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Copyright © The McGraw-Hill Companies, Inc.
Permission required for reproduction or display.
PowerPoint to accompany
Krar • Gill • Smid
Technology of Machine Tools6th Edition
Gear Cutting
Unit 70
70-2
Objectives
• Select the proper cutter for any gear to be
cut
• Calculate gear-tooth dimensions for inch
gears
• Calculate gear-tooth dimensions for
metric gears
• Set up and cut a spur gear
70-3
Gear Cutting
• Usually cut to repair or replace gear broken
or lost or no longer carried in inventory
• Industry mass-produces gears on special
machines designed for this purpose
– Gear-shaping machines
– Gear-hobbing machines
70-4
Involute Gear Cutters
• Sharpened on face
• Ensures exact duplication of shape of teeth
– Regardless of how far back face of tooth has
been ground
• Available in many sizes
– Range from 1 to 48 diametral pitch (DP)
– Special cutters for teeth smaller than 48 DP
70-5
Comparative Gear-Tooth Sizes: 4 to 16 DP
Copyright © The McGraw-Hill Companies, Inc.
Permission required for reproduction or display.
70-6
Gear Cutting
• Cutter must be chosen to suit both DP and number
of teeth (N)
– Tooth space for small pinion cannot be same shape as
tooth space for large mating gear
– Teeth on smaller gears must be more curved to prevent
binding of meshing gear teeth
• Sets of gear cutters
– Made in series of slightly different shapes to permit
cutting of any desired number of teeth with assurance
that teeth will mesh with another gear(same DP)
70-7
Cutters
• Generally made in sets of eight
– Numbered from 1 to 8 (also in half sizes)
• Gradual change in shape (sides)
– #1 cutter with straight to #8 with curved sides
• Number of teeth
– #1 will cut teeth in gear 135 teeth to a rack
– #8 will cut only 12 and 13 teeth
• Cutter number permits a more accurate meshing of
teeth (for gears to mesh must have same DP)
70-8
Cutter
Number Range
1 135 teeth to a rack
11⁄2 80 to 134 teeth
2 55 to 134 teeth
21⁄2 42 to 54 teeth
3 35 to 54 teeth
31⁄2 30 to 34 teeth
4 26 to 34 teeth
41⁄2 23 to 25 teeth
Cutter
Number Range
5 21 to 25 teeth
51⁄2 19 and 20 teeth
6 17 to 20 teeth
61⁄2 15 and 16 teeth
7 14 to 16 teeth
71⁄2 13 teeth
8 12 and 13 teeth
Involute Gear Cutters
70-9
Example: Selecting a Cutter
A 10-DP gear and a pinion in mesh have 100 teeth
and 24 teeth, respectively. What cutters should be
used to cut these gears?
Cutter Selection
Since the gears are in mesh, both must be cut with a
10-DP cutter.
A #2 cutter should be used to cut the teeth on
the gear, since it will cut from 55 to 134 teeth.
A #5 cutter should be used to cut the pinion,
since it will cut from 21 to 25 teeth.
70-10
Procedure For Machining a Spur Gear
Example: A 52-tooth gear with an 8 DP is required
1. Calculate all necessary gear data (See previous table)
in. 750.68
54
8
2522 Ndiameter Outside a. ==
+=
+=
DP
in. 2697.8
157.2157.2 tooth ofdepth Wholeb. ===
DP
Cutter number = 3 (35 to 54 teeth)
Continue …
70-11
d. Indexing (using Cincinnati standard plate)
circle hole 39on holes 30 3
3 x
13
10
52
4040====
N
2. Turn gear blank to proper outside diameter
(6.750 in.)
3. Press gear blank firmly onto mandrel
4. Mount index head and footstock, and check the
alignment of the index centers
5. Set dividing head so index pin fits into hole on
39-hole circle and sector arms set for 30 holes
70-12
6. Mount mandrel (and workpiece), with
large end toward indexing head, between
index centers
7. Move table close to column to keep setup
as rigid as possible
8. Mount an 8 DP#3 cutter on milling
machine arbor over approximate center of
the gear
• Be sure to have cutter rotating in direction of
indexing head
70-13
9. Center gear blank with cutter by either of the following methods:
• Place square against outside diameter of gear
• With pair of inside calipers or rule, check distance between square and side of cutter
• Adjust table until distances from both sides of gear blank to sides of cutter are the same
• More accurate method of centralizing cutter is to use gage blocks instead of inside calipers
10. LOCK THE CROSS-SLIDE
11. Start milling cutter and run work under cutter
70-14
12. Raise table until cutter just touches work
13. Set graduated feed collar on the vertical
feed to zero
14. Move work clear of cutter by means of
the longitudinal feed handle
• Raise table to 2/3 depth of tooth (.180 in.)
