Gear Cutting Tools : Fundamentals of Design and Computation
23 Feb 2010-
TL;DR: In this article, the authors present a framework for the design of a single-parametric motes for the development of a cutting tool for a given gear, which is used in the context of form-gear cutting tools.
Abstract: Part I: Basics Gears: Geometry of the Tooth Flanks Basic Kinds of Gears Analytical Description of Gear Tooth Flanks Gear Tooth Surfaces those Allowing Sliding Over Them Principal Kinematics of Gear Machining Operations Relative Motions in Gear Machining Rolling of the Conjugate Surfaces Kinematics of Continuously Indexing Methods of Gear Machining Processes Vectorial Representation of the Gear Machining Mesh Kinematic Relationships for the Gear Machining Mesh Configuration of the Vectors of Relative Motions Kinematics of Gear Machining Processes Elements of Coordinate Systems Transformations Coordinate Systems Transformation Conversion of the Coordinate System Orientation Direct Transformation of Surfaces Fundamental Forms Part II: Form Gear Cutting Tools Gear Broaching Tools Kinematics of the Gear Broaching Process Generating Surface of a Gear Broach Cutting Edges of the Gear Broaching Tools Chip Removal Diagrams Sharpening of Gear Broaches A Concept of Precision Gear Broaching Tool for Machining Involute Gears Application of Gear Broaching Tools Shear-Speed Cutting Rotary Broaches: Slater Tools Broaching Bevel Gear Teeth End-Type Gear Milling Cutters Kinematics of Gear Cutting with End-Type Milling Cutter Generating Surface of the End-Type Gear Milling Cutter Cutting Edge of the End-Type Gear Milling Cutter Accuracy of the Gear Tooth Flanks Machined with End-Type Milling Cutter Application of the End-Type Gear Milling Cutters Disk-Type Gear Milling Cutters Kinematics of Gear Cutting with Disk-Type Milling Cutter Generating Surface of the Disk-Type Gear Milling Cutter Cutting Edges of the Disk-Type Gear Milling Cutter Profiling of the Disk-Type Gear Milling Cutters Cutting Edge Geometry of the Disk-Type Milling Cutter Disk-Type Milling Cutters for Roughing of Gears Accuracy of the Gear Tooth Flanks Machined with the Disk-Type Milling Cutters Application of Disk-Type Gear Milling Cutters Nontraditional Methods of Gear Machining with Form Cutting Tools Plurality of Single-Parametric Motions Implementation of the Single-Parametric Motions for Designing of Form Gear Cutting Tool Diversity of Form Tools for Machining a Given Gear On Classification of Form Gear Tools Part III: Cutting Tools for Gear Generating Parallel-Axis Gear Machining Mesh Kinematics of the Parallel-Axis Gear Machining Mesh Rack Cutters for Planing of Gears Generating Surface of Rack Cutter On the Variety of Feasible Tooth Profiles of the Rack Cutters Cutting Edges of the Rack Cutter Profiling of the Rack Cutters Cutting Edge Geometry of the Rack Cutter Chip Thickness Cut by Cutting Edges of the Rack Cutter Tooth Accuracy of the Machined Gear Application of the Rack Cutters Potential Methods of Gear Cutting and Designs of Rack-Type Gear Cutting Tools Gear Shaper Cutters I: External Gear Machining Mesh Kinematics of Gear Shaping Operation Generating Surface of Gear Shaper Cutter Cutting Edges of the Shaper Cutter Profiling of Shaper Cutters Critical Distance to the Nominal Cross-Section of the Shaper Cutter The Cutting Edge Geometry of a Shaper Cutter Tooth Desired Corrections to the Shaper Cutter Tooth Profile Thickness of Chip Cut by Shaper Cutter Tooth Accuracy of Gears Cut with the Shaper Cutter Application of Gear Shaper Cutters Gear Shaper Cutters II: Internal Gear Machining Mesh Kinematics of Shaping Operation of an Internal Gear Design of Shaper Cutters Thickness of Chip Cut by the Gear Shaper Cutter Tooth Accuracy of the Shaped Internal Gears Enveloping Gear Shaper Cutters Application of Gear Shaper Cutters Part IV: Cutting Tools for Gear Generation Intersecting-Axis Gear Machining Mesh Kinematics of the Intersecting-Axis Gear Machining Mesh Gear Shapers with Tilted Axis of Rotation Kinematics of Gear Shaping Operation with the Shaping