The Study of the Profile Errors of Straight Teethed Shaper Cutters in the CAD-Environment

Abstract

It is well known that straight-teethed shaper cutters present theoretical profile error, which leads to a deviation of the cut gear tooth profile from the involute profile. Taking advantage of the CAD environment, we have visualized and studied shaper cutters at different stages of sharpening. This is advantageous because the effect of any shape or dimension modification of the rake face can be immediately and easily controlled in the design process, thereby saving precious design time. The aim of our research was to create a 3D model in a CAD environment to visualize different sharpening methods and the profile of shaper cutters at different wear stages, and to estimate the inherent profile errors. The aim of using different sharpening methods was to improve the lateral cutting geometry (especially the lateral relief angle) and also to reduce or – at least – keep the profile error within the accepted limits. During the measurements, both the rake angle and the cutter rack profile angle were changed in order to improve the geometry. The edge was generated using numerically computed points and Autodesk Inventor's special commands. Comparative analyses were performed.