Chapter 5 GEAR-CUTTING MACHINES

I. GEAR-CUTTING METHODS
1. Form-cutting method
2. Generating method

II. GEAR-HOBBING MACHINES

1. Processing capacities
2. Kinematic structure
3. Gear diagram

1
 I. GEAR-CUTTING METHODS
1. Form-cutting method

2
 I. GEAR-CUTTING METHODS
1. Form-cutting method

Formative motions:
 Primary cutting motion V : rotary motion of the milling cutter nd
 Feed motion S : straight-line motion of the blank along its axis Sd
 Indexing motion: rotation of the blank after milling a groove
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 I. GEAR-CUTTING METHODS
1. Form-cutting method

Designation 1 1½ 2 2½ 3 3½ 4 4½

8 cutters per set 12 ÷ 13 14 ÷ 16 17 ÷ 20 21 ÷ 25

15 cutters per set 12 13 14 15 ÷ 16 17 ÷ 18 19 ÷ 20 21 ÷ 22 23 ÷ 25

Designation 5 5½ 6 6½ 7 7½ 8

8 cutters per set 26 ÷ 34 35 ÷ 54 55 ÷ 134 135

15 cutters per set 26 ÷ 29 30 ÷ 34 35 ÷ 41 42 ÷ 54 55 ÷ 80 81 ÷ 134 135
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 I. GEAR-CUTTING METHODS
2. Generating method
a. The meshing principle of gear – rack-type cutter
b. The meshing principle of gear – gear-shaper cutter

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 I. GEAR-CUTTING METHODS
a. The meshing principle of gear – rack-type cutter

Formative motions:
 Primary cutting motion V : rotary motion of the milling cutter nd
 Generating motion : rotary motion of the blank np
1 1
revolution of the cutter  revolution of the blank
k Z
k
or 1 revolution of the cutter  revolutions of the blank
Z
 Feed motion: straight-line motion of the milling cutter along the
vertical direction Sđ 6
 I. GEAR-CUTTING METHODS
a. The meshing principle of gear – rack-type cutter

Layout of a gear-hobbing machine

1  blank; 2  work arbor; 3  hob
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 I. GEAR-CUTTING METHODS
a. The meshing principle of gear – rack-type cutter

Universal semiautomatic
gear-hobbing machine,
model 5K32
1  bed;
2  table saddle;
3  circular work table;
4  work support with arm 4a;
5  work arbor;
6  hob slide;
7  stanchion

8
 I. GEAR-CUTTING METHODS
b. The meshing principle of gear – gear-shaper cutter

Formative motions:
 Primary cutting motion V: reciprocating motion of the shaper cutter nhtk
 Generating motion : rotary motion of the shaper cutter nd and rotary
motion of the blank np
1 1
revolution of the cutter  revolution of the blank
Zd Zp
Z
or 1 revolution of the cutter  d revolutions of the blank
Zp
 Feed motion: straight-line motion of the cutter axis in a direction toward
the blank axis Shk 9
 II. GEAR-HOBBING MACHINES
1. Processing capacities
a. Cutting a spur gear

Formative motions:
 Primary cutting motion V : rotary motion of the milling cutter nd
 Generating motion : rotary motion of the blank np
 Feed motion: straight-line motion of the milling cutter along the
vertical direction Sđ
10
 II. GEAR-HOBBING MACHINES
1. Processing capacities
b. Cutting a helical gear

Formative motions:
 Primary cutting motion V : rotary motion of the milling cutter nd
 Generating motion : rotary motion of the blank np
 Feed motion: straight-line motion of the milling cutter along the
vertical direction Sđ
 Differential motion: increment motion of the blank during vertical feed
of the hob through a distance equal to the lead of the helical teeth
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 II. GEAR-HOBBING MACHINES
1. Processing capacities nd
np
b. Cutting a helical gear

s1
nvs
Differential motion has the following relation:

Z s1
1 revolution of the blank   revolutions of the cutter
k tp

where tp : pitch of the helical teeth on the gear D ms Z mnZ

tp   
tg tg sin
or more simply Differential motion has the other following relation :
1 revolution of the blank  the cutter travels in the vertical direction tp

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 II. GEAR-HOBBING MACHINES
1. Processing capacities
c. Cutting a worm wheel Formative motions:
 Primary cutting motion V : rotary motion of the milling cutter nd
 Generating motion : rotary motion of the blank np
k
1 revolution of the cutter  revolutions of the blank
Z
 Feed motion:
Method 1: Radial feed
Method 2: Axial feed

