Gear Cutting Tools Fundamentals of Design and Computation

This book presents the DG/K-based method of surface generation, a novel and practical mathematical method for designing gear cutting tools with optimal parameters. The author, an industry leader for the past 30 years, proposes a scientific classification for all possible kinds of the gear machining meshes before discussing optimal designs of gear cutting tools. This classification makes it possible to consider all possible designs of gear cutting tools, including those currently used in practice and those expected to be used in the future. It also allows the author to develop scientific predictions and optimal designs. In most cases, solutions appear in analytical form and/or graphical form.

Part I: Basics Gears: Geometry of the Tooth FlanksBasic Kinds of GearsAnalytical Description of Gear Tooth FlanksGear Tooth Surfaces those Allowing Sliding Over ThemPrincipal Kinematics of Gear Machining OperationsRelative Motions in Gear Machining Rolling of the Conjugate SurfacesKinematics 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 TransformationsCoordinate Systems Transformation Conversion of the Coordinate System Orientation Direct Transformation of Surfaces Fundamental Forms Part II: Form Gear Cutting ToolsGear Broaching Tools Kinematics of the Gear Broaching Process Generating Surface of a Gear BroachCutting Edges of the Gear Broaching ToolsChip Removal Diagrams Sharpening of Gear Broaches A Concept of Precision Gear Broaching Tool for Machining Involute GearsApplication of Gear Broaching ToolsShear-Speed CuttingRotary Broaches: Slater ToolsBroaching Bevel Gear Teeth End-Type Gear Milling CuttersKinematics of Gear Cutting with End-Type Milling Cutter Generating Surface of the End-Type Gear Milling CutterCutting 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 CuttersKinematics of Gear Cutting with Disk-Type Milling Cutter Generating Surface of the Disk-Type Gear Milling CutterCutting Edges of the Disk-Type Gear Milling CutterProfiling of the Disk-Type Gear Milling CuttersCutting Edge Geometry of the Disk-Type Milling Cutter Disk-Type Milling Cutters for Roughing of GearsAccuracy of the Gear Tooth Flanks Machined with the Disk-Type Milling CuttersApplication of Disk-Type Gear Milling CuttersNontraditional Methods of Gear Machining with Form Cutting ToolsPlurality of Single-Parametric Motions Implementation of the Single-Parametric Motions for Designing of Form Gear CuttingToolDiversity 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 MeshRack Cutters for Planing of Gears Generating Surface of Rack CutterOn the Variety of Feasible Tooth Profiles of the Rack Cutters Cutting Edges of the Rack Cutter Profiling of the Rack CuttersCutting Edge Geometry of the Rack CutterChip Thickness Cut by Cutting Edges of the Rack Cutter Tooth Accuracy of the Machined GearApplication of the Rack Cutters Potential Methods of Gear Cutting and Designs of Rack-Type Gear Cutting ToolsGear Shaper Cutters I: External Gear Machining MeshKinematics 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 ProfileThickness of Chip Cut by Shaper Cutter ToothAccuracy of Gears Cut with the Shaper CutterApplication of Gear Shaper CuttersGear Shaper Cutters II: Internal Gear Machining Mesh Kinematics of Shaping Operation of an Internal GearDesign of Shaper CuttersThickness 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 MeshGear 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 GearsPrincipal Elements of Kinematics of Bevel Gear GenerationGeometry of the Interacting Tooth SurfacesPeculiarities of Generation of Straight Bevel Gears with Offset TeethGeneration of Straight Bevel Gear Teeth Peculiarities of Straight Bevel Gear CuttingMilling of Straight Bevel GearsMachining of Bevel Gears having Curved Teeth Gear Shaper Cutters Having Tilted Axis of Rotation: Internal Gear Machining MeshPrincipal 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 MeshGenerating Surface of the Gear Cutting Tool Kinematics of External Spatial Gear Machining Mesh Auxiliary Generating Surface of the Gear Cutting ToolExamples of Possible Kinds of Auxiliary Generating Surfaces of Gear Cutting ToolsGeneration of Generating Surface of a Gear Cutting Tool Use of the DG-Based Methods for the Determination of the Design Parameters ofGenerating Surfaces of the Gear Cutting ToolsPossible Kinds of Generating Surfaces of Gear Cutting ToolsConstraints 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 ToolGeometry and Generation of Rake Surface of a Gear HobGeometry 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 ToothConstraints 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 CutterDesign of Gear Shaving Cutters Axial Method of Gear Shaving ProcessDiagonal Method of Gear Shaving ProcessTangential Method of Gear Shaving Process Plunge Method of Gear Shaving Process Advances in Design of Shaving CutterPeculiarities of Gear Shaving Process Examples of Implementation of the Classification of Kinds of the Gear Machining Meshes A Hob for Tangential Gear HobbingA Hob for Plunge Gear HobbingHobbing of a Face GearA 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 GearsA Gear Cutting Tool for Machining a Worm in Continuously Indexing Method Rack Shaving Cutters A Tool for Reinforcement of a Gear by Surface Plastic DeformationConical 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 MeshGear 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 ConclusionAppendicesReferencesIndex