CHAPTER 13

GEAR_CT,-TTIN G N{ACHINES

I3-1. Gear-Cutting Methods

The two principal methods ernploved at present in the manufacture of

t,-,othed gears are: form cutting and generating.
Form-cutting process. This methocl makes use of a cutting tool whose
cutting edges have been formed to the shape of the tooth space to be cut.
Eramples of such tools are gear-tooth milling cutters of the disk or end-mill
irpe (Fig. 246a and b) and form tools (Fig.246c).
If a single tool is employed, the cutting of the spaces alternates with
indexing, i.e., turning the blank to the next tooth space or 1 revolution,
;;here z is the number of teeth on the gear being cut. The production capacity
,-f this method is low since each tooth space is machined separately, and
time is lost in returning the tool to its initial position and in indexing the
gear blank.
Iloreover, since the tooth profiIe depends upon the module, pressure angle
and number of teeth, it is theoreticall_v necessary to have a tool with a special
pr,rfile (milling cutter or form tool) for each gear rvith a different number
,-i teeth or module. In actual practice, hower,er, sets of gear-tooth milling
crrtters are used (B cutters per set or. for more accurate gears, 15 and, less
fiequently, 26 cutters) for each module of gear. Each cutter in the set is
d,tsigned for cutting a limited range of numbers of teeth. Gears cut by this
r,ethod are not very accurate since, in addition to the errors associated with
i:.accurate operation of the indering mechanism, there are inevitable errors
irirerent in the cutting tool. In consequence, this gear-making method is

c4
Llu
WH
t"/
VJ
(r)
I

ll
__,_+_-
(8)
g @
Fig. 246. Gear manufacttrrc by thc form-cutting process:
lvith a gear-tooth cutter; (b) with an end-mill type gear milling cutter; (c) r/ith a lorm 10()1

23*
356 GEAR.C UTTIN G 1 MACHINES

Fig. 24i. Principle of the multiple- Fig, 248. Generation of involute

tool shapirrg cutter head:' profiles:
I-gear blank; g-form tools; 3-body J-gear blank; z-cutting tool
ol the heaal

resorted to in regular production only if a gear-cutting machine is no

available. It is used, horvever, in repairs, in making single gears, in scimr
cases for cutting herringbone gears, and in roughing the tooth spaces (ir
roughing operations).
In mass production the forrn-cutting principle is applied in the multiple.
tool shaping cutter head (Fig. 247) used to cut all the tooth spaces of a gear
at the same time. This cutter head has as many radially arranged form tools
as there are spaces (or teetii) on the gear being cut. The profile of the toois
is exactly of the some shape as the gear-tooth spaces. During each full stroke
(cutting and leturn) of the cutter or gear blank (in a directi-on perpendicular
to the plane of the drarving) each tool is fed radially toward the blink, by an
arnount equal to the infeed, prior to each cutting stroke. AII the tools are
simultaneousiy retracted from the rvork on the return stroke to avoid rubbing
of the tool clearance surfaces against the machined surfaces. All the tootir
spaces are cub simult,aneously, and the gear is finished rvhen the tools reach
their {ul} depth of cut.
lhe prociuction capacity of this gear-cutting method is verv high and
the accuracy of the cut gears ciepencis only upon the accuracy of tlie cuttcrr
head rvhich may be sufficiently high. Drawbacks of this methrid are the
comparativeLy comple-x manufacture of the cutter heads and the necessitv
of having a separate head for each size of gear.
Another high-production forur-cutting process used in gear naking is
broaching which is economically justified only in the mass production of
identical gears. Broaching produces highly accurate gears wit[ an ercellent
surface finish.

The generating proccss. This method is based upon the meshing of the
cuLter rvith the gear being produced to develop the tooth b)'the relative
 -l

T3-3. GEAR-HOBBING ]\IACHINES 35?

rolling motion of the cutter and the work. For this purpcse the cutter is
shaped like a gear, gear rack or \\-orm, i.e., a parl rhich could mesh with
the gear being cut, or the tool is made so that its cutting edges descriLe in
space the surfaces of the tooth profiles of a certain imaginary gear or rack.
knorvn as the generating gear or rack. In this meshing action of the work anci.
tcol, to nhich an additional cutting notion is imparted, the cutting edges
of the tool, gradually removing material lrcn the tocth spaces' shape the
gear teeth to profiles that are the enr-elope of the consecutive positions of thc
cutting edges of the tool (Fig. 248).
Though the generating methcd canrrot compare in output with form cut-
ting, as used in the multiple-tool shaping cutter heads cr in broaching,
it is much more universal. A tool of a certain mcdule, operating by the
generating principle, can cut gears with any numter of teeth of the same
module, including modified gears.