Cutters Having Tilted Axis of Rotation Determination of Generating Surface of a Shaper having Tilted Axis of Rotation Illustration of Capabilities of the External Intersecting-Axis Gear Machining Mesh Gear Cutting Tools for Machining Bevel Gears Principal Elements of Kinematics of Bevel Gear Generation Geometry of the Interacting Tooth Surfaces Peculiarities of Generation of Straight Bevel Gears with Offset Teeth Generation of Straight Bevel Gear Teeth Peculiarities of Straight Bevel Gear Cutting Milling of Straight Bevel Gears Machining of Bevel Gears having Curved Teeth Gear Shaper Cutters Having Tilted Axis of Rotation: Internal Gear Machining Mesh Principal Kinematics of Internal Gear Machining Mesh Peculiarities of Design of Gear Cutting Tools Part V: CUTTING TOOLS FOR GENERATING OF GEARS: Spatial Gear Machining Mesh Section V-A: Design of Gear Cutting Tools: External Gear Machining Mesh Generating Surface of the Gear Cutting Tool Kinematics of External Spatial Gear Machining Mesh Auxiliary Generating Surface of the Gear Cutting Tool Examples of Possible Kinds of Auxiliary Generating Surfaces of Gear Cutting Tools Generation of Generating Surface of a Gear Cutting Tool Use of the DG-Based Methods for the Determination of the Design Parameters of Generating Surfaces of the Gear Cutting Tools Possible Kinds of Generating Surfaces of Gear Cutting Tools Constraints on the Design Parameters of Generating Surface of a Gear Cutting Tool Hobs for Machining Gears Transformation of the Generating Surface into a Workable Gear Cutting Tool Geometry and Generation of Rake Surface of a Gear Hob Geometry and Generation of Clearance Surfaces of Gear Hobs Accuracy of Hobs for Machining of Involute Gears Design of Gear Hobs The Cutting Edge Geometry of a Gear Hob Tooth Constraints on the Parameters of Modification of the Hob Tooth Profile Application of Hobs for Machining Gears Gear Shaving Cutters Transformation of Generating Surface into a Workable Gear Shaving Cutter Design of Gear Shaving Cutters Axial Method of Gear Shaving Process Diagonal Method of Gear Shaving Process Tangential Method of Gear Shaving Process Plunge Method of Gear Shaving Process Advances in Design of Shaving Cutter Peculiarities of Gear Shaving Process Examples of Implementation of the Classification of Kinds of the Gear Machining Meshes A Hob for Tangential Gear Hobbing A Hob for Plunge Gear Hobbing Hobbing of a Face Gear A Worm-Type Gear Cutting Tool Having the Continuous HS-Cutting Edge Cutting Tools for Scudding Gears A Shaper Cutter with the Tilted Axis of Rotation for Shaping Cylindrical Gears A Gear Cutting Tool for Machining a Worm in Continuously Indexing Method Rack Shaving Cutters A Tool for Reinforcement of a Gear by Surface Plastic Deformation Conical Hob for Palloid Method of Gear Cutting Section V-B: Design of Gear Cutting Tools: Quasi-Planar Gear Machining Mesh Kinematics of Quasi-Planar Gear Machining Mesh Gear Cutting Tools for Machining Bevel Gears Design of a Gear Cutting Tool for Plunge Method of Machining of Bevel Gears Face Hob for Cutting Bevel Gear More Possibilities for Designing Gear Cutting Tools Based on Quasi-Planar Gear Machining Mesh Section V-C: Internal Work-Gear to Cutting Tool Mesh Kinematics of Internal Spatial Work-Gear to Cutting Tool Mesh Gear Cutting Tools Featuring Enveloping Generating Surface Gear Cutting Tools having a Cylindrical Generating Surface Gear Cutting Tools having Conical Generating Surface Gear Cutting Tools having a Toroidal Generating Surface Gear Cutting Tools for Machining Internal Gears Principal Design Parameters of a Gear Cutting Tool for Machining an Internal Gear Examples of Gear Cutting Tool for Machining an Internal Gear Conclusion Appendices References Index
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30 citations
TL;DR: In this paper, a finite element-based model of gear hobbing and milling is presented, which explicitly meshes gear cutter geometries with dozens of teeth and is used to simulate the complicated kinematic motion between tool and workpiece.
