A 'generated'
surface, whether curved or parallel, is formed by the continuous motion of an
angle, line, or surface. The gear shaper cutters produced depend on how the producing point moves. The most basic
example is the creation of a cylinder on a turning lathe. When the piece of
metal is turned, the tool's cutting point forms a circle. As the tool moves
axially, a cylindrical component is formed.
The gear shaping
process is generally a geometrical precision of the circular component, which
depends on various factors like the trueness of the piece rotation, parallelism
of the motion with the work-spindle axis, and the effect of tool wear. It does
not rely on the state of a tool profile. Again, the process is ongoing. In gear
shapers, the generating above principle is used in the following way:
To aid cutting, the cutter is made harder disc-shaped with a slightly dished bottom (also known as the top rake and clearance). The teeth possess the desired profile along with the pressure angle.
Gear Shaping Machine
The cutter is
reciprocated at the desired cutting speed for removing the stock along the face
of the workpiece, then gradually fed outwardly to plunge it for the proper
teeth depth using a cam. A relieving mechanism allows the cutter to eliminate
the work during non-cutting or return strokes.
The constant
motion is achieved by feeding the gear cutting tools to total depth and gently rotating the cutter and workpiece
in the correct ratio to their respective number of teeth using a chain of gears
that includes changing gears. The cutter is regarded as the driving gear, and
the workpiece is the driven member, with a third component of the gear train
influencing the exact gearbox of motion.
The workpiece gearing is entirely created when the cutter penetrates the workpiece to the correct tooth depth, and the teeth are wholly eliminated and uniformly along the entire perimeter of the workpiece gear. When the workpiece gear is completely cut, the machine automatically stops.
Gear Shaper Principle
The cutting process of a pinion-type cutter used to manufacture a gear. The generating method of cutting gear has the advantage of being able to correctly cut gears with identical components but varied numbers of teeth using a specific cutter module. This makes the production process more functional and cost-effective for gear manufacturing.
In summary, an
involute gear can rotate with any additional gear about the same normal basis
pitch. Hence, the concept has been used in the gear shaper (a process for gear
fabrication). This cutter is designed as a pinion with relieved cutting sides,
and both the blade and the work are rotated about their separate axes to
imitate the conditions that would occur. If both components were complete,
gears rolled alongside at the correct centre distance. This is accomplished by
gearing the cutting tool to the job in proportion to the number of teeth within
the cutter and the finished piece. In this case, cutting is accomplished by
giving the cutter axial reciprocating motion that coincides with its rolling
action, with the ram's stroke length somewhat more than the total length of the
blank.
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