13-2. Gear-Cntting Machine Glassification

Gear-cutting machines can be classified according to the following fea-
t ures:
(1) The type of machining and tool used: into gear hobbers, gear shapers,
gear planeri, gear-broaching machines, gear-shaving_machines, gear grind-
ets, gear lappers, gear-tooth honers, and gear-tooth _rounding machines.
(2)'-Purpose: into machines for cuttingspur and helical gears, worm'$heels,
herringbone geals, gear lacks, straight bevel gears, and curved-tooth bevel
qears.
" (3) The finish of the machined tooth surfaces: into machines for roughing
the teeth, for finishing the teelh' and for microfinishing the active surfaces
of the teeth.

l3-3. 0ear-Hobbing Machines

Se miautomatic gear'-hobbing machines are the most commonly used ma-
chines in gear manufacture. This is due mainly to their ccmparatively high,
- Figure 249capacity,
production versatility and sufficiently high accuracy.
illustrates a universal semiautcrnatic gear hobber. Gear hob-
tersian cut external spur and helical gear-s, as l-el} as \rolm I'hcels. Cer-
tain mcdels permit the cutting of spline shafls, as well a.s other parts having;
projections, recesses or flats of identical shape, equally spaced ab-out the
periphery of the part, at the same distance frcm the centre (Fig. 250):-
- Gear irobhers can also cut internal gears of sufficiently large size. This
requires a speciall attachment operating by the fornn-cutting method and
 GEAR.CUTTING TIACHINES

SiR#

a,
/

Fig- 249' Univcrsal semiautomatic gear-hobbing machine, model 5KB2[I:

r-bed; z-tabre saddre; r-circ"t*
T3ii"L:l?;"i;:tl5;tii,*upport with a,m 4ai 5-work arbori

a mechanism for manual indexing of the blank from tooth to tooth.

getrc arer very rarely cut in-gear hobbers; they can be cut more Internal
accurately
ancl much faster in a gear shaper.
Notwithstanding the great variety of types and
.have sizes, all gear hobbers
the same elementary gear trai; (Fig."i51).

I
 13.3. GEAR-HOBBING TIACHINES 359

ffiwffi
Fig. 250. \,'arious l-orlipieces that can be

6i
hobbed

zt

J,
I

Elementary hobbing-machine gear train:

i-hob;:2-*orm wheel blank; 3-index worm; 4-index rvorm wheel; 5-change gears
 360 GEAR-CUTTING }IACHINES

vr rp

W
(o) cu,*irc 3 wor'r ."n*,,=*,,Ili;*i?:i*"j.':d;l;1..l,i.1il'":t'J;:;-
wheer with ransenria, feed
of rhe hob; (c) cutrins a spur sear rvith axiaiieed; iirl;i;i",?; i,iii""^i"g!""
with axiaIfeed

. Gea.r hobbers operate on the generating principre. The rotary motions

imparted to the gear blank and cutting iooi
of the worm wheel and worm in worm"geurils. ftoli) are ihu .u*, as those
TtrgLJ rru"r. i"ligiJiv
attached to the index worm wheel which'is drii'en ry ?n*-i"aux rvorm. The
latter-is linked kinematical_lV to the hob fy
-."". ;i ;h;;g. gears. The re_
quired ratio of hob and blank sp_eeds is estabiist.o ly trr" .rrunge gears in such
a manner that during one revolution of the hob tnb ilant< tJrnI through as
many teeth as there are starts (threads) on the hob, i.;:, the blank must
make I revolutions per revolution of the hob, where k is the number of
starts on the hob and z is the number of teeth on the gear being cut. In aclcli-
tion to the continuous indexing motion, it is neceis;;y to obtain on the
Tachine the primar-y cutting motion, feed motion anJ"motions for tenta-
tivelysettingthetoolandblankintheinitiatworr<ingposiir"".. c;;*q";;;i;,
the actual gear train of a
-gear hobber includes meJhanisms-lvhich determine
the kinematic features of-the various moders g.;; [;bers (for ,oo*
detailed discussion se_e Vol. 2, part Three, Sec."f5_5i.'-- """" "
In c^utting worm wheels the axis of the nol i. J.t perpendicurar to the
axis of rotation of the blank (Fig. 251). The following pli"-.ip"r motions are

