Gear-Shaping Machine,

Model 5M14

A Case Study
Introduction
■ The model 5M14 (Fig. 232) is a vertical gear
shaper, intended for cutting:
■ external and internal spur gears, and
is adapted to cut gear clusters.
■ With special helical guides; the machine can
also shape helical gears.
Fig. 232 Gear-shaping machine, model 5M14
1-base; 2-work table; 3-spindle head; 4 -spindle
radial-infeed mechanism.
Blank and Cutter Relative Movements
Specifications
■ maximum diameter of gear blank, 500 mm;
■ maximum gear face width to be cut, 105 mm;
■ maximum module of steel gears to be cut, 5 mm;
■ maximum external diameter of internal gear blank,
550 mm;
■ length of cutter spindle travel, up to 125 mm;
■ minimum pitch circle diameter of shaping cutter, 100
mm;
■ maximum travel of saddle, 500 mm,
■ main motor power, 3 KW
■ overall dimensions, 1800 X 1350 X 2200 mm.
Working Principle of the Machine
■ The shaping of gears is effected by the generating
method.
■ In operation, the shaping cutter is imparted a
reciprocating movement parallel to the gear blank
axis (the principal movement) and simultaneously,
rotation about its axis.
■ The gear blank, mounted on the work table mandrel,
receives interrelated rotations from the cutter.
■ The interrelated rotations of the cutter and the blank
form a complex generating roll movement (circular
feed).
Blank and Cutter Relative Movements
■ At the beginning of shaping, the cutter moves
automatically towards the gear blank axis (radial
infeed), until the whole depth of tooth space is
reached.
■ The radial infeed is then terminated, and the blank is
shaped during a full revolution with the circular feed
only.
■ Depending on the module of the gear being
machined, its cutting is carried out in one, two, or
three passes.
■ When cutting in several passes, the infeed motion is
repeated before each pass.
Schematic Diagram of Radial Infeed
Motion
■ When moving downwards, the shaping cutter
performs the cutting stroke, removing stock from the
blank.
■ During the return stroke, which is the idle one, the
work table with the blank is slightly withdrawn from
the cutter.
■ Before the beginning of the cutting stroke, the work
table returns to the initial position.
■ When the gear cutting is completed, the machine
stops automatically.
Blank and Cutter Relative Movements
Movements in the machine
Reciprocating movement of the shaping cutter is
effected (Fig. 233) by:
■ Motor (N = 3 kW; n = 1430 rpm) through
V-belt, drive 100/280,
■ shaft I, carries two double gear clusters G1
and G2;
■ shaft II carries 4 fixed gears. Mounted on the
left end of this shaft is a crank disc with a
radial slot housing an adjustable pin linked
with a connecting rod on which rack m = 3.25
mm is cut;
Fig. 233 Kinematic diagram of
model 5M14
Gear Shaper model 5M14
Fig. 233 Partial Kinematic diagram
of model 5M14
Partial Kinematic Diagram of Gear
Shaper model 5M14
Schematic Diagram of Crank Disc and
Adjustable Pin
■ Rack and pinion (z = 26) transmission;
■ shaft III;
■ Pinion-and-rack (z = 26), the rack being
secured on the cutter sleeve.
■ As the crank mechanism with the rack and
pinion imparts to shaft III a
rotary-reciprocating (swinging) movement,
the spindle receives a rectilinear
reciprocating movement.
Movements in the machine
The basic displacements for the cutting
speed kinematic chain are:
1430 rpm of the motor n double strokes
per min of the shaping cutter.
The Kinematic balance equation for speed of
shaft n :
II
Kinematic balance equation for speed of
shaft n II

Hence, nII = 125, 179, 265, and 400 double strokes per min.
The required number of strokes for the shaping
cutter is determined from the formula:
n = (1000 Vm)/2l
Where,
Vm = selected mean cutting speed, m/min
l = b + c = length of cutter travel, mm
b = face width of blank, mm
c = over travel of cutter to either side of blank, mm

