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Gear Cutting Tools
Fundamentals of Design and Computation




ISBN 9781439819678
Published February 23, 2010 by CRC Press
786 Pages 501 B/W Illustrations

 
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Book 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.

Table of 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

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