k,
r
 r3-3. GEAR-HOBBING IIACHINES 361

required for tiris operation (Fig. 252): principal rolary q.U$!-+g_!S_Stion u

-,f the hob, rotaryrmotion u. of the gear blank (continuous ind-xing motion),
mo,t-io_grvhich can be either radial infeed s; (Fig. 252a) or tangential
and feed '@x-nSZUl.
ieed-T1 naaiat infeed ceases when'tie"full depth of"cut is
reached. If tangential feed is employed, the hob is set at the beginning
to the full depth of cut and it feeds into the blank by an axial feed
ir otion.
Th" tudiul$ed-gqlbpd has a higher production capacity. However,
a cornparatively few hob teeth cut each tooth on the gear, producing more
,,r less visible llats that reduce the tooth profile accuracy. Furthermore, in
radial infeed only a small part of the hob length is actually doing the cut-
ting. As a result, the hob \ryears nonuniformly. This also has an unfavourable
effect on the tooth profile accuracy.
If multiple-start hobs are employed, or if high gear accuracy is required,
tire tangential feed method is used. It can be used, however, only when
a special hob slide is available to transmit power axial travel to the hob.
Single-tooth fly-cutting hobs (Fig. 253a), or tapered hobs (Fig. 253b), or
cvlindrical hobs with a tapered entering end are used in tangential feed
lear cutting.
Fly-cutting hobs (also called fly cutters) are used in piece production since
they are considerably cheaper than hobs. Cylindrical hobs with a tapered
entering end and tapered hobs wear uniformly since they cut along their
full length. The high tooth profile accuracy attainable in tangential feed
gear cutting is due to the large number of hob teeth that cut each tooth of
the lvorm r,vheel.
To cut spur or helical gears the hob is set so that the threads of thelhob
on the side facing the gear blank are directed along the axes of the tooth
spaces when spur gears are being cut (vertically in the most common type
of gear hobber), and at the helix angle B of the teeth when helical gears are
being cut. This is done by setting the hob axis, in the first case, at an angle

Fig. 253. Fly-cutting-hobs (a) and tapercd hobs (b)

i
F-*:-

TABI,E 38

Maximum Powcr of Net

di ameter drivc weight,
Type of machine of blank, motor,
mm kw approx.

330 to I,930 0.(i Ilorizontal blank axis.

Travelling hob slide
carriage

Semiautomatic 53OII 50 L 200 to 2,000 0.5 350 Vcrtical travel of blank.

gear hobbers 53OBA 80 { 63 to 400 I 1 ,500 Radial infecrl of hob
5K30tB 125 2.5 115 to 500 1.7 I,300 slide saddle

5306K 200 5 90 to 450 5.5 3,000 Vertical blank axis. Mov-

5307K 320 6 100 to 400 7.5 4,500 ing table type
5K324A 500 8 40 to 310 7.5 6,200
5K32TI 800 10 40 to .310 7.5 7,200

5K328II I,250 12 40 to 200 t4 {2,800 Vertical blank axis. Mov-

5A342rr 2,000 20 18 to 100 1.4 22,800 ing stanchion type
5343II 3,200 30 10 to 60 25 9,800
5345 5,000 30 t0 to 60 25 tB, 600
5346 8,000 40 10 1o 60 25 200,000
5348 12,500 40 l0 to 60 25 200,000
Strrr iir tt l,orrlt l, ic I ) il rnc l,rr t' I 5( ) , 8 l,o 250 7.5 3 ,1)00
horizontal spline length 700 to 2,000 to
hobber 4,600

Ilorizontal blank axis.

IIori zontal 5A37OTI Diameter 500, 16 to 100 22,000 Travelling hob slide
hobbers length 2,000 carriage
to 3,000
5373A Diameter 800, l0 to 60 49,000
length 4,000
5A375 Diamctcr 1,21-r(), 10 to flO 20 {ift, ir00
Icrrgtlr 5,(i0{)

Ccnt re-to-cerr tle

distancc y maxi-
rrrum modulc, rnm
ITobbers for
mak- (E3-57) 320x12 11 to 189 7.5 6,900 ltadial infecd of stan-
ing globoicl 548 800 x 26 0.01 to 45 t3 30,000 chion in roughing
worms and worm 549NI 1,600x50 0.002 to 25 17 60,000 Ilotary feed of tablo in
wheels finishing
 JU4 GEAR-CUTTING MACHINES

