Gear Finishing by

Shaving, Rolling &

Honing - Part I
John P. Dugas
Nationa:1 Broach & Ma!chine Co.
Mt CI,emens, IMI
There are several methods available for irn-

The Rotary Gear Sbaving Process

proving the quality of spur and helical gears

Gear shaving is a free-cutting gear finishing

following tile standard roughing operations of

operation that removes small amounts of metal

hobbing or shaping. Rotary gear shaving and

from the working surfaces of gear teeth .. It

eoll-finishing are done in the green or soft state

prior to heat treating. These processes have the

purpose is to correct errors in index, helix angle,

tooth profile, and eccentricity (Fig. 1). The pro-

ability to modify the gear geometry to cornpen-

cess also Improvesmoth

sate for the distortionsthat

eliminates, by crowned tooth forms, the danger

occur during heat

treatment. Gear honing is a particularly

effec-

surface

finish and

oftooth end load concentrations in service, Shav-

tive method of removing nicks and burrs from

ing provides for profile modifications

the active profiles of the teeth after heat treat-

duce gear noise and increase a gear's

ment. Combined

with its ability to improve

carrying capacity, its factor of safety, and its

surface finish and make minor form correc-

service life. Gear finishing (shaving) is not to be

tions. the boning process is rapidly being ac

confused with gear cutting (roughing), They are

cepted as an operation

essentially different Any machine designed pri-

through which many

gears are processed following heat treatment.

that reload-

marily for one cannot be expected to do both

with equal effectiveness or with ,equal economy.

INVOLUTE

PROFILE

CHECKS

Gear shaving is the logical remedy for the

inaccuracies inherent in gear cutting. Uis equally
effective
dislortion

as a control for those trouble ome

caused by heat treatment

The form of the shaving cutter can be reground

,001"

to make profile allowance

treatment movements

for different

heat-

due to varying heats of

steel, The shaving machine can be reset to make

AS SHAVED

AS HOBBED

LEAD CHECKS

allowance for lead change in heat treatment.

Rotary gear shaving is a production process
that utilizes a high-speed
ground, ultraprecision

steel, hardened and

shaving cutter. The cut-

teris made in the form of a helical gear. It has

gashes in the flanks of the teeth that act as the
cutting edges.
The cutter is meshed with the work gear in
crossedaxe
AS HOBBED

AS SHAVED

Fig. 1 Improvement in pl'ofil'eand lead, S.7 NPD .20, NPA, 3'.8S", P.D.,
crov ned shaved with stock removal of 0.011" over pins.

14

GEAR

TECHNOLOGY

relation hip (Fig. 2) and rotated in

both directions during the work cycle while the

center distance is reduced incrementally. Simultaneously, tile work is traversed back. and forth

across the width of the cutter. The traverse path

can be either parallel or diagonal to the work
gear axis, depending on the type of work gear.
the production

rate, and finish requirements.

The gear shaving process can be performed at

high production rate . It removes material in the

form of fine hair-like chips.
Machines are available to shave external spur
and helical gears up to Sm (200") in diameter.
Other machines are also available for shaving
internal spur or helical. gears. For be t results
with shaving. the hardness of the gear teeth
should not exceed 30 Rockwell C cale. U stock
removal is kept to recommended

limits and the

gears are properly qualified, the shaving process

will finish gear teeth in the 3.6- to 2.S-m (7-to

Fig ..1 - Crossed axes me "bing of shaving

cutter andwork gear..

lO-pitch) range to the following accuracies: involute profile, 0.005 mm (0.0002 in); tooth-totooth spacing, 0.0075 nun (0.0003 in); lead or
parallelism. 0.005 mm (0.0002 in.)