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 II. GEAR-HOBBING MACHINES
2. Kinematic structure of a gear-hobbing machine

tx

iv

is
a. Cutting speed chain
ix
VS nđc . iv = nd
iv : gear ratio of the cutting
speed chain
iy
b. Generating chain
k
1revolution of the cutter . ix .icñ1  revolutions of the blank
Z
ix : gear ratio of the quadrant of the generating chain
icđ1 : fixed gear ratio of the generating chain 14
 II. GEAR-HOBBING MACHINES
2. Kinematic structure of a gear-hobbing machine
c. Vertical feed chain

1 revolution of the blank. icđ2 . is . t1 = Sđ

is : gear ratio of the quadrant of the vertical feed chain

icđ2 : fixed gear ratio of the vertical feed chain
tx : pitch of the vertical lead screw (mm)
Sđ : vertical feed (mm/rev of blank)

d. Differential chain 1 revolution of the blank. icđ3 . ix . ivs . iy . tx = tp

icđ3 : fixed gear ratio of the differential chain

ivs : gear ratio of the differential mechanism
iy : gear ratio of the quadrant of the differential chain mnZ
tp 
tp : pitch of the helical teeth on the gear sin
15
3. Gear diagram of the gear-hobbing machine, model 5E32
a. Cutting speed chain
nđc . iv = nd
18
72
25
Blank 25
k=2 20
Hob
t1 = 10mm a2 c2
is =
b2 d2

k=5 45 30
30 k=2 24

20 a1 c1
96 t2 = 10mm Differential f ix =
k=1 30 b1 d1
N=0,18kW 30
mechanism
n=1400v/p k=1
9 25
ÑC3 46
25
120 t4=5mm 46 C2 e
30
k=1 16 20 25 32
18 a c
Þ240 iv =
72 25 C1 35 b d
C4 C3
42 48
Hob 16 ÑC2
35 19 16 35

16 N=1kW 45
19
50 16 n=1410v/p
t3 = 2 a3 c3
N=4,5kW ÑC1 36 iy =
k=1 35 b3 d3
n=1440v/p Þ126
16
3. Gear diagram of the gear-hobbing machine, model 5E32
k
b. Generating chain 1revolution of the cutter . ix .icñ1  revolutions of the blank
Z
18
72
25
Blank 25
k=2 20
Hob
t1 = 10mm a2 c2
is =
b2 d2

k=5 45 30
k=2 24
30
20 a1 c1
96 t2 = 10mm f ix =
k=1 Differential 30
b1 d1
N=0,18kW 30 mechanism k=1
n=1400v/p 25
9
ÑC3 46
25
120 t4=5mm 46 30 C2 e
k=1 16 20 25 32
a c
18
Þ240 iv =
72 25 C1 35 b d
C4 C3
42 46
Hob 16 ÑC2
35 19 16 35

16 N=1kW 45
19
50 16 n=1410v/p
t3 = 2 a3 c3
N=4,5kW ÑC1 36 iy =
k=1 35 b3 d3
n=1410v/p Þ126
17
3. Gear diagram of the gear-hobbing machine, model 5E32
c. Vertical feed chain 1 revolution of the blank. icđ2 . is . t1 = Sđ
18
72
25
Blank 25
k=2 20
Hob
t1 = 10mm a2 c2
is =
b2 d2

k=5 45 30
k=2 24
30
20 a1 c1
96 t2 = 10mm Differential f ix =
k=1 mechanism 30 b1 d1
N=0,18kW 30 k=1
n=1400v/p 25
9
ÑC3 46
25
120 t4=5mm 46 30 C2 e
k=1 16 20 25 32
a c
18
Þ240 iv =
72 25 C1 35 b d
C4 C3
42 46
Hob 16 ÑC2
35 19 16 35

16 N=1kW 45
19
50 16 n=1410v/p
t3 = 2 a3 c3
N=4,5kW ÑC1 36 iy =
k=1 35 b3 d3
n=1410v/p Þ126
18
3. Gear diagram of the gear-hobbing machine, model 5E32
d. Radical feed chain 1 revolution of the blank . icñ2 . is . t2 = Sn
18
72
25
Blank 25
k=2 20
Hob
t1 = 10mm a2 c2
is =
b2 d2

k=5 45 30
k=2 24
30
20 a1 c1
96 t2 = 10mm Differential f ix =
k=1 mechanism 30 b1 d1
N=0,18kW 30 k=1
n=1400v/p 25
9
ÑC3 46
25
120 t4=5mm 46 30 C2 e
k=1 16 20 25 32
20 a c
18
Þ240 iv =
72 25 C1 35 b d
C4 C3
42 46
Hob 16 ÑC2
35 19 16 35