o to the horizontal, equal to the helix angle of the hob (Fig.252c). In the
second case, the hob isiet at an angle ? : 13 -F a, where B is the helix angle
of the helical gear being cut (Fig. 252d). If the hand of the helical gear and
that of the hob are different (one right-hand and the other left-hand), the
plus sign should be used in the above equation; if the hand is the same, the
minus sign should be usecl.
The feed motion s in cutting spur and helical gears is the travel of the hob
along the axis of the gear blanli (Fig. 252)- In cutting helical geals an incre-
rnenl motion is impaited to the table rvith the gear blank, with a! angulqr
velocity that rvouid provide one full_ additional revolution of the blank
durirrg vertical feed of the hob through a distance equal to the lead of the
helical teeth on the gear.
The principal dimensions of a geql hobber are the maximum diameter
and module of guut that can be cut (Table 3B)'
Depending upon the disposition of the blank axis, geat hobbers may be
eithei vertiCal or horizontal models'
Horizontal hobbers are intendedj chiefly for cutting pinion shafts (in
which the gear is integral \\,ith its shaft) and spline shafts.. The hob is set
to the depti of cut andlhe feed in these machines is accomplished by motions
of the cutter head.
Vertical hobbers have either a moving worl< table or a moving hob slide
stanchion. In the moving table models, the hob is set to the depth -of cut
unJ f"a into the blank 6y travel of the table with the gear blank' In the
moving stanchion models, positioning-motions and radial infeed are accon]-
plishei by travel of the stanchion with the hob slide and hob.

13-4. Setting Up and Holding

the Gear Blanks in Hobbing
The accuracy rvith which gear teeth. ale cut depends_for the most-part
upon the accuracy with rvhich-the gear blank-is-set-lp i-n the machine' There-
#t;; i-h; iocating hole axis or shift axis of the blank must coincide' and
lfr" io*ii"g faceif the blank must be square, with the axis of rotation of the
*otf. i"nf""*ithin specifie.l iolerarrces *hett the blank is set up on the hobber
table.
In cto-ping the blanks, they must be supported as near.as possible to the
point of appli"cation oi t[" cutt"ing for_c-e. This provides for depen-dable clamp-
i;t; p;;;l"ting all shifting of ine blank under the action of the cuttinc
force.
The setting-up accuracy is checked with a dial indicator, the contaci
poi"i of
'*triri ir upplied either to the a1611ting (locating) hole of "the blarrk

li
 I3-4. SETTING UP AND'.HOLDING THEf,GEAR BLANKS IN HOBBING 365

or shaft journals, or to the outside surface of the blank (to measure radial
runout), as well as to the locating face of the blank.
Radial runout of the gear blank may be due to a lack of concentricity
hetween the locating and outside surfaces, or misalignment of the axis of
the locating surface and the axis of table rotation. The first of these cases
has no significant effect on the accuracy of the gear being cut since the pitch
circle will be concentric rvith the locating surface.
Radial runout, due to misalignment of the axis of the locating surface
and that of table rotation, should be maintained at a minimum value and
should not exceed the values listed in Table 39'
TABLE 39

Grade of Ilaximum permisslble radial runout, microns, in hobbing a blank

acc u racy of diameter, mln
ofgear
b0i ng
cut accrrrd-
ing to
USSR up to 200 up to 800 up to up to 2,000 up to 4,000
Std GOST
1643-56

.): 70 100
0 20 50
7 60 80 130 200
8 50 80 100 150 250
o 4,t0 180 220 300 500

Si{e runout of the gear blank, due to inaccurate setting up on the hobber
table (misalignment of the rvork supports, dents on the locating or seating
surfaces, chips or dirt under the locating surface of the blank' etc-), should
not exceed the follolving permissible values (where f : permissible radial
runout of the outside diameter, microns; Dro: diameter of the circle on
which the side runout is checked, mm; and b : face width of the gear, mm):

Grade of accuracy of
gear being cut accord-
ing to USSR
std GosT 1643-56

Permissible side runout

o.r5 F D;
0.2 F D;. a.25 F+ os F
D{o

The method used to hold the blank depends upon the size, construction
and required accuracy of the gear to be cut. Figure 254 illustrates typical
366 GEAR-CUTTING MACHINES

Fig. 254. Methods of holding the gear blanks in hobbing machines

methods of holding gear blanks in hobbing machines. small gear blanks l'
X,lh hole can be held either seplrately (Fig. 214a)"or in a stack
(Fig. l_tgg.uting
254b) on a rigid arbor, or mandrel, 2, which
-Jy nuu.'a pilot at the,
upper end that is supported in the bushing of the work-support arm. Large
and.medium-siz-e.gears -/ are held on cast-iion supports z inine form of feEt
or rings (Fig. 254c ul+_d).- I{ pinion shafts 1 are iut in the horizontal type
of hobher, one end of blank I il secured in fixture z (Fig. 2b4e) and the ot"hir
is supported in bushing qt the support bracket. tne nta"ti is rotated by
faceplate 4 through the {body of the fixture and detachable driving dog ;"..