(Please see figure in the next slide)

Cutter and the workpiece
Circular Feed Gear Train
■ The speed of cutter rotation defines the
generating-roll movement speed (circular feed).
■ Circular feed, sc is usually expressed for gear
shapers as the circular travel of the shaping cutter
along the pitch circle arc per double stroke of the
cutter.
■ Accordingly, the circular-feed gear train relates the
cutter rotation to the double stroke of the cutter, i.e. 1
rotation of shaft II, as per rotation of shaft II, cutter
performs 1 double stroke.
The basic displacements for the circular-feed
gear train are:
1 double stroke of the shaping cutter sc mm of
move along pitch circle arc of cutter
Circular Feed
Circular Feed Gear Train
The kinemaic balance equation for the feed
gear train is:

Hence, the set-up formula of the circular-feed change-

Gear train is:

Where m and zsc are the cutter module and number of

teeth, respectively.
In this machine tool A + B = 89.
The machine is provided with a set of pick-off
gears with the numbers of teeth as follows:

23, 24, 25 (2 pieces each), 30, 34, 35, 37,

40, 41, 43, 45, 47, 48, 50, 53, 55, 58, 59, 60,
61, 62, 65, 67, 70, 71, 73, 79, 80, 83, 85, 89,
90, 92, 95, 98, 100.
■ Example Problem #1:
■ Determine approximately the teeth number of the Gears, A
and B of the circular feed change gear train if the
following are known:
■ Zsc =50
■ m = 2.0 mm (cutter module)
■ sc = 0.5 mm/double stroke of the cutter (Circular feed)
■ A + B = 89
■ Available gears are: 23, 24, 25 (2 pieces each), 30, 34, 35,
37, 40, 41, 43, 45, 47, 48, 50, 53, 55, 58, 59, 60, 61, 62,
65, 67, 70, 71, 73, 79, 80, 83, 85, 89, 90, 92, 95, 98, 100.
Solution:
A + B = 89 (1)
A = 89 –B (1’)
A/B = 366 Sc/m . Zsc (2)
A = (366 Sc x B)/(m x Zsc) (2’)
Or, (89 –B) = (366 Sc x B)/(m x Zsc) (3)
Or, (89 – B) = (366 x 0.5 x B)/(2 x 50)
Or, (89 – B) = (183 B)/100
Or, 8900 – 100 B = 183 B
Or, 283 B = 8900
Or, B = 8900/283 = 31.5
Therefore, A = 89-30 = 59
A = 59, B = 30
Indexing Gear Train
Rotation of the gear blank is linked with rotation
of the shaping cutter by means of an indexing gear
train. The blank should make zsc/Z revolutions for
every revolution of the cutter (Fig. 233).

The basic displacements are:

1 rotation of the cutter zsc/z rotation of the
gear blank.
[Since, Z rotation of Cutter = ZSC rotation of Gear Blank,
Therefore, 1 rotation of Cutter = Z/ZSC rotation of Gear
Blank]
Ration of Cutter and Gear Blank
Rotations
■ The kinematic balance equation for the indexing gear
train is:

■ and the set-up formula for the indexing change-gear

train is:

■ To simplify the calculation of the change gears

(a/b) x (c/d), c is taken to be divisible by the number
of teeth of the cutter, their ratio being 1:1 or 2:1,
i.e. c = zsc or c = 2zsc
■ Example Problem #2:
■ Determine the teeth number of the Gears, a, b, c and
d of the indexing change gear quadrant if the
following are known:
■ Zsc =100 (Cutter teeth number)
■ Z =100 (Gear teeth number)
■ c = zsc = 100
■ Available gears are:
23, 24, 25 (2 pieces each), 30, 34, 35, 37, 40, 41, 43,
45, 47, 48, 50, 53, 55, 58, 59, 60, 61, 62, 65, 67, 70,
71, 73, 79, 80, 83, 85, 89, 90, 92, 95, 98, 100.
Solution:
a/b x c/d = 2.4 (Zsc/Z)
= (24/10) x (100/100)
= (24/10) x (100/10x10)
= (24/2x5) x (100/2x5x10)
= (24/25) x (100/2x2x10)
= (24/25) x (100/40)
Radial Infeed Gear Train
■ Radial infeed, sr mm is the radial move of the cutter
per double stroke of of the same (i.e. 1 rotation of
shaft II).

