Samputensili Hobbing

Hobs and gear
hobbing
Hobs and gear hobbing
Preamble
It is possible to manufacture such an extensive range of

hobs nowadays that not all of them may be examined in a
presentation. Just a few examples covering a narrow
range of applications will therefore be examined.
The growing needs of gear manufacturers in terms of

efficiency, productivity and economy make it increasingly
necessary to deviate from DIN 8002 A or DIN 8002 B
manufacturing standards. At the same time more and more
expectations are placed on gears to the extent where it
may even be necessary to deviate from DIN 3972 or DIN
58412, for example, as regards the rack profile or other
gear design adjustments.
2
Design methods (1)
Hob design primarily depends on the tool holding fixtures

in place on the hobbing machine and on customer
requirements in terms of other related criteria such as
desired tool life or hobbing times.
Clamping by means of an arbour which slides into the hob

bore is by large the most common system utilised. With
this type of system the hob is driven by a longitudinal
keyway, a one or double-sided clutch keyway or no
keyway (in this case the hob is just driven by the axial
clamping force of the hobbing machine). Bore-type hob with longitudinal keyway
Hob with special clamping fixture
3
Design methods (2)
In certain types of application, where small diameter hobs
are required for example, bore-type hobs cannot be
utilised. In such cases, hobs are designed with a clamping
shank which also serves to drive the hob. Certainly the
most well-known example of this type of application is
helical gear hobbing. Carbide hobs, which are becoming
increasingly popular, are also nearly always shank-type
hobs.
The type of shank depends on the clamping system of the

hobbing machine. The following are possible shank-type
hob clamping variants:
Shank-type hob
 double-sided parallel support shank

 double-sided tapered shank
 parallel support shank and tapered shank
The clamping systems on most machines are arranged so

that both sides are different, making incorrect mounting of
the hob impossible.
Double bore-type hob with clutch keyway
4
Nomenclature of the parts of the hob
Back of tooth Cutting

Number of face Collar
threads
Flanks Gash
Groove
Hobbed length / usable length

Side faces
Total length
5
Technology: The hobbing process
It is then necessary to decide on the feed direction in
relation to the workpiece axis.
• Axial hobbing: During machining the hob only Axial hobbing fa

moves in the axial direction of the workpiece. The
approach travel is therefore large.
• Radial hobbing: During machining the hob only
moves in the radial direction of the workpiece (only
for worm wheels). fa
• Radial-Axial hobbing: The hob dips with the radial
feed until it reaches the required feed depth and it
then continues hobbing with an axial feed. This
process reduces approach travel.
Radial hobbing
• Tangential hobbing: The movement of the hob is in
a tangential direction in relation to the workpiece axis
(only for worm wheel production)
• Diagonal hobbing: This is a combination of radial
hobbing, axial hobbing and tangential hobbing. With
this process, in addition to the axial feed, the hob is
also fed tangentially to the workpiece axis. fa
Tangential hobbing
6
Dimensions: The taper
In certain types of gear / hob meshing (such as workpieces
with a large number of teeth, large modules or very large
helix angles), it is sometimes impossible to fully cover the
whole work area of a cylindrical hob.
In fact, even if the hob has not been in operation for very
long, wear will begin to form quickly on some of the teeth
while other teeth will bear no particular signs of wear at all.
To ensure better cutting edge resistance for such
applications, hobs are designed with a tapered outside
diameter. Depending on whether the hob is used in climb
hobbing or in conventional hobbing, this taper can be found
either on the approach side or on the exit side of the hob. Tapered hob with double-sided keyway
fa
Tangential hobbing with a tapered hob
7
Dimensions: Outside diameter
The size of the outside diameter of bore-type hobs is 10
determined first of all by the material remaining between 9
Centre distance from
longitudinal keyway to gash
the bore or the longitudinal keyway and the beginning of 8
the hob gashes. This mass must give the hob enough Resharpenable length on tooth tip
.
7
stability to withstand the cutting force.
Centre distance [mm]

