Prepared By:-Sumesh Vijayan 08626 G

Prepared By :-
Sumesh Vijayan
08626 G
Gear shaping is a machinery process for generating
teeth by a corresponding cutter. Gear shaping has
become a convenient operation and one of the most
versatile of all gear cutting operations.
By using a gear-shaped corresponding cutter that is rotated (in
relation to a blank gear) produces the gear teeth.
The cutters that are rotated are timed with the workpiece.
This process produces internal gears, external gears, and integral
gear-pinion arrangements.
The developing process of gear shaping involves a toothed disk

cutter which reciprocates in axial rotations. The workpiece (or
blank gear) rotates on a second shaft (spindle). The workpiece is
correspondent with the cutter and it gradually feeds into the
cutter while rotating. If a two-step process is used, all tooth
spaces are partially cut before the finishing.
The machine used for gear shaping generally consists of a base,
column spindle, and an arbor.
The gear cutter is then mounted on the spindle, and the gear blank
is mounted on the arbor.
The cutter reciprocates up and down while the work piece is
gradually fed into the cutter.
There are following types of Gear Shaper cutter available:
Disc Type Shaper Cutter
Shank Type Cutters
Disk Type Helical Shaper Cutter
Deep Counterbore Type Shaper Cutter
Coniflex CutterPinion Type Cutter
Spiral Bevel Cutter
* Disc Type Shaper Cutter:
Disc type cutters are effective for cutting
any type of gear. Internal, external, spur,
helical etc. Popular cutters have bore
diameters between 10mm-120mm or ½"
to 4".
* Shank Type Cutters:

They are essentially designed to cut
internal gears, both spur and helical. Can
also be designed for externals. A bit of
problem in the shank type cutters is the
strength factor.
* Disk Type Helical Shaper Cutter:
This cutter is applied to cut helical
gears. The helix angle of the gear
determines the number of teeth that
the cutter would have.
* Deep Counterbore Type Shaper

Cutter:
This type of cutter is commonly
applied to cut shoulder gears.
* Pinion Type Cutter:

Pinion type cutters are typically
shaped like spur gears. The Pinion
type cutters are adept in cutting
teeth of the internal gears.
* Coniflex Cutter:
Straight Bevel Gears are easily cut
with Coniflex gear cutter.
Coniflex gear cutters produce
gear teeth with an accurate tooth
contact. So the gears made this
way operate in a smooth fashion.
* Spiral Bevel Cutter:

As is seen from the image Spiral
Bevel cutters are shaped like
crowns and they are used to
generate Spiral Bevel gears.
Due to high economical efficiency, the gear shaving process
is widely used process for soft finishing of gears in the
manufacturing industry.
However due to high increased efficiency, other gear

finishing processes, especially Gear Hobbing have recently
become competitive with the shaving process for soft
finishing of gears.
It is cold working process accomplished by rolling the gear in

contact and under pressure with three hardened burnishing
gears.
In this case, a cutter harder than the work and in the form of
conjugate gear which meshes with it in such a way that when
rotated together, relative sliding between the cutter and work teeth
obtains, is used.
In action one member of the pair is driven and makes the other
rotate.
The value of the crossed axis angle controls the finish produced to
some extent since smaller the angle, finer the finish.
Shaving improves gear tooth finish where the cutting process has
not provided the required standard. The process is ideal for
automotive gear box gears after hobbing and before hardening.
There is a wide range of available shaving cutter types:
Transverse Shaving Cutters
Diagonal Shaving Cutters
Plunge Shaving Cutters
Underpass Shaving Cutters

• The gear that is shaved
reciprocates in the direction of
its own axis.
• The tool and the gear are in
mesh.
• With each step of reciprocation,
there is an occurrence of small
quantity of radial feeding of the
shaving cutter.
• However, this method is not
suited to shaving shoulder
gears.
• Here the gear selected for
shaving reciprocates obliquely in
direction to its own axis.
• The gear and the tool are made
to stay in a mesh.
• The diagonal angle can be got by
positioning of the workpiece
table in an oblique manner.
• As with each reciprocation, there
is a radial feeding of the shaving
cutter.
• This is described in the diagram:
• In this method there is no worktable translation.
• Instead there takes place a radial feed of the workpiece
against the tool that is used as shaving cutter.
• Plunge shaving is particularly good for shaving of shoulder
gear.
• Underpass shaving is primarily identical to diagonal shaving with
a small variation in the form of a diagonal angle of 90 degrees.
• In underpass shaving no axial table reciprocation takes place.
• In its place, the workpiece reciprocates at right angles to its
own axis.
Improves tooth surface finish.
Eliminates, the problem of tooth end load concentrations.
Effective reduction in the noise of gears with modification in

the tooth profile.
Increase the gear’s load capacity.
Improved safety and service life.

The surface of the tooth is covered with amorphous
or smear metal rather than metal having true
crystalline structure.
Wikipedia
Google
Production Technology by R.K. Jain
Gear Technology.com
THE
END

Prepared By:-Sumesh Vijayan 08626 G

Uploaded by

Prepared By:-Sumesh Vijayan 08626 G

Uploaded by

Prepared By :-

The developing process of gear shaping involves a toothed disk

* Shank Type Cutters:

* Deep Counterbore Type Shaper

* Pinion Type Cutter:

* Spiral Bevel Cutter:

However due to high increased efficiency, other gear

It is cold working process accomplished by rolling the gear in

Transverse Shaving Cutters

Diagonal Shaving Cutters

Plunge Shaving Cutters

Underpass Shaving Cutters

Eliminates, the problem of tooth end load concentrations.

Effective reduction in the noise of gears with modification in

Increase the gear’s load capacity.

Improved safety and service life.

Production Technology by R.K. Jain

You might also like