In any event, it should be remembered that

gear shaving can remove from 65% to 80% of the
errors in the bobbed or shaped gear. It will make
a good gear better ..The quality of the sha ved gear
is dependent to a large degree on having good
hobbed or shaped gear teeth.
Excellent surface finish is achieved with gear
shaving. A value of approximately
normal finish achieved

2511. in is the

with production

gear

shaving, although much finer finishes are possible by slowing theproee s. In some cases,
shaving cutters will finish up to 80,000 gears
before they need harpening, They many generally be sharpened from four to ten times,
The shaving process offer

Fig ..3 - Assortment of rotary gear shaving cutters ..

attractive advan-

to modify the tooth form, If a

tages in theabihty

variety of standardized

production

equipment

crowned tooth form or a tapered tooth form are

available, ranging from hand loading to fully

desired to avoid end bearing conditions,

automatic loading and unloading,

these

Basic Prlnelples

can be 'easily provided by shaving.

If modifications

are desired in the involute

The rotary gear shaving process is based on

profile, these can be made by unable modifica-

fundamental

tio ns in the grou ed cutter tooth form. U a crowned

gashed rotary cutter in the form of a helical gear

tooth form or a tapered tooth form are desired to

having a helix angle different from that of the

avoid end bearing conditions, these can be easily

gear to be shaved (Fig. 3). The axes of cutter and

provided by shaving.

gear are crossed at a predetermined

Modification

in the involute profile can be

made by suitable modifications

in the ground

cutter tooth form. If heat-treatment

distortions

principles.

This process

uses a

angle dur-

ingthe shaving operation. When cutter and work

gear are rotated in close mesh. the edge of each
cutter gash. as it moves over the

urface of a

can be controlled toa minimum, t.he rno t inex-

work gear tooth, shaves a fine, hair-like chip.

pensive way to produce an accurate, quiet, high-

The finer the cut, the less pressure is required

performance gear is to specify hobbing followed

between tool and work, eliminating

by gear shaving .. Tille shaving process has a

dency to cold work the surface metal of the

the len-

,John P. Dugas
is the Sales Manager (II
National Broach & Machine Co .. Mr. Clemens.
Ml. He is the author of

numerous articles
gearing subjects.
!,lARCH

APRil

1~92

OJI

15

other cylinder is increased up to 90, their common plane remains a parallelogram,

but its area

decreases as the axial angle increases. The same

conditions prevail when, instead of the two plain
cylinders, a shaving cutter and a work gear are
meshed together. When the angle between their
axes is from 10 to 15, tooth surface contact is
reduced and pressure required

for cutting is

small. As the work gear is moved away axially

from the point of intersection

backlash devel-

ops. Conversely. as it is returned to the point of

axial intersection,
two members

backlash decreases until the

engage in tight mesh with the

teeth ofthe cutter wedging between

those of

the work gear. Thus, each succeeding

cutting

edge sinks deeper into the work gear tooth

Fig ..4 - 12" Rotary gear shaving machine ..

until the point of axial intersection

is reached.

For shaving, the cutter and work gear axes are

work gear teeth.

crossed at an angle usually in the range of lO~o

This process is performed in a shaving machine (Fig. 4), which has a motor-driven cutter
head and a reciprocating work table. The cutter

15 or approximately

equal to the difference in

their helix angles ..

Crossing of the axes produces reasonably uni-

head is adjustable to obtain the desired crossed

form diagonal sliding action from the tips of the

axes relationship with the work. The work car-

teeth to the roots. This not only compensates for

ried between live centers is driven by the cutter.

the nonuniform involute action typical of gears

During the shaving cycle, the work is recipro-

in mesh on parallel axes, but also provides the

cated parallel to its axis across the face of the

necessary shearing action for stock removal.

cutter and up-fed an increment into the cutter

Relationship

Between Cutting and Guiding

with each stroke of the table. This shavingcycle

Action - Increasing the angle between cutter and

(conventional)

work axes increases cutting action, but, as this

is one of several methods.