■ Radial infeed, sr per double stroke of the cutter is

selected depending on the material hardness, module
and required surface finish of the gear to be cut.
Radial Infeed Motion
■ Basic Displacement of this Gear train is:
1 double stroke of the cutter (i.e. 1 rotation of shaft
II) sr mm of radial feed per double stroke

■ Cam K1 (Fig. 233), imparting radial infeed to the

cutter, receives rotation from Shaft II through the
following kinematic chain:
■ shaft II, gears 28/28, shaft IV, shaft XIII, pick-off gears
(a1/b1) x (c1/d1) of the radial infeed change-gear train,
shaft XIV, bevel gears 24/48, shaft XV, worm gearing
1/40, clutch C2, shaft XVI, worm gearing 2/40, shaft
XVII.
■ Cam K1 imparts a straight movement through roller R
to feed screw XVIII linked with the saddle by means
of a nut integral with bevel gear z = 30.
Radial Infeed Gear Train
■ Radial infeed ,sr per double stroke of the cutter is:

■where, H is the lead of the Archimedean spiral on cam

K1 in mm.
Therefore,
■ Example Problem #3:
■ Determine the teeth number of the Gears, a1, b1, c1
and d1 of the indexing change gear quadrant if the
following are known:
■ sr =0.50 mm/double stroke (Radial Feed)
■ H =1200 mm (Helical Lead of the Archimedean
Spiral)
■ Available gears are:
23, 24, 25 (2 pieces each), 30, 34, 35, 37, 40, 41, 43,
45, 47, 48, 50, 53, 55, 58, 59, 60, 61, 62, 65, 67, 70,
71, 73, 79, 80, 83, 85, 89, 90, 92, 95, 98, 100.
Solution:
Given,
(a/b) x (c/d) = (1600/H) x Sr
Or, (a/b) x (c/d) = (1600/1200) x 0.5
Or, (a/b) x (c/d) = (16/12) x 1/2
Or, (a/b) x (c/d) = (4/3) x 1/2
Or, (a/b) x (c/d) = (4/3) x 1/2
Or, (a/b) x (c/d) = [(4x20)/(3x20)] x (1x25)/(2x25)
Or, (a/b) x (c/d) = (80/60) x (25)/(50)
Therefore, a = 80, b = 60, c = 25 and d = 50
Cams used in Radial Infeed Gear Train

■ Radial infeed per double stroke of the cutter is

performed in one, two or three passes, the cycle
being set up by means of interchangeable cams (Fig.
234).
■ “Single pass cam” (Fig. 234a)
■ It has a rise on the lobe section ab.
■ During rotation of the cam, this section (ab) controls
radial displacement of the cutter towards the blank,
i.e. radial infeed.
Fig. 234 Spindle Radial Infeed Cams
■ The profile of the cam section bc is outlined with a
circle arc of 90°, and through this section no radial
movement is imparted to the cutter.
■ As the cam turns through the above sections, the
table with the blank makes one full revolution.
■ From point d the cycle is repeated.

■ The "two-pass" cam (Fig. 234b) is intended for

machining in two revolutions of the blank while the
cam correspondingly turns through 180°. Sections ab
and cd control the infeed for the first and the second
passes, respectively.
Fig. 234 Spindle Radial Infeed Cams
■ The "three-pass" cam (Fig. 234c) is used for
machining in three revolutions of the blank (apart
from the infeed) while the cam turns through 270°.