16 N=1kW 45
19
50 16 n=1410v/p
t3 = 2 a3 c3
N=4,5kW ÑC1 36 iy =
k=1 35 b3 d3
n=1410v/p Þ126
19
3. Gear diagram of the gear-hobbing machine, model 5E32
e. Differential chain 1 revolution of the blank. icđ3 . ix . ivs . iy . tx = tp
18
72
25
Blank 25
k=2 20
Hob
t1 = 10mm a2 c2
is =
b2 d2

k=5 45 30
k=2 24
30
20 a1 c1
96 t2 = 10mm Differential f ix =
k=1 mechanism 30 b1 d1
N=0,18kW 30 k=1
n=1400v/p 25
9
ÑC3 46
25
120 t4=5mm 46 30 C2 e
k=1 16 20 25 32
a c
18
Þ240 iv =
72 25 C1 35 b d
C4 C3
42 46
Hob 16 ÑC2
35 19 16 35

16 N=1kW 45
19
50 16 n=1410v/p
t3 = 2 a3 c3
N=4,5kW ÑC1 36 iy =
k=1 35 b3 d3
n=1410v/p Þ126
20
3. Gear diagram of the gear-hobbing machine, model 5E32
f. Axial feed chain (with a differential mechanism)
18 1 rev of blank.icđ4 . 1 . ivs . 1 . t3 = mZ
72 ix iy
25
Blank 25
k=2 20
Hob
t1 = 10mm a2 c2
is =
b2 d2

k=5 45 30
k=2 24
30
20 a1 c1
96 t2 = 10mm Differential
f ix =
k=1 mechanism 30 b1 d1
N=0,18kW 30 k=1
n=1400v/p 25
9
ÑC3 46
25
120 t4=5mm 46 30 C2 e
k=1 16 20 25 32
a c
18
Þ240 iv =
72 25 C1 35 b d
C4 C3
42 46
Hob 16 ÑC2
35 19 16 35

16 N=1kW 45
19
50 16 n=1410v/p
t3 = 2 a3 c3
N=4,5kW ÑC1 36 iy =
k=1 35 b3 d3
n=1410v/p Þ126
21
3. Gear diagram of the gear-hobbing machine, model 5E32
f. Axial feed chain (without a differential mechanism)
18
1 revolution of the blank . icñ5 . is . t3 = St
72
25
Blank 25
k=2 20
Hob
t1 = 10mm a2 c2
is =
b2 d2

k=5 45 30
k=2 24
30
20 a1 c1
96 t2 = 10mm Differential f ix =
k=1 mechanism 30 b1 d1
N=0,18kW 30 k=1
n=1400v/p 25
9
ÑC3 46
25
120 t4=5mm 46 30 C2 e
k=1 16 20 25 32
a c
18
Þ240 iv =
72 25 C1 35 b d
C4 C3
42 46
Hob 16 ÑC2
35 19 16 35

16 N=1kW 45
19
50 16 n=1410v/p
t3 = 2 a3 c3
N=4,5kW ÑC1 36 iy =
k=1 35 b3 d3
n=1410v/p Þ126
22
3. Gear diagram of the gear-hobbing machine, model 5E32
h. Rapid traverse feed chain nñc2 . icñ6 . t1 = Sñnhanh
18
72 nñc2 . icñ6 . t2 = Snnhanh
25
Blank 25
k=2 20
Hob
t1 = 10mm a2 c2
is =
b2 d2

k=5 45 30
k=2 24
30
20 a1 c1
96 t2 = 10mm Differential f ix =
k=1 mechanism 30 b1 d1
N=0,18kW 30 k=1
n=1400v/p 25
9
ÑC3 46
25
120 t4=5mm 46 30 C2 e
k=1 16 20 25 32
a c
18
Þ240 iv =
72 25 C1 35 b d
C4 C3
42 46
Hob 16 ÑC2
35 19 16 35

16 N=1kW 45
19
50 16 n=1410v/p
t3 = 2 a3 c3
N=4,5kW ÑC1 36 iy =
k=1 35 b3 d3
n=1410v/p Þ126
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