The Crossed Axis Principle - To visual:ize the

reduces the width of the contact zone, guiding

crossed axis principle, consider two parallel cyl-

action is sacrificed. Conversely, guiding action

inders of the same length and diameter (Fig. 5).

can be increased by reducing the angle of crossed

When brought together under pressure,

axes, but at the expense of cutting action.

their

common contact surface is a rectangle having a

Preparation Prior to Shaving - The first con-

length of a cylinder and width that varies with

sideration in manufacturing a gear is to select the

contact pressure and cylinder diameter.

locating surfaces and use them throughout the

When one of these cylinders is swung around

so that the angle between its axis and that of the

process sequence. Close relationship

between

the locating surface and the face of the gear itself

must be held, Otherwise, when the teeth are cut
and finished with tooling that necessarily contacts the gear faces, the teeth win be in an
improper relationship

PARALLEL DIAMETER CONTACT

~a

with the locating or re-

lated surface on which the gear operates. Gears

that locate on round diameters or spline teeth
must fit the work arbors closely, or these critical
hole-to-face relationships

CROSSED-AXES CONTACT

Typical manufacturing

will be destroyed.
tolerances

for gear

blanks prior to cutting of the teeth are shown in

Table 1.
RIGHT ANGLE CONTACT

Fig. 5 - Contact between cylinders changes as crossed axes are varied.

16

GEAR

TECHNOLOGY

Once the gear blank has been manufactured,

it is necessary to cut the gear teeth. The most

Table I. TypicollGeor Blank Tol'ell'ilnces

'F"".

r: PRE.S. HAVED

Hole
Taper

Hole
Roundness

0,0.

0,0.

In.-

Runout

lo.lln.

In.- Max

Max

lo.

Up 10 .1. 0.0003- 0.0003 0.0002l-in. Thiel, O,I)OO1i 0.0006 0.000]

0.00020.0003

0.003 0.003

1104. up
I-In
11rick

0.0003 0.0005

0.005

0.005

Blank

Dia.
ID_

RUOOOl

In,

Hole
Size
In.

0,0008

0.00050.00 I

4 108

0.0006
OJI0I2

0.1)00& 0,0002(1.0012 0.0003

0.00040.0006

0.005

0.007

811012

(1.001-

0.0010.00 15

0.00050.0007

0.005

0.008

10

Q,(I(){)4.

o.(m

0.00020.0003

0.00020.0003

common method today for rough-culling gear

teeth axe hobblng Bindshapercutting. Of primary
concern 10 the shaving cutter manufacturer i
the fillet produced by the roughing operation.
The lip . of the shaving cutter teeth must not
contact the gear root fillet during the shaving
operation. If such contact does occur. excessive
wear of t he cutter res 1.1 Its, and. the accuracy of the
involute profile i affected.
The shaving cutter just fini hes the gear tooth
below its active profile. Thu the height of the
fill lei should not exceed the lowest point of
contact between the having cutter teeth and the
teeth on the work gear.
Protuberance-type hobs and simper cutters
are often used priorto having to produce a slight
undercut or relief ncar the base of the gear tooth.
Thi method a ures a smooth blending of the
shaved tooth profile and the un haved tooth
fillet, as well as reduce sn3ving cutter tooth tip
wear (Fig. 6). The amount nf undercut produced
by the protuberance-type tool hould be made
for the thin end of [he tooth. The position of the
undercut should be uch that its upper margin
meets the involute profile at a point below its
contact diameter.
Shaving Stock - The amount of stock removed
during the shaving process isakey to its succe sful applicstion. Sufficient toek hould be removed [0 penni! correction of errors in the
pre haved teeth. However, if too much stock is
removed ..cutter life and part accuracy are effectively reduced.
Table 2 shews the recommended amounts of

stock to be removed during shaving and the

cortesponding amount of undercut required.
Shaving Metilods - There are four basic methods for rotary having of eternal pur andhelical gear: (W)axial or conventional. (2) diagonal.
(3) tangential or underpass and (4) plunge, The
principal diUerence among the various method