25 citations
TL;DR: The influence of the modification parameters on tooth deviation, contact path, and transmission error are all investigated, showing that localized contact pattern and polynomial transmission error can be realized through cutter offset correction for one gear and cutter tilted (or crossed angle) correction for the other gear.
Abstract: As a prospective machining method for cylindrical gear, gear skiving has been promoted by many commercial companies, such as Gleason, Mitsubishi, and Prawema recently. Although the principle and mathematical model for gear skiving has been discussed by many works, the tooth modification was left behind in the literature. In fact, machine kinematics correction and tooth contact analysis (TCA) are widely used for tooth modification in gear processing, such as hobbing, grinding, and milling. Focusing on this, the paper generalizes machine kinematics correction and TCA to gear skiving. The influence of the modification parameters on tooth deviation, contact path, and transmission error are all investigated, showing that localized contact pattern and polynomial transmission error can be realized through cutter offset correction for one gear and cutter tilted (or crossed angle) correction for the other gear.
16 citations
TL;DR: In this paper, an analysis of the modification of the profile on the tooth tip is presented to compensate for the tooth deflection under loading and to improve the conditions of gear operation.
Abstract: The article presents an analysis of the modification of the toothing of spur gears. The aim of the modification of the profile on the tooth tip is to compensate for the tooth deflection under loading and to improve the conditions of gear operation. Cases of longitudinal toothing modification of a convex-convex (Cv-Cv type) tooth are described, where the tooth is biconvex and the gear teeth are convex-concave (Cv-Cc type). The conditions of mating of modified gears have been analyzed. A method of machining gears by the step-by-step method has been proposed, which can be used in unit machining of large-module gears with an arbitrary profile modification system.
15 citations
Cites methods from "Gear Cutting Tools : Fundamentals o..."
...Because of the versatility of the method, the step-by-step (sbs) machining technology, being widely used in mould machining areas, can be successfully adapted to the manufacture of gear wheels with a longitudinal profile modification [11]....
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...Step-by-step machining can be accomplished on basic 4-axis CNC milling machines (the fourth rotary axis is that of the workpiece) using simple and inexpensive tools (such as ball-end finger mill), which is consistent with a general worldwide trend to move the machining of gear wheels and gears from specialized machine tools using special tooling to universal CNC machine tools using universal and simple machining tools [11, 12, 13]....
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TL;DR: A method of interactive synthesis is finally worked out with which especially the geometry of cylindrical gear drives can be optimised with regard to their load-carrying capacity or contact strength.
Abstract: This paper presents a procedure for the geometric synthesis of heavy-duty, cylindrical gear drives. Particularly tooth profile forms were generated here which have almost constant contact stresses along their entire line of engagement. The synthesis is based on analysing the properties of the entire meshing zone in detail. The concept of the synthesis is developed by analysing various methods for increasing the load-carrying capacity of gear drives through optimised gear geometries, by analysing and selecting quality criteria for evaluating gears as well as examining the zone of meshing. Based on the concept of synthesis, a method of interactive synthesis is finally worked out with which especially the geometry of cylindrical gear drives can be optimised with regard to their load-carrying capacity or contact strength. The maximum or rather demanded load-carrying capacity or contact strength are used as reference parameters here.
15 citations