6
The presence of some form of shoulder such as a large
5
collar is also another reason for limiting the size of the
4
outside diameter.
3
Basically if the number of gashes is constant, the principal
2
applies that the larger the outside diameter, the larger the
1
resharpenable length of the hob will be. When determining
0
the size of the outside diameter it is necessary to take 100 95 90 85 80 75 70 65 60 55 50
hobbing times into consideration (see chapter: Calculation Hob outside diameter [mm]
of hobbing times).
The graph to the right shows how the resharpenable length
of hob tooth tips depends on the outside diameter of the
hob itself. The following values are examples.
Outside diameter = 65
View of gashes
View of gashes
Normal module = 2,00
Rack profile as per DIN 3972, BP I
Bore diameter = 32
Number of gashes = 12
Longitudinal keyway as per DIN 138
8
Dimensions: Overall length / useful length (1)
The desire to increase tool life between resharpenings is
increasingly expressed by gear producers. Tool
changeover, resharpening and at times recoating all cause
significant costs in terms of time and money.
The DIN 8002 normative only gives a rough indication of
hob length. In fact it only states that there must be 3-4
teeth on each tooth row. There has been a great deal of
research by tool manufacturers in terms of tool duration
such as the idea of using rake angles or of dividing the of
roughing and finishing teeth for example. All of these trials,
however, have been unable to eliminate the high costs
deriving from hob resharpening operations.
The simplest way to increase tool life is to increase the
shifting area of the hob.
The following picture clarifies this notion, illustrating the
work areas of the hob.
9
Dimensions: Overall length / useful length (2)
Shifting
direction
Work areas on the hob

Zone 1 This can not be used for machining since there are teeth in this area which are not completely formed.
Zone 2 The roughing area depends primarily on da2, h2 and fa.
Zone 3 The finishing area is identical to the contact area between the workpiece and the hob.
In this area the workpiece teeth are profiled.
Areas 1 to 3 have fixed dimensions regardless of the machining application
Zone 4 The Shifting area is for hob shifting requirements
10
Number of threads
The number of hob threads influences manufacturing time
and the quality of the hobbed workpiece.
By increasing the number of threads, the number of
workpiece rotations increases which results in a reduction
of hobbing time if feed is constant. This can in fact be seen
from the formula below.
As regards single start hobs with a constant number of
gashes, as the number of threads increases, the profile is
generated by fewer enveloping cuts and has larger
enveloping cut deviations (see the chapter on Gear
quality).
In order to prevent indexing or pitch errors on the hob from
being transferred to the workpiece, it is necessary to
ensure that each hob tooth works each gear tooth vane
when determining the number of threads and gashes of a
hob. In order to achieve this condition, the following must
be fulfilled:
Increasing the number of threads can result in an increase

in tool life.
Number of hob rotations Number of workpiece teeth


Number of workpiece rotations Number of hob threads
Number of flutes  Number of workpiece teeth

 not a whole number
Number of hob threads
11
Dimensions: Direction of helix
When hobbing spur gears the helix direction is not
particularly significant and right-handed or left-handed
helix hobs may be used. In general the preference is to
use right-handed helix hobs.
For hobbing helical gears, the climb hobbing method is

generally used and it is therefore necessary that the helix
direction of the hob is identical to that of the gear. If the Left-handed helix
helix direction of the hob and the workpiece is different, the hob
conventional hobbing process must be used.
Right-handed
helix hob
12
Dimensions – Number of grooves / number of gashes
The choice of the number of gashes depends on different 16
15
criteria and fundamentally on the requirements of the
.
14
customer in terms of process optimisation. 13
resharpenable length on tooth tip

A large number of gashes increases the machining ability 12
of the hob, decreases hobbing time, reduces wear and 11
increases the number of enveloping cuts that form the 10
9
involute curve. The disadvantage of a large number of
8
gashes is that with a constant outside diameter, the usable 7
tooth length is reduced. Should the outside diameter be 6
increased to combat this disadvantage, the approach and 5
exit travel of the hob increase and consequently so does 4
3
hobbing time (see chapter: calculation of hobbing time). Up
2
to a lead angle of around 6°, the hob gashes will be 1
straight. If the lead angle is above 6° the gashes will be 0
spiral, so as to compensate the different rake angles of the 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38
approaching and exiting tooth flanks. Number of tooth segments
Normal module = 2,00