I r-SHAVEO

POINT OF INTERSECTION
OF PRESH ..WED PROFILE
WITH PROTUBERANCE UNDERCUT
--

FORM DIAMETER

, .ooo~
-

GREATER THAN SHAVING STOCK

.001 (DEPENDING ON DlA. PITCH)

/'

POINT OF MAXIMUM UNDERCUT

(MAXIMUM HEIGHT OF
ROOT FILLET)
TYPICAL PROTUBERANCE
ROOT FILLET
BASIC HOB TOOTH FORM
AS GENERATED BV PRESHAVING TOOL

TYPE

Fig..6- ndereut produced by pr,otuberance hob and basic bob to.oth form.
TabJe

n -Recommeaded

Shaving

Stock and'

ndercnt For Pre-shaved

Gcaxs
TollI.ll'U ndercut

Shuvi~ Stock

Dia:~l:1~'lcb

(In. per Si e of TOOLh)

lin. per Side of Tooth)

2104

0.0015 to 0.0020

R0025

5106

0.0012 [00.0018

0.0023 10 0.0028

710110

0.0010 to 0.0015

0.001:5 100.11020

lito

0 ..0008 ro 0.00 13

0.0012 tu 0.001.7

.14

161018

0.0005 to 0.00 I0

20104H

0.0003 10 0.0008

521072

0,0001 100.0003

10 0 0030

is the direction of reciprocation (traverse) ofthe

work through and under the tool.
Axial or Conventional - Axial shaving is
widely \I ed in low- and medium-producnon
operation (Fig. 7). It is the mosteconomical
method for shaving wide-face-width gears. In
thi method, the traver se path i along theaxis of
the work gear. The number of stroke may vary
due to the amount of stock to be removed. The
length of traver, e is determined by the face
width of the work. For best results, thelength of
traverse should be approximately 1.6 mm ([/
16") greater than the face width of the work.

FULL STROKE

CROSSED
AXES ANGLE

I~

~I!t"""=--t~

GEAR
TAAVEIRSE

: PATH

"--+--',..- -- ....

MARCH

AIPRI~

111112

Ill'

By use of this method, shaving

reduced by a, much as 50%. In diagonal shaving,

SHAVING CUnE

the urn of the traverse angle and the crosses axes

angle is limited to approximately

WORK

times are

differential-type

GEIl,

55, unless

serrations are used; otherwise,

the serrations will track. The relative face widths

ofthe gear and the shaving cutter have an imporFig. 8, Rocking table action (or crowning during convendonal shaving.

tantrelanonshipwith

the diagonal traverse angle.

A wide-face-width work gear and a narrow shaving cutter restrict the diagonal traverse to a small
angle. Increasing the cutter face width permits

an increase in the diagonal angle. Crowning the

gear teeth can be accomplished

by rocking the

machine table, provided the sum of the traverse

angle and crossed axes angle does

110t

exceed

5SO. When using high diagonal angles, it is

TRAVERSE

preferable to grind a reverse crown (hollow) in

ANGLE

GEAR
CUTTER

the lead of the shaving tool.

In most cases, the diagonal traverse angle will
vary from 30 to 60 to obtain optimum condi-

Fig. 9 Diagonal shaving ..

tions of cutting speed and work gear quality.

With diagonal traverse shaving, the center-

GEAR

TRAVERSE
PATH

line of crossed axes is not restricted to a. single

position on the cutter asin conventional shaving,

but is migrated across the cutter face, evening

CROSSED
AXES ANGLE
FULL

GEAR

STROKE
ANGLE

out the wear. Consequently,

cutter life is ex-

tended. Although conventional shaving requires

a number of table strokes,each

with its incre-

ment of upfeed, diagonal shaving of finer-pitch

CUTTER

TRAVERSE
Fig. 10 Tangential shaving (underpass),

gear

may be done in just two strokes with no

upfeed and a fixed center distance between cutter and work. Au automatic upfeed mechanism
on the shaving machine rnaterially enlarges the
scope of diagonal. shaving by making it available

CUTTER
GEAR

for multistroke operations. This device feeds the

work into the cutter in a series of small increments, synchronized
Removing

small increment.