13-5. Gear Shapers

Semiautomatic and automatic gear shapers cut external and internal
spur and helical gears, cluster gears, flanged gears, toothed clutches, gear
racks, ratchet wheels, cams, etc.
. In this general_ type of gear-cutting machines, the cutting tool resembles
eilhel a gear rack and is called araik-type cutter (Fig. zbb;), or a gear, in
rvhich case it is called a rotary gear shalper cutter (ni[. zsBaj. G.;rlh;p;
 -f
I3-5, GEAR SHAPERS Jhl

(a) w*h
" "".o-1;?;
?il;.ll:lTi,flT"lliJ'I^. shaper cutrer

arotary cutter har.e found much wider application because they have.
".jlg,
a higher output (the "biank)
_cutting process is not inteirupted to index the
and can perforrn all the operafions done in hobbers, except for cutting rvorm
wleels..They can additionally cut internal gears b), the ginerating prlnciple.
I'he, output of gear shapers is less than that of hobbers. They are indispen-
sable, holever, for such jobs as cutting internal gears of practically'any
diameter, as rvell as cluster gears in wiirch the diitance beilveen the gear
rims is not suf-frcient for the required overtravel of a hob.
'r\ geal shaper (operating witli the rotary-type cuLter) has the folrorvirrg
principal
.motions (Fig. 256): A. straight-iin;- primary cufling motion r,i
accomplish.4 !v ,travel of the cutter only in on. dit"ciion (cut"ting strokei
and return of the?ii'ttei to the initial position u" (return stro)ie). B]Continl
uous rotation of the_shaper cutter (ulfand of the'gear blank (u2l to obttrin
the circttlar feed (indexing motion). The speeds of Jutter ancl blank rotatiol
are co-ordinated by means of change ge_ars in such a manner that in one
revolution of the cutter the blank makes 19 revolutions, lvhere zc : number
of teeth on the cutter and z : numbbr of teeth on the gear to be cut. c. Feed-
in Ilotion sii (radial or circular infeed) of the cutter"is obtained bv travel
of tlie cutter axis in a direction torvard thg _bl_q4k u*i. lr;itii ,l.ipi"*Ii""
of the cutter and circular feed. \\hen the cutlei't us fe-f in-to the'requirecl
rlepth, i.e., to the rvhole depth of the teeth, the feed-in
maticalll' rvhile the circular feed and the cutting motion -oiioo ceases auto-
continue until
the gear blank makes one full revolution. This crits all ihe teeth and the
machine is automatically stopped. A gear can be cut in one, two or three
passes. D. \\rithdrawal of the iable wilh the blank from the
cutter, or tlie
cutter from the blank takes place during each return stroke. Its purpose
7a

368 GEAR-CUTTING MAC}IINES

,6"lll">
t tn*L)
h

:t
,ii
.)
i{r
;Jl ,, l
'rl I'" q"%
\ji Cear biank
i

i
I ,d Lta*lo)
I
(

,.\
Fig.756. Principle of the gear shaper:
l-saddle; p-rail; r-rrbte
V
is to prevent rubbing.and conseqqelt intensive

l"'1
from the cu*er during Thu
""tu"'"
.ti'"r.r o"il" ;0).
yrear of the cutting
;; ;##;
iii; #ilr,ir"*i'g
edges

motion
p 'fAltLlt 4{}

Nunrber of Power ol Nct

full strokes drivc wcigh t, nemarks
Typc of gcar slrapcr of cutter motor, lig
pcr min kw approx.

Operating rvith a sin-

gle rotary cuttcr:
Automatic shapcr 51074 80 400 to 2,000 0.6 850 Cutter ram 'withdrawal
on return strokc

Scmiautornatic 5M12 200 200 to 700 1.7 1,900 Tablc rvithtlras'al on rc-
shapers turn stroke

51zr0ll 500 TJ 90 to 550 1.5-4.5 4,400 Cutter ram withdra*'al

58 15011 800 t2 30 to 1il0 7.5 10,000 on return strol<e
5616111 1,2'-.t0 12 25 to 150 7.5 t0'400
It3-{58 2,000 12 40 to 210 7 .5 {0,800

Operating rvitlt a mul- 5A{10 t25 5 60 to 120 14 1l,800 All the tcct'h oI tlre gear
tiplc-tool shapi ng 5A120 200 6 1r0 l,o 120 17 13,7(X) arc cut simultancouslY
cuttcr lroad 5A130 320 10 i]2 to 1(X) 20 t 5,700
 :J70 GEAR-CUTTING MACHINES

