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Shaving Techniques for Cylindrical Gears

This document discusses various types of gears and gear cutting methods. It describes cylindrical gears including spur and helical gears. It also describes bevel gears which can be straight or curved, as well as worm wheels and worms. The main gear cutting methods discussed are hobbing, shaping, broaching, grinding, and lapping. Hobbing uses a hob cutter in a generating process to cut gear teeth. Shaping also uses a generating process with either a circular or rack cutter. Broaching cuts gear teeth from a pre-machined hole. Grinding and lapping are finishing processes used to improve the surface quality of hardened gears. The document provides examples and illustrations of the different gear types and cutting methods.

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madream7
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301 views44 pages

Shaving Techniques for Cylindrical Gears

This document discusses various types of gears and gear cutting methods. It describes cylindrical gears including spur and helical gears. It also describes bevel gears which can be straight or curved, as well as worm wheels and worms. The main gear cutting methods discussed are hobbing, shaping, broaching, grinding, and lapping. Hobbing uses a hob cutter in a generating process to cut gear teeth. Shaping also uses a generating process with either a circular or rack cutter. Broaching cuts gear teeth from a pre-machined hole. Grinding and lapping are finishing processes used to improve the surface quality of hardened gears. The document provides examples and illustrations of the different gear types and cutting methods.

Uploaded by

madream7
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
  • Gear Types
  • Involute Tooth Profile
  • Gear Cutting Methods
  • Broaching
  • Finishing Gear Teeth
  • Cutting Bevel Gears
  • Worms and Worm Gears
  • Closing Remarks

1

GEAR TYPES
Cylindrical gears:
- spur
- helical
Bevel gears:
- straight
- curved (spiral)
Worm wheels and worms
2
Involute tooth profile
3
Spur and helical gears cutting
METHODS:
form milling using a cutter (with the same
edge profile as the shape of the tooth space)
and a dividing device
hobbing using a hob and a generating
process for creating a tooth profile
shaping using a shaper cutter and a
generating process for creating a tooth profile
broaching
4
Gear machining form milling
(single gear tooth cutter)
5
Gear machining form milling
6
Gear machining - hobbing
Hob a tool designed as a worm shaped
cutter, which acts by the cutting as a worm
cooperating with the machined gear wheel
7
Hobbing cutter
8
Gear hobbing
9
Gear hobbing
10
Gear hobbing machine tool
11
Gear hobbing machine tool
12
Gear hobbing kinematic schema
13
Gear machining - shaping

circular shaper
cutter

rack shaper cutter

14
Gear shaping a circular cutter
15
Gear shaping a circular cutter
16
Gear shaping the principle
17
Gear shaping a circular cutter
18
Gear shaping a rack cutter
19
Gear shaper with the rack cutter
Broaching
Very productive method
Broach has the shape of gear
Ideal for internal gears
Tooth gaps one after another
All gaps simultaneously
Desc.:
1 elongated body, 2 teeth, 3
gullets, 4 teeth gaps, 5 axis, 6
follower end, 7 pull end, 10
outside shape of broach
Broaching
From a premachined hole a final gear is made
22
Spur and helical gears finishing
METHODS:
shaving for gears without heat treatment
grinding mostly for gears after heat
treatment
- form grinding
- involute - generating grinding
lapping
teeth rounding creating a shape of tooth
(in the direction parallely to the axis of
rotation) to make changing gears easier
23
GEAR WHEELS SHAVING
A gear wheel being shaved is
run in contact with a
shaving cutter
Shaving cutter HSS tool;
teeth with serrations, which
are acting in the shaving
24
GEAR WHEELS SHAVING
The gear and the cutter are run in mesh with their
axes crossed at a small angle. During the rotation the
gear is reciprocated longitudinally across the cutter.
This shaving process causes very fine chips are cut
from the tooth surface (process requires less than 1
minute)
25
Form gear grinding
26
Form splining grinding
27
Involute-generating grinding
28
Involute-generating grinder
29
Involute-generating grinder
Gear lapping
On finished, shaved and hardened gears.
The gear runs in contact with one or more cast
iron lapping gears
Flow of oil with abrasive is used
Improves surface quality at low costs then
grinding
Ra = 0,1 0,2
31
Teeth rounding
32
Teeth rounding
33
Straight bevel gears cutting
METHODS:
form milling using a cutter (with the same
form as the tooth face) and creating first one,
than the opposite face flank of the tooth
involute-generating milling using two
cutters representing one tooth of a rack and a
generating process for creating a tooth profile
shaping using a shaping rack tool and a
generating process for creating a tooth profile
broaching using rotational broach
34
Straight bevel gears
involute-generating milling
35
Straight bevel gears - shaping
36
Straight bevel gears - broaching
37
Straight bevel gears - broaching
38
Curved bevel gears cutting
METHODS:
Gleason teeth curved in the form of
circle
Oerlikon teeth curved in the form of
epicycloid
Klingelnberg teeth curved in the
form of involute
Gleason method
Tool is a composition of a
round body and cutting
tools. The can be
adjusted separatelly.
40
Curved bevel gears - Oerlikon
41
Curved bevel gears - Oerlikon
Worms and worm gears
Worms produced by turning or form milling
Worms and worm gears
Worm gears produced by hobbing
Worm hob has a small diameter
In feed machining
THANK YOU

1 GEAR TYPES • Cylindrical gears: - spur - helical • Bevel gears: - straight - curved (spiral) • Worm wheels and worm
2 Involute tooth profile
3 Spur and helical gears cutting METHODS: • form milling – using a cutter (with the same edge profile as the shape of the
4 Gear machining – form milling (single gear tooth cutter)
5 Gear machining – form milling
6 Gear machining - hobbing • Hob – a tool designed as a worm shaped cutter, which acts by the cutting as a worm cooperati
7 Hobbing cutter
8 Gear hobbing
9 Gear hobbing
10 Gear hobbing machine tool

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