CROSSED
AXES

with table reciprocation.

tock from the workgear in a series of

instead of two large incre-

ments. further increases cutter life. It also makes

the process feasible for gears requiring more
stock removal than can be handled ana two!Fig. n -Plunge shaviling.

stroke cycle. When upfeed is completely automatico there can be no danger of an error in

work face. In axial shaving. in order to induce

selecting feed rate .,Inasmuch as the cycle starts

lead crown, it is necessary to rock the machine

and stops in a position of maximum backlash,

table by use of the built-in crowning mechanism

loading and unloading can be very fast.

(Fig. 8).

Tan~ential or Underpass - In the tangential.

Diagonal - In diagonal shaving, the traverse

18

GSAR

TECHNOLOGY

(underpass)

method of shaving

(Fig ..10), the

path is at an angle to the gear axis (Fig. 9).

traverse path of the work is perpendicular

Diagonal shaving is used primarily in medium-

axis .. Tangential

and high-production

high-production operations and is ideally suited

operations.

to its

shaving is used primarily

i.11

for shaving

gears with restricting

shoulders.

When using this method. the serrations on the

cutter must be

or the differential

type. Also. the

face width of the cutter must be larger than that

of the work gear.
Plunge - Plunge shaving is used in high production operarlons (Fig. 11). In this method, the
work gear

fed into the shaving cutter with no

table reciprocation.

The shaving cutter mu

erration

or cutting

action will be impaired. To obtain

a crowned

have the differential-type

lead on the work. it is nece sary to grind into the

having cutter lead a reverse crown or hollow. In
all cases of plunge shaving, tile face width of the
shaving tool must be greater than that of the
work gear. The primary advantage of plunge
shaving is a very short cycle time.
Shaving Internal' Gears -Internal
be shaved on special machines

gears can

in which the

work drives the cutter (Fig. 12), or by internal

cutter head attachments

on external

shaving

machines (Fig. 13).

Because of tile crossed axes relation hip between the cutter and the workgear in internal
having, the cutter require

a slight amount of

crown in the teeth to avoid interference with the

work gear teeth. Crowning ofthe teeth on gears
over 19 mm (3/4") wideis best achieved by a
rocking action of the work head similar to the
rocking table action with external gear shaving.
When internalgear

are.19 mm (3/4") wide

Fig. 1.3- Ex~.ernal shaver wHit internal. cutter headattachment,

and under, or should Interference limit the work

and crossed axes angle, plunge

Feed is fine and the tool contact zone is re-

shaviag can be applied. The cutter is provided

stricted. Cutter life depends on . everal factor :

with differential

operating

reciprocation

errations and plunge-fed

up-

peed. feed ..material and hardne s of

ward into the work. If lead crown is desired on

the work gear, its required tolerances, type of

the work gear, a reverse crowned cutter is used

coolant, and the size ratio of culler to work gear.

Design - Rotary gear shaving cutters are de-

with the plunge feed shaving process.

signed much like other helical involute gears.

The Shaving Cutter

Rotary

having cutter

The serrations on the tooth profiles, in conjunc-

are high-precision.

hardened and ground, high-speed steel generat-

tion with the crossing of the axes of the cutter and

ing tools held to Class A and AA tolerances in

the work gear, make it a cutting tool. In design-

all principle elements (Fig. 14). The gashe

ing rotary gear shaving cutters, the following are

in

the having cutter extend 'the fun length of the

some of the points that must be considered:

space at the

I. Normal diametral pitch and normal pres-

bottom. The e clearance spaces provide unre-

sure angle must be the same as those of the gears

stricted channel

to be shaved.

tooth, terminating

in a clearance

for a constant flow of coolant

to promptly di pose of chips. They also permit

uniform depth of serration penetration

and in-

crease cutter life.