■ Sections ab, cd, and ef control the infeed for the first,
second, and third passes respectively.
Fig. 234 Spindle Radial Infeed Cams
The set-up of the shaping cutter
■ The set-up of the shaping cutter on the
machine is shown in Fig. 236.
■ The cutter is tightly fitted on the spindle with
the cutting edges facing down.
Fig. 236. Placement of shaping cutter
(a)
Fig. 236. Revrese arrangement of
shaping cutter
The set-up of the gear blank
Mounting of the Gear Blank:
■ The mandrel for mounting the blank is
inserted into the taper hole of the work table
spindle.
■ The mandrel setting is checked for radial
run-out and parallel alignment of the mandrel
axis to the direction of cutter movement.
Fig. 236. Placement of workpiece (b)
Accuracy of mandrel radial run-out

■ The mandrel radial run-out should not exceed 0.01

mm at a height of 200 mm from the table surface, and
0.008 mm at the level of the table surface.
■ The permissible radial run-out of the blank diameter
is from 0.01 to 0.05 mm (depending on the module,
diameter, and required accuracy of the gear to be
cut).
Cutting internal gears
■ For changing over from machining external to internal
gears it is essential to displace the cutter spindle
head to the right from the table centre and change
the direction of the blank rotation, the latter being
done by introducing an idler gear in the indexing
change-gear train.
■ Otherwise, the set-up is accomplished in the same
manner as for external gears.
■ To prevent the tooth addendum flank of internal gears
from undercutting, the ratio between the number of
teeth of the gear being cut and that of the shaping
cutter should be taken into consideration.
■ With the working transverse pressure angle equal to
20°, the permissible difference between the numbers
of gear blank and cutter teeth should not be less than
12.
Cutting of helical gears
■ Cutting helical gears is accomplished by helical
shaping cutters in the following manner (Fig. 235).
■ A special helical guide for the cutter spindle is
installed in the saddle in place of a straight guide.
■ The helix lead of the guide should be equal to that of
the cutter used for shaping a given gear.
Fig. 235. Set-up for cutting helical gears
1-movable part of helical guide, 2-shaping cutter, 3 –
workpiece.
■ The helical guide consists of two parts: a movable
one secured to the cutter spindle, and an immovable
one mounted in the sleeve of worm wheel z = 100
(Fig. 233).
■ The immovable part rotates with the worm wheel,
while the movable one, reciprocates with the cutter
spindle, receiving additional forced rotation from the
fixed part.
Adjusting the length of travel of the
cutter
■ Adjusting the length of travel of the cutter is
effected by means of a crank mechanism (Fig. 237).
■ Crank disc 2 with pin 3 (Fig. 237) is rigidly secured at
the left end of shaft II (Fig. 233) of the speed
gearbox.
■ To adjust the length of travel of the cutter, nut 11 on
pin 3 of crank disc 2 (Fig. 237) is released and
square a of adjusting screw 1 is turned with a
spanner, until the pointer on the reading device
indicates the required graduation on the scale.
■ Nut 11 should then be tightened after the adjustment
Fig. 237. Mechanism for adjusting cutter
travel length

11 10 8 9
1- adjusting screw, 2 - Crank disc, 3 – pin, 4 - connecting rod,
5 – Screw, 6 – sleeve, 7 – adjusting nut, 8 - splined shaft, 9- pinion,
10 - lock screw, 11 – Nut, a, b - squares
Fig. 233 (Partial)
Crank Disc (Left side view)
Adjusting the Initial position of the
cutter relative to the blank
■ The initial position of the cutter travel in respect to
the blank is adjusted as follows:
■ First, nut 7 and lock screw 10 are released, and then
square b (Fig. 237) is turned with a handle.
■ Screw 5 is screwed in or out thus displacing sleeve 6
with the rack, thus adjusting the length of the rod
connecting the eccentric pin and the rack.
■ The rack rotates pinion 9 which is mounted on splined
shaft 8 (Fig. 237) (z=26 mounted at the left side of
shaft III of Fig 233).
Fig. 237. Mechanism for adjusting cutter
travel length