is imparted to the ram rvith the cutter i' the heavier machines (moclels El40B,
58150fI, etc.).
Gear shapers are available rvith either
The horizontal spindre shapers ur"uiiy operate or horizo'tal spindles.
'erticalr,r,ith trvo rotary shaping
cuLters travelling torvard each c,ther. tn.v .u,i
and inIernaI spur and helical gears,
#;;,;i;.tl l.or e.rternal
gears (rvithoul, a clearance gop-;. ^..unif
,;;;;;";;"1-ii,-,h herrirrgbone
The vertical type of geaishaper is more rvidely used.
machines using a rotary gear- siraping cutter, operating In acldition to the
principle, rnodels a.u urrullubte rvhicfr operate on tno generating
an$,lse a,mu.lriple-rool shaping cutter head (see Lv
tn* f-ormlcutting process
Fic. i4ii"'^
-the.outpur, of this lasr typc of gear-cutti'g maJhine is B_
of^ ordinary gear shapers, un,i rrori" thuo 4-f;ld ir." ,rtp"i 1o l0_folri rhat
machines. The most serious drarvbacri of trroru ;,;.d;;.- of gcar-hobbing
complex cutter head must be avairable for each,iru ot:g"*
is that a special
module and number of teeth). lo be rnacre (each
The kinematic chains of gear shapers is tar<en up in cletail
Vol. 2, Sec. 5-4. in part Three,

t3-6. Bevel 0ear Generators

Bevel gears'can be cut, as mentioned previously (see Sec. g-3),
sal miiling r'achines or shapers. Horvever,_ the accuracy of in univer-
by this rnethod, is so lorv that such rnethods u",r;;;irlir*,i-.un bevel gears, cut
be emproyed
only in extreme cases rvhel no special gear_-cutting machines for level
gears
are available. rforer'e., t"hu output of "millers
i'. u".y lorv rvhen
they are used for cutting bevel gears. ^rd;h;;;;
..
At the present time, 6evel g.ito urn manufacturecr both by trre form cut-
p.ocesses."The form-c.utting_ pri'crp1.-i, ,,s.a in cutring
l::g^el^{.^q"lnllting
Iarge ile\-el gears up to 5,000 mn i' diameter and ivith a rlodule
(Tq.lle 41) rvith a iingle toor o. up to s0;;
tools_rvhjch operate ro a temprate.
The.generating principle is basecl"'ii[-iiuo
on reproducing ttie-slaes of the teeth
tTucinary crorvn ge.ar in space_by meins of th"e c'tting edges
::_ul
tng cutlers or rcciprocarirg tools iFig. 252). The profiler"or of rotatl
cutting edgcs coincjde rvith tlrt,oppo.irig sides of Lrr.o leetS _itru .r,:.igh-t
cro\yn, or generating, gear rvith rvhichihu grur, b;;g-;;i ol' tlrc imasirrr'v
primary culting motion' either rotation oi reciprociation.;. is;;;;f.'Thi
transmitted
X{otion of the Ii.rs^t typc ('r"i"ii""i'i, accomptis}red
l: "tl::::."ll-:^q :gg"r.
bevel gear generators clesigned for cutting bevel gears u,ith a short
:l^S^,i1iqll
race \rroilr. these generators use rotating
generating principle (for erample, modeli230, _circular critters operating b1'the
see fufri" ZfJ.
 13-tt. REVEL (;l'l-\R (ill\ERATOFS ?,7 I

v
-?----

f is. !i7 . T,ruls rr itlr

slririglrt lul tirrq t'rlqls
Ilrul lorrrr iltr0 l,rutll SnuCO
Fic. l5S. L,r'trct';ttittg
of tlrc irnaginarY clorvtr a strriqlrl hotoI gt'ar
gL\tlll:
rvilh tirlirlirrg cit'crtlar
t-be\.el sear l)larlk; .?-im- t:r rttcis
aginar-\ clo\\:11 gear; i-tools

The rotating cuttels (Fig. 258) IeYol\-e about lheir a\es to

pTo\,ide the
.";ti"g otiioii(", ""T tiltr".il i' planes pa-ssing through the sides of the
teeth o' the i'raginary t'orvn gear io shape the teet!,.alongtheir.length'
ancl at the same tinclde'-partic-ipate i1 the relative rollilg
motion betl'een
the cutbers antl blarrli to ,,btain the retluirecl tooth profile (u1 and u2)'
":Sti.uigf.f
linc cutting i-q 'r.cle use _of in the slraight b-e'el ^gearbeeth generators
5eing
that lave trvo recipru.loling toof. rvliich ,lrape thc pI9!.i... of the
is rotated (n1 rpm)'
cut. In t1 rlachine oiliiir;yp., geal bla'li ? 1Fig.':;rr) bools rvhich repre-
,ur,,, r;"L"t.d is cradie Z 1rr, tpittj rvith the recipiocatirrg
.",'l i.inrnralicalll, tt," uap.int siclcs of a tooth in an irnaginary crown
*ott,,o,
_slidcs 3rvith toois 4 reciprocate (r) along \\.il).s arrangg$ o" gear
the
l:c,:
pllcrl
in their tnotiolt tc,rx'ard the ape-t oI tlre
of crarlle 2. Ihe l.ools cut
cone.'fhe tools clo iiot cut on tlie leturn stroke, rvhen thel' are
\Yithdlawn
irorn the blanji to oi.oia clamaging the n'rachined surfaces of the teeth'
positiotrs of the tools antl gea' blauli
Fl g*re 260 shor.i s thc succei-*i'e
ilurirg goneration. .fi'iJr. beel;";ng'ot the tooth cutting process, tlie tool
to cgt into lhe blank i