The shaving cutter i rotated at high speeds
up to 122m (400 and more surface ft.) per minute.

2. Helix angle is chosen to give a desired

crossed axis angle between the cutter and work.
The crossed axis angle is the difference between
the helix angles of the shaving cutter and work
gear. The desired range is from 5 to 1.5.
MARCH

APRILI~92

19

approximately

0.74 mm (0.005").

An exces-

sively dull or damaged tool must be ground until

all traces of dullness or damage are removed.
The number of sharpenings varies with pitch
and available depth of serrations. Usually a cutter can be sharpened until the depth of serrations
has been reduced to approximately 0.115 to 0.30
111m

(0.006 to 0.012").

Sbaving Machines
Rotary gear shaving machines are manufactured in various configurations to meet the needs
of the gear producing industry. Gears smaller than
25mm (I. ") and as large as 5.1. m (200") require
different approaches.

Rotary gear shaving uti-

lizes a shaving machine that has a motor-driven

cutter ami a reciprocating work

table ..The cutter

head is adju table to obtain the desired crossed

axis relationship with the work. The work carried
between centers is driven by the cutter. Ma-

Fig. M Vari.ety ofshaviag cutters.

chines are available ranging from mechanical. to

3. The number of teeth is chosen to give the

appropriate
inghelix

During the shaving cycle, the work is recipro-

angle and diarnetral pitch. Hunting

cated and fed incrementally into the cutter with

tooth conditions and machine capacity are also

each stroke of the table. The number of infeeds

important factors.

and strokes depends on the shaving method and

4. Tooth thickness of the cutter is selected to

provide

for optimum

operating

conditions

throughout the life of the tool.

5. The addendum is always calculated so the

the Work:

Gear ..The work gear should be shaved from the

same locating points or surfaces used in the
from these same surfaces .. Locating faces must

ing gear. Tooth thickne.

be clean, parallel, and square with the gear bore.

and addendum of the

'Gears with splined bores may be located from

the major diameter, pitch diameter, or minor

6. Cuner . errations are lands and gashes in the

diameter. When shaving from centers, the true

involute profile of the tool. They extend from the

center angle should be qualified and the surfaces

top to the bottom of the tooth clearing into a relief

should be free of nicks, scale, and burrs. Locat-

hole at its base. The width or size is determined by

ing points of work arbors and fixtures should 'be

the work gear to be shaved. Differential serrations

held within a tolerance of 0.005 mm (0.0002").

with a control lead are produced on shaving

The arbor should fit the gear hole snugly. Head

cutters used for plunge shaving and diagonal with

and tailstock centers should run within 0.005

the traverse angle over 55.

mm (O.OOO2") for dependable

7. The involute profile of the shaving cutter

results.

Gears

should be shaved from their own centers whenever possible. If this is not possible, rigid, hard-

must be modified to produce the desired involute

ened, and ground arbors having large

form or modifications in the profile of the gears

centers should be used (Fig. 15). Integral tool-

being shaved.

ing is another popular method of holding the

Sharpening Shaving Cutlers - The shaving

H N a LOG Y

Setup - Mounting

preshave operation. It. should also be checked

tooth is not always a true involute. Very often, it

TEe

The Machine

below the lowest point of contact with the mat-

pitch diameter.

C! EAR

amount of shaving stock to be removed.

shaving cutter will finish the gear profile slightly

cutter are not necessarily given to the theoretical

,20

one CNC axis to full five CNC axes.

pitch diameter required, consider-

workpiece,

especially in highproduction,

afety

This

cutter, like other tools, dulls with use. In sharp-

consists of hardened and ground plugs, instead

ening, minimum stock is removed on the tooth

of centers, mounted on the head and tailstock

faces. With normal dullness, the resharpening

(Fig. 16). These plugs are easily detached and

operations

replaced when nece

usually reduce the tooth thickness

sary. They locate in the

bore and against the face of'the gear. It is therefore essential that the gear faces be square and
bore tolerances held to assure a good slip fit on
the plugs ..
Mounting the Cutter. Great care is required in
handling the shaving cutter to avoid any accidental contacts 'between its teeth and other hard
objects. The slightest bump may nick a tooth.