11 10 8 9
1- adjusting screw, 2 - Crank disc, 3 – pin, 4 - connecting rod,
5 – Screw, 6 – sleeve, 7 – adjusting nut, 8 - splined shaft, 9- pinion,
10 - lock screw, 11 – Nut, a, b - squares
Fig. 233 (Partial)
■ This in turn rotates a pinion which meshes
with a rack secured to the cutter spindle
sleeve (Pinion z=26 on the right side of shaft
III of Fig 233) and displaces the cutter up or
down.
■ Upon the completion of adjustment, nut 7 and
lock screw 10 on the split portion of
connecting rod 4 should be tightened.
Fig. 237. Mechanism for adjusting cutter
travel length

11 10 8 9
1- adjusting screw, 2 - Crank disc, 3 – pin, 4 - connecting rod,
5 – Screw, 6 – sleeve, 7 – adjusting nut, 8 - splined shaft, 9- pinion,
10 - lock screw, 11 – Nut, a, b - squares
Mechanism for table and blank
oscillation

■ Withdrawal of the table with the blank

during the return stroke of the cutter is
accomplished by an eccentric drive and a
crank mechanism (Fig. 233 and 238).
Fig. 233 (Enlarged)
Fig. 238. Mechanism for table
oscillation

1 – rocker, 2 – carrier, 3
- link rod, 4 – frame,
5 shaft, 6 - Eccentric
disc, 7 – stop, 8 – Strip,
9 - table housing,
10 - connecting rod, 11
– pin, 12 - crank disc,
13 – shaft.
Mechanism for table and blank
oscillation
■ The right end of shaft II carries eccentric
disc E (Fig. 233), (Disc 6 of Fig. 238).
■ This disc imparts a reciprocating motion to
frame 4, linked to rod 3 and carrier 2.
■ Carrier 2 is connected to rocker 1 fastened
on shaft 13.
■ At the opposite end of shaft 13, crank disc
12 with an eccentric pin 11 is fastened,
■ A connecting rod (10) is attached to pin 11
at one end and the table at the other end.
■ When the cutter returns upwards, eccentric
disc 6 moves frame 4 downwards, the crank
disc 12 turns clockwise, withdrawing the table
with the blank from the cutter.
■ Strip 8 and stop 7 are provided to prevent
impacts resulting from the table oscillation
movement.
Mechanism for Engagement of Radial infeed
and the counting and switching-off device
■ This mechanism is shown in Fig. 239.
■ Feed- screw 17, linked with the saddle, has at its right end
roller 13 which is constantly urged to infeed control cam
16 by a spring mounted in the left part, of the saddle (not
shown in the diagram).
■ At the beginning of every work cycle the roller is in the
recess of the cam.
■ The cutter is brought to mesh with the workpiece manually
by rotating a handle (Fig.233) while the reciprocating
motion of the cutter is switched on.
■ When the feed motion is engaged, the cam rotates and
the roller moves along the rise lobe of the cam [along arc
ab of the cams, Fig. 234], displacing screw 17 and the
saddle along with the cutter to the right to impart radial
infeed motion.
 Fig. 239. Cutter infeed mechanism with
counting and switching-off device
1 – segment, 2 –
pawl, 3, 6 – gears,
4, 5 shafts, 8, 9 –
springs, 10 - lock
pin, 11 - hand lever,
12 – lever, 13 –
roller, 14 – stop, 15 -
limit switch, 16 –
cam, 17 – screw, 18
– dog, 19 - ratchet
wheel, 20 – worm,
21 - link rod, C –
clutch,
Fig. 233: Radial Feed Gear Train
Fig. 234 Spindle Radial Infeed Cams
■ Cam 16 is driven from shaft 5 through change gears
6, bevel gears 4, worm gearing 7-22, shaft 23, clutch
C, worm 20, worm wheel 3, cam, C and roller, 13
during the radial infeed mechanism.
Engagement of Radial infeed of the saddle
■ This is done by shifting hand lever 11 to the right,
beneath lock pin 10.
■ Here, lever 11 shifts clutch C to the right and engages
it by means of link rod 21 and a shifting fork.
■ Simultaneously, dog 18 lifts pawl 2 and holds it out of
engagement with ratchet wheel 19.
 Fig. 239. Cutter infeed mechanism with
counting and switching-off device

