shaping is the most practical method for such cases (Figure 6.17a). Shaping can also be applied in cutting a worm (Figure 6.17b) where the cutter involves no axial stroke. Figure 6.18 shows a simplified kinematic diagram and mechanical drives of a gear shaper. Table 6.2 illustrates some typical products produced on the Liebherr gear shaper WS1. The examples quoted are typical of the requirement of mass production. The table shows the product specifications, tooling, machining data, and the machining time, which ranges from 0.3 to 1.2 min.
Gear Shaper Cutters I: External Gear Machining Mesh
Published in Stephen P. Radzevich, Gear Cutting Tools, 2017
Gear shaping operation is a type of continuous indexing method of gear machining. The kinematics of the machining process of a work gear with the gear shaper cutter is illustrated in Figure 10.3. When shaping a gear using the gear shaper cutter, the work gear is rotating about its axis of rotation Og. The gear shaper cutter is rotating about its axis of rotation Oc. The rotation of the gear ωg is synchronized with the rotation of the gear shaper cutter ωc so that the ratio ωg/ωc = Nc/Ng is valid.
Modeling and experimental verification of cutting forces in gear tooth cutting
Published in Machining Science and Technology, 2018
There are some works available in the literature related to the estimation of cutting forces in gear cutting. Erkorkmaz et al. (2016) performed a study to predict the chip geometry and cutting forces in gear shaping. They utilized a discrete model and used the removed material geometry in the prediction of cutting forces. Habibi and Chen (2016) presented a study in which the projection of the instantaneous undeformed chip geometry is derived semianalytically and the cutting forces are predicted in face hobbing of bevel gear. Sabkhi et al. (2016) presented a mechanistic approach to predict cutting force components generated during the hobbing process. Dimitriou and Antoniadis (2009) proposed a computer aided design (CAD)-based simulation program used for the simulation of the gear hobbing process, for the manufacturing of spur and helical gears.