• Lock knee clamp
15. Slightly notch all gear teeth on end of
work to check for correct indexing
70-15
16. Rough-out first tooth and set automatic
feed trip dog after cutter is clear of work
17. Return table to starting position
• Clear end of work with cutter
18. Cut remaining teeth and return table to
starting position
19. Loosen knee clamp, raise table to full
depth of .270 in., and lock knee clamp
20. Finish-cut all teeth
70-16
Metric Gears
• Countries using metric system usually use
module system of gearing
– Module (M) of a gear equal pitch diameter (PD)
divided by number of teeth (N)
– M is actual dimension
N
PDM =
Table 70.2 in text gives
necessary rules and
formulas for metric
spur gears
70-17
Metric Module Gear Cutters
• Most common available in modules
ranging from 0.5 to 10 mm
• Available in set of eight cutters numbered
from #1 to #8
– Range of each cutter reverse of DP cutter
• Table on next slide shows cutters available
and rang of each cutter in set
70-18
Milling Cutter Numbers
ModuleSize (mm) Cutter No. For Cutting
0.5 3.5
0.75 3.75 1 12 to 13 teeth
1 4 2 14 to 16 teeth
1.25 4.5 3 17 to 20 teeth
1.5 5 4 21 to 25 teeth
1.75 5.5 5 26 to 34 teeth
2 6 6 35 to 54 teeth
2.25 6.5 7 55 to 134 teeth
2.5 7 8 135 teeth to rack
2.75 8
3 9
3.25 10
Metric
Module
Gear
Cutters
70-19
Metric Example:
A spur gear has a PD of 60 mm and 20 teeth. Calculate:
1. Module
2. Circular pitch
3. Addendum
4. Outside diameter
5. Dedendum
6. Whole depth
7. Cutter number
70-20
Solution:
mm320
60
N
PDM .1 ===
mm 9.425 3.1416 x 3 x M CP .2 === π
mm 3.498 1.166 x 3 1.166 x M D .5 ===
mm 66 3 x 22 M x 2) (N OD .4 ==+=
mm 3 M A .3 ==
mm 6.498 2.166 x 3 2.166 x M WD.6 ===
3 table)previous (seenumber utter .7 =C
70-21
Another Metric Example:
Two identical gears in mesh have a CCD of 120 mm. Each gear has 24 teeth. Calculate:
1. Pitch diameter
2. Module
3. Outside diameter
4. Whole depth
5. Circular pitch
6. Chordal thickness
70-22
Solution:
mm 1202
240
2
120 x 2
2
CD x 2 PD 1. ====
524
120
N
PD M 2. ===
mm 130 5 x 26 M x 2) (N OD 3. ==+=
mm 10.83 2.166 x 5 2.166 x M WD4. ===
mm 15.708 3.1416 x 5 x M CP 5. === π
mm 85.72
3.1416 x 5
2
x M CT 6. ===
π
70-23
Gear-Tooth Measurement
• Measure with gear tooth vernier caliper
– Set to corrected addendum
• May also be checked by measuring over wires or pins of a specific diameter placed in two diametrically opposite tooth spaces of the gear
– Tables in most handbooks give measurement over wires having given number of teeth and specific pressure angle
70-24
Gear-Tooth Measurement
• Accurate measurement of inch gears need diametral pitch and number of teeth of gear
– For metric gears, the module must be known
• Wire or pin size to use determined by
1. For external inch spur gears, wire or pin size equal to 1.728 divided by DP of gear
2. For internal inch spur gears, wire size equal to 1.44 divided by DP of gear
3. Metric module gears measured using wire size equal to 1.728 multiplied by module of gear
70-25
Example (Inch):
Determine wire size and measurement over the
wires for a 10-DP external gear having 28 teeth
and a 14.50º pressure angle.
in. 1728.10
1.728 size Wire ==
In handbook tables, size over wires for gear having
28 teeth and 14.50º pressure angle should be
30.4374 in. divided by DP.
in. 0437.310
30.4374 ==
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