1 – segment, 2 – pawl,
3, 6 – gears,
4, 5 shafts, 8, 9 –
springs, 10 - lock pin,
11 - hand lever, 12 –
lever, 13 – roller, 14 –
stop, 15 - limit switch,
16 – cam, 17 – screw,
18 – dog, 19 - ratchet
wheel, 20 – worm, 21 -
link rod, C – clutch,
 Engagement of the switching and Counting Off Device:
■Lever 12, carrying lock pin 10, is, supported by a circular segment
located at the rear face of the cam 16, shown in the next slide.
■As soon as the infeed is ended, the circular support for lever 12
comes to an end and it drops under the action of spring 9 raising
lock pin 10 which releases lever 11.
■In turn, lever 11 shifts to the left under the action of spring 8, and
thereby disengaging clutch C, and displacing dog 18 to the left.
Thus pawl 2 is released, it falls onto ratchet wheel 19 under the
force of gravity.
■Thus the radial infeed is disconnected and radial feed cam starts to
receive motion from shaft X of the gearbox (Fig. 233) as follow:
Rear View of the Cam profile
■ Ratchet wheel (19, Fig. 239) turns by 1 tooth
every time due to the swinging motion of pawl
2, which is mounted on segment 1.
■ Segment 1 in tern receives swinging motion
from cam K2 secured on shaft X (Fig. 233).
 Fig. 239. Cutter infeed mechanism with
counting and switching-off device
1 – segment, 2 –
pawl, 3, 6 – gears,
4, 5 shafts, 8, 9 –
springs, 10 - lock
pin, 11 - hand lever,
12 – lever, 13 –
roller, 14 – stop, 15 -
limit switch, 16 –
cam, 17 – screw, 18
– dog, 19 - ratchet
wheel, 20 – worm,
21 - link rod, C –
clutch,
K2 - cam
Fig. 233: Counting and Switching Off
Device
■ In each swinging of the pawl, the ratchet wheel is
indexed by one tooth, so driving cam 16 through
worm gearing 20-3 (Fig. 239).
■ During this time roller 13 moves along the circular
section of the profile of cam 16, and the radial infeed
does not take place.
■ Upon completion of the work cycle roller 13 gets into
the recess on cam 16.
■ Thereby, screw 17 shifts to the left under the action of
a spring (not shown in Figure) and stop 14 runs up
against limit switch 15, so switching off the machine.
 Fig. 239. Cutter infeed mechanism with
counting and switching-off device
1 – segment, 2 –
pawl, 3, 6 – gears,
4, 5 shafts, 8, 9 –
springs, 10 - lock
pin, 11 - hand lever,
12 – lever, 13 –
roller, 14 – stop, 15 -
limit switch, 16 –
cam, 17 – screw, 18
– dog, 19 - ratchet
wheel, 20 – worm,
21 - link rod, C –
clutch,
K2 - cam
Kinematic Balance Equation for ratched
Wheel-pawl transmission
1 (rotation of Work) x 240/1 x 1/48 x 2/40 =
number of Cam K1 rotation = ¼ rotation of
Cam K1 (Rotation through 90 degrees of the
cam)
Fig. 233: Radial Feed Gear Train
Gear Shaper model 5M14