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Gear Cutting Tools

Fundamentals of Design and Computation

By Stephen P. Radzevich

CRC Press – 2010 – 786 pages

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    978-1-43-981967-8
    February 22nd 2010

Description

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.

Contents

Part I: Basics

Gears: Geometry of the Tooth Flanks

Basic Kinds of Gears

Analytical Description of Gear Tooth Flanks

Gear Tooth Surfaces those Allowing Sliding Over Them

Principal Kinematics of Gear Machining Operations

Relative Motions in Gear Machining

Rolling of the Conjugate Surfaces

Kinematics 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 Transformations

Coordinate Systems Transformation

Conversion of the Coordinate System Orientation

Direct Transformation of Surfaces Fundamental Forms

Part II: Form Gear Cutting Tools

Gear Broaching Tools

Kinematics of the Gear Broaching Process

Generating Surface of a Gear Broach

Cutting Edges of the Gear Broaching Tools

Chip Removal Diagrams

Sharpening of Gear Broaches

A Concept of Precision Gear Broaching Tool for Machining Involute Gears

Application of Gear Broaching Tools

Shear-Speed Cutting

Rotary Broaches: Slater Tools

Broaching Bevel Gear Teeth

End-Type Gear Milling Cutters

Kinematics of Gear Cutting with End-Type Milling Cutter

Generating Surface of the End-Type Gear Milling Cutter

Cutting 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 Cutters

Kinematics of Gear Cutting with Disk-Type Milling Cutter

Generating Surface of the Disk-Type Gear Milling Cutter

Cutting Edges of the Disk-Type Gear Milling Cutter

Profiling of the Disk-Type Gear Milling Cutters

Cutting Edge Geometry of the Disk-Type Milling Cutter

Disk-Type Milling Cutters for Roughing of Gears

Accuracy of the Gear Tooth Flanks Machined with the Disk-Type Milling Cutters

Application of Disk-Type Gear Milling Cutters

Nontraditional Methods of Gear Machining with Form Cutting Tools

Plurality of Single-Parametric Motions

Implementation of the Single-Parametric Motions for Designing of Form Gear Cutting

Tool

Diversity 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 Mesh

Rack Cutters for Planing of Gears

Generating Surface of Rack Cutter

On the Variety of Feasible Tooth Profiles of the Rack Cutters

Cutting Edges of the Rack Cutter

Profiling of the Rack Cutters

Cutting Edge Geometry of the Rack Cutter

Chip Thickness Cut by Cutting Edges of the Rack Cutter Tooth

Accuracy of the Machined Gear

Application of the Rack Cutters

Potential Methods of Gear Cutting and Designs of Rack-Type Gear Cutting Tools

Gear Shaper Cutters I: External Gear Machining Mesh

Kinematics 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 Profile

Thickness of Chip Cut by Shaper Cutter Tooth

Accuracy of Gears Cut with the Shaper Cutter

Application of Gear Shaper Cutters

Gear Shaper Cutters II: Internal Gear Machining Mesh

Kinematics of Shaping Operation of an Internal Gear

Design of Shaper Cutters

Thickness 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 Mesh

Gear 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 Gears

Principal Elements of Kinematics of Bevel Gear Generation

Geometry of the Interacting Tooth Surfaces

Peculiarities of Generation of Straight Bevel Gears with Offset Teeth

Generation of Straight Bevel Gear Teeth

Peculiarities of Straight Bevel Gear Cutting

Milling of Straight Bevel Gears

Machining of Bevel Gears having Curved Teeth

Gear Shaper Cutters Having Tilted Axis of Rotation: Internal Gear Machining Mesh

Principal 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 Mesh

Generating Surface of the Gear Cutting Tool

Kinematics of External Spatial Gear Machining Mesh

Auxiliary Generating Surface of the Gear Cutting Tool

Examples of Possible Kinds of Auxiliary Generating Surfaces of Gear Cutting Tools

Generation of Generating Surface of a Gear Cutting Tool

Use of the DG-Based Methods for the Determination of the Design Parameters of

Generating Surfaces of the Gear Cutting Tools

Possible Kinds of Generating Surfaces of Gear Cutting Tools

Constraints 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 Tool

Geometry and Generation of Rake Surface of a Gear Hob

Geometry 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 Tooth

Constraints 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 Cutter

Design of Gear Shaving Cutters

Axial Method of Gear Shaving Process

Diagonal Method of Gear Shaving Process

Tangential Method of Gear Shaving Process

Plunge Method of Gear Shaving Process

Advances in Design of Shaving Cutter

Peculiarities of Gear Shaving Process

Examples of Implementation of the Classification of Kinds of the Gear Machining Meshes

A Hob for Tangential Gear Hobbing

A Hob for Plunge Gear Hobbing

Hobbing of a Face Gear

A 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 Gears

A Gear Cutting Tool for Machining a Worm in Continuously Indexing Method

Rack Shaving Cutters

A Tool for Reinforcement of a Gear by Surface Plastic Deformation

Conical 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 Mesh

Gear 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

Conclusion

Appendices

References

Index

Name: Gear Cutting Tools: Fundamentals of Design and Computation (Hardback)CRC Press 
Description: By Stephen P. Radzevich. 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...
Categories: Industrial Engineering & Manufacturing, Automotive Technology & Engineering, Machine Design