BASIC

PLUGCLJP

Until the cutter is placed on its spindle it should

FLANGED

PLLJG-CLJP

lie flat and away from other objects. The cutter

spindle and spacers should be thoroughly cleaned

and the spindle checked before the cutter is

Fig. IS- Ty-pical. hardened and ground work-holding

mounted. The spindle should run within a 0.005

arbors.

.-"~-",,",,,"r-

-""\
I

mm (0.0002") on the 0.0. and 0.0025 mm

I
I

(0.0001 ") on the flange full indicator reading.

After mounting,
indicated

fI

,.......-~-t:LJ

the cutter face should be

to check mounting

accuracy.

Face

runout should not exceed 0.02 mm (0.0008") for

a 30.5-em (I 20") cutter; 0.0] 5 mm (0.0006") for

INTEGRAL

PLUGCUP

Fig. 16- Integral work-holding

INTEGRAL

formula for determining the table traverse rate

I8-cm (7") cutter.

(in.lmin) 10 produce a] .O-mm (0.040") effective

speeds will vary with the gear material hardness,

I8-em (7") cutter on a 2.5-m (lO-pitch)
speed will be approximately
using a 23-cm (9")cuUer,

Table traverse rate [mmlmin (in.zminj]

1.0 mmc(0.040") x Gear r/min.

ill

Rf

gear

spindle

200 r/min; or,

where

1.60r/rnin. This speed

figured on the pitch circle is approximately

surface

EXPANDING

feed rare:

finish. and size of part. Normally, when using a

having a 7.6-cm (3") pitch diameter,

J)

arbors.

a 23-cm (9") cutter; or 0.10I mm (0.0004") for a

Feeds and Speeds. Shaving cutter spindle

__

Rf

122

(400 surface ft) per minute and this

sine traverse angle

tangent crossed axes angle

cosine traverse angle

generally produces good results.

The following are formulae for determining

These suggested feed rates may be varied

cutter and gear speeds (r/min):

Cutter r/min ;;;;:desired surface speed per min
cutter diameter x

1t

depending on indi vidual operating conditions. If

higher production is desired, the table feed rate
can be increased, but this may result in some

Gear rlmin;;;;:

sacrifice of the quality of tooth finish. Where

cutter r{min x number of teeth in cutter

surface finish is very important.as

w:ith aviation

and marine gears, table feeds are reduced below

number of teeth in gear

the amounts indicated. In some ca es (notably.

For conventional

shaving.

about

0.25 mm

(0.010") per revolution of the gear is considered

I.

large tractor applications), feeds considerably in

excess of those indicated are used.

a good starting point and becomes a factor in the

foUowing formula:
Table feed rate [mmlm:in (in.lrnin)] :::::
0.25 (0.010) x 'Gear r/rnin
For diagonal shaving ,an "effecti ve feed rate" of

From Dudley's Gear Handbook. Znd ed. Dennis

P. Townsend. ed., 1991 by McGraw-Hill.

Re-

printed by permission of McGraw-Hill Publishing Co.

appro imately LOmrn (0..0.40.") per revolution of

gear is considered a good starting point. Effec-

This is the conclusion of Part 1. Part llof this

tive feed rate is the rate of the speed at which the

article, which will run in our next issue, will

point ofcrossed axes migrates across tbe face of

cover gear roll-finishing and rotary gear honing

the gear and having cutter ..The following is the

of both shaved and ground gears.

t.I " R CHI

It P R

1 992

21