1rr rnacirining o1e ni t,tr" sirie slrtacei of the teeth starts

ielg. :AO, po-.itio', Z or.a 2). The'. the secr,rn4 tool, rle-signetl to -shape the I

,,rh.r sirle surfaces oith" teeth, begins to cuL the gear (Fig' 260' positions 3 I

gcnerat'ed' Upon
,,,,,iij.',it ifrir pltirt, iile lirst to,ith_ has beenrutrcoiipletely
otrl oI rnesh wit'h the gear l

i".if*. totuii""'(r"ili'of the cradlc the one Iooth-space of t]re

tools
irnaginary
l

lrltrrrlt. silce the trvo tools represetit only

.;;rr.;' g"nr. ff."t.f;t;; nh;ir-ihe tooth'has beeu shaped, both l:rlank and
21+*
lr=- I

TABLE dl
l\Iaximum Powcr of Net
di ameter
| *:io.lt,'.?:" dri vc weight,
Type of machine Iuodel of blank, 'tl:'oTiJ'
cut, mm
motor, kg
mm kw approx.
I

FulI strokes
per min
Straight bevel gear 5T23B 125 1..5 up to 800 0.6 3,000 Operate with tvo rc-
gencrators 5A25OII 500 8 75 to 472 8,000 ciprocating tools
5282| 800 t6 30 to 307 7.5 12,000

Operates rvith t\Yo

Tcrnplatc-t,ypc 5.,\ 283 1 ,600 30 1.7 Lo 727 7.5 19,0(X) tools
straight bevcl gcar: 52Tr,r2 3, 200 40 3.5 to 80 l0 40,000
Operate rvilli a single
plancrs (5285) 5,000 80 :1.5 to 15 t4 50 ,000
tool

m pcr mln
Spiral bcvel gcar 1 ,600 up to 80 l7 35 ,000 Gcnerates gearn'itlr a
planing generalor single tool. Illarik
inclexes ono tooth il
full stroke of tool

Straiglit bcvel gear 27 to 180 7 ,000 Opotatis rvith tn'o

gcnerator rotating cllItcrs

Spiral bevel gear gelr- 5T234 12it 2 1+3to 51t0 0.8 3,000 Opetatc r,ith farle-mill
erltors 5T244 250 0 200 to 500 3.5 5,000 type cttttcrs
5278 500 10 25 to 32;t 4.'-,'t 10,500
52BTI 800 15 21 to 300 10 14 ,000
 Fig, 259. Principle of tbe straight bevel gear generator

l> ,--^ --f=1

.V-,
'-fffi)'(fld) ,#f,e))
-

\:z \5/ "\i7

\ \v
123

,@,reD,=@
456
260. Successive positions ot,n. ,331-.it#" gear blank in generating a straight

tz

Fig. 261. Curved-tooth bevel gear being cut on a generating-type machine

 614 GD..\IT-(] i]1'TIN IIi [I,\OHINES

e
\-
l|i
uei n,

t\
(o) t0J

!'ig. 262. '\rrangornctrts of tho qcar blanh.arrd the face-rnil.l t)'pe cutter irr rclatiorl to tht'
, rirrllu aris

il

cradle are rcversed. At thc cld of this reverse rolatiou. the lllauli is indered
io tfr" nert tooth (Fig.260. posilions 5 ancl 6). This procedure is rcpeated
for cac[ toot]r of the gear in tlie same scquerrce. 'I'he brvo tools are not subject-
ed to the same loacl-in opcratiorr since one o[ l,hern cuts into the blank fc'r
each tooth and wears f;i-qter than the other tool. To eliminate the effect
of this nonuniforn wear on the profile accuracy, the tceth arc linish cut
l:

ii
I
after roughing the tooth spaces' -\Iost of the stocli i-q removerl in the roughinr
operation.
-Roughing
I
i-q done either rvith siuglc incie-ting in rvhich tooth spac-es a_t'e
cut in'sircc-ession, or by corttinuous irrtle\ing to eYery other l,ooth. In tlie
latter case, both l,ools operate urtdcr ideritical conditiorl-q'
Curvecl-tootli bevel genrs of the spiral bevel, zerol and hl,poid types al'e
l

cut in rtrachines using the face-lnill t,vptl of cubters ancl operatirtg on tlit
I

generating principle (motlel rT23r\ and others). In the cutting pr:ocess.

