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.
Types of cutters used for gear shaping can be grouped into about four categories: #disk, #hub, #shank, and #helical cutters.
The cutters are essentially gears that are used to form the teeth. This method of gear cutting is based on the principle that any two gears will mesh if they are of the same pitch, proper helix angle, and proper tooth depth and thickness
Process Characteristics:
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
Process Schematic:
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.
Setup and Equipment:
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(gear blank) is gradually fed into the cutter. At the end of each cutting rotation, the spindle is retracted slightly to discourage anymore cutting into the new cut teeth of the gear.
References and External Links:
Todd, R (1994). "Gear Shaping", Manufacturing Processes Reference Guide.
Gear Shaping Machines. Gear Shaping Machines. Retrieved on January 13, 2009.
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