Study on Gear Plunge Shaving Cutter Generated by Grinding Worm

Abstract

The gear shaving is usually used for gear finishing process before heat treatment. Gears processed by shaving can adjust the lead profile of the gears and improve the gear surface roughness after gear hobbing process. Until now, it has been used to produce gears used in the automotive industry. The gear plunge-shaving method is the fastest production method in the gear shaving processes, which reduces the number of axes of motion that must be controlled by the machine tool. However, the tooth profile of the plunge shaving cutter is a hyperboloid with hollow tooth form, and the plunge-shaving cutter is more difficult to manufacture than other conventional shaving cutter. The traditional way to manufacture the plunge-shaving cutter is to use the cone grinding wheel to generate the profile of the cutter, and under such a processing process, the production speed is relatively slow. In this subject, the idea is to use a grinding worm and control the center distance between the worm and the shaving cutter blank during the machining process to complete the plunge-shaving cutter making. Compared to using a cone grinding wheel, we will use a standard grinding worm to help speed up the cutter making process. In the article, a useful mathematical model for the gear plunge shaving cutter generated by a grinding worm is established. And also a numerical example calculation is provided to verify that the tool tooth surface topography error of this machining method is small and can be achieved.