h

t
[Le guur 6eing cit meshes l'it]r an imaginarl' crow1. or geleratillg' geal'
I
I of rvf,ich the ictive surfacc of tlie rolating cufter represents one tooth-'Iltt
tooth forrn is olttained as a re'sult of a rclat,ive rollirig motion betrveen tlie
cutter and the blanl<.
I Spiral bevetl gear generators havo the foilorving principal tnoLiotr:
f
I
(Fig.261): (a) piimarl' cuttirrg nrotion drreto independenI rotation of cttt-
ier"l (nl iprn); (b) roll motion corrsisting of rotation o1 of cradle 3 rvith tht
imaginarv crown gcar arrcl rotation ro of gear blanl< 2 rvhich is co-ordinateti
t rvitf, crarile roll tlirough change gears (not -qhorvn in the diagram); (c) *'ith-
clrawal of the blank from thc cutter aftcr cuttirrg each tooth; and (d) inderins
l
 L 3-7. G EAT:i.!.INISIII\ \I.A.CH{N I]S D/J
'i
Illolioll $ltich is transrnittcd to the blanh rvhen the cradle returns to its
irriiial position after cutting each tootli.
curverl-Looth bevel gears may be crrt either rvith tlie aid of a crown gear.
irr rvhich case the aris of the cutler is parallel 1o thc craclle aris fs in
I:ig-,262a (rnoticl oT23A), or rvith a ber-el gcnerating gcar
trig. ziizrrl.
In tlre latter ctrse. the blank aud the crrtter ian be siviiettea'tniougtr a'n
arrglc z1.q_in-reference to the plane ol rotation of the craclle (this priiclpie
is applied, for erarnple, in rnoclel ol7]l).
.
I'he kinematic principles involvecl in cutting bevel gears an{ the gearing
tliagrarn-s of the mac]rines used for tliis purpoie rvill ije consiclereci ln pari
Three, Vol. 2, Sec. 5-6.

13-7. Gear-Finishing Machines

. .hi the great rnajority of cases. the tectli cif machinecl gears urrclergo a fin-
isirilg operation since after cutling 1[e gear the surface"finish on tiie tooth
proflles or the meshing errors do nut coniply rvith the requirernents speciiiecl
irr the gears. Gear-Iinishing methocls inclucle: burnishin[. shar.ing. llpping,
erinding and honing.
As-the result of plastic cieformation of the surface la)rer
"I"({olllg,tlt!9.
tttetal. the sirle surfaces oI the teeth of uriharclened gears are compresiecl
br- burnishing. This operation consists es-qenbially in rilling the rvork gear
u'ith one or several burnishing gears ri'ho-.e teethire very hird, smooth"and
accurate' 'Ihe latter gears are driven bv a rnotor. The requirecl load is applieJ
b1- a rveight.or by means of electric. pneunratic c,r hjdraulic der.ice-".
..The capacity of a gear-burnishing liachine j-q speciliecl hy the maximum
rliameter of gear it accornrnodates. Trie capacit-r' of geariburnishing ma-
chin^es procluced in the soviet Union tangcs fr,om 12ito 5,000 rnm"(Tab-
le 42).
.Qear sltari\g is based on tlre cutiing o[ fine clrips fr,rrn 0.00j to 0.1 mm
tLick {ronr the gear-tooth profiles by the cutting eclges of the tool during
tho_ relatir-.e sljding rnotion of the tooih profrles on t"he me-.liing ruort geoi
,rrtcl tool. The latter is called the gear-shaving cutter. The forrns of tne c.r"tte,
t.rrrr€Spond to thc trvo methods of -.liaving, rotary anci linear (rach). The
r'ltary metho_d employs a gearlilie cutter; the rtrck method uses a cutting tool
having. the shape of a rack arrd is employed to a les.qer ertelt than thi first
rnetl'rocl. The cuttcr teeth are scrratecl to form a series of cutting edges (Fig.
Itj3). To obtain the rela.tive sliciing action betrveen the tooth'ptofitn., ttL
l-orh gear ancl the shaling cuttcr are sct up in the gear,-shar,ing machine
'.r'ith crossed ares in thc form.of spiral gearing. Tlie mo_qt efficiint angles
i,et\\'een the axes are betrvee'10" aid t;d. ttre"teast perrnisslbte ang.le iE i.
'*'hich i-q used in shaving gears having a flange or shoulcler that
iiterferes
.i'ith tlie cutter at a larger angle.