Rack profile according to DIN 3972,
BP I
Bore diameter = 32
Longitudinal keyway according to
DIN 138
The resharpenable tooth length depends on the number of

gashes.
13
Dimensions – Hob material / carbide (1)
Materials that are produced by powder metallurgy are
grouped under the category of carbide. These are basically Characteristic Unit HSS HM
composed hard materials like Wolfram carbide and Tantalum
1200 -
carbide with Cobalt as the binding metal. Hardness HV10 800 - 900
1900
HSS in comparison is clearly tougher than carbide but the
1000 -
latter is more resistant to wear because of its high hardness Bending strength N/mm² 5000
2500
levels.
Density g/cm³ 8 - 8,3 11 - 15
Being so tough, HSS creates less problems in production.
10³
It is not wise to use HSS if extremely high cutting speeds Elasticity module 217 480 - 660
N/mm²
must be programmed or if the hardness level of the gear to
Thermal elongation µm/(m*°C
be hobbed is too high. 10 - 13 5-7
coefficient )
Due to the variation in composition, in grain size and in other
Thermal
structural parameters, the number of carbide types available
conductivity (up to W/(m*°C) 19 30 - 100
on the market has gradually increased. The division of these
carbide types is in relation to the application possibilities or 20°C)
the so-called main machining groups as per the ISO 513 Work temperature °C ca. 500 ca. 1000
normative.
In the field of gear manufacturing the P and K groups are the
most important.
14
Dimensions – Hob material / carbide (2)
Overview of carbide groups
Main machining Structural Application

For machining Work conditions
groups composition groups
P10 Finishing
resistance and cutting speed

increasing hardness, wear
WC P20 General
Steel, cast steel, long-
TiC
P C
chip cast tempered P30 light roughing
steel
Co P40 middle roughing
P50 heavy roughing
K05 Finishing
resistance and cutting speed

increasing hardness, wear
Cast iron, short-chip K10 General
WC cast tempered steel,
K Co hardened steel, NE-
K20 light roughing
Metal K30 middle roughing
K40 heavy roughing
15
Dimensions – Hob material / Comparison between carbide - HSS
Carbide HSS-PM
Relatively high bending

 High edge strength 
strength
Favourable toughness
 Strong resistance to pressure 
properties
Strong resistance to heat-
  Fairly priced
related wear
Tendency of the cutting edges
  Easy to obtain
to break
Sensitive to changes in load
Reduced hardness at high
 (tensile stress/compressive 
temperatures
stress)
 Expensive
16
Dimensions – Hob material / Cost comparison
2.500,00 € Material TiN coating TiCN coating TiAlN coating
M35 654,00 € 700,00 € 714,00 €
2.000,00 € TiN coated bore-type ASP 30 711,00 € 757,00 € 771,00 €
hob S 390 729,00 € 775,00 € 789,00 €
1.500,00 €
CPM Rex M35 711,00 € 757,00 € 771,00 €
1.000,00 €
CPM Rex T15 882,00 € 928,00 € 942,00 €
CPM Rex T76 905,00 € 951,00 € 965,00 €
500,00 € CPM Rex 121 1.146,00 € 1.292,00 € 1.306,00 €
Carbide 2.436,00 € 2.971,00 € 2.978,00 €
- €
5 0 90 35 15 76 21 ll
M3 P3 S3 xM exT exT x1 et a
AS R e R R Re art m
M M M M H
CP CP CP CP
Bore-type hob Ø 90 x 150/140 x Ø 32
2.500,00 € Material TiN coating TiCN coating TiAlN coating

M35 580,00 € 626,00 € 640,00 €
2.000,00 € TiN coated shank-type ASP 30 619,00 € 665,00 € 679,00 €
hob S 390 631,00 € 677,00 € 691,00 €
1.500,00 €
CPM Rex M35 619,00 € 665,00 € 679,00 €
1.000,00 € CPM Rex T15 723,00 € 769,00 € 783,00 €
CPM Rex T76 736,00 € 782,00 € 796,00 €
500,00 € CPM Rex 121 923,00 € 1.069,00 € 1.083,00 €
Carbide 2.925,00 € 2.948,00 € 2.955,00 €
- €
M3
5
P3
0 90 35 T1
5 76 21 ta ll
AS S3 ex M Rex exT ex1 rt me
R R R Ha
M M M M
CP CP CP CP
Shank-type hob Ø 60 x 200/130 x Ø 22 + SK30
17
Coatings
Friction Coating
max. work Hardness
Reference Composition coeffizient thickness in Colour
temperature (°C) (HV0,05)
(Steel - dry) µm
SUNITE® Gold TiN 600 2500 0,4 1-4 gold-gelb

gold-yellow
SUNITE® Carbonium TiCN 450 3300 0,4 1-4 grey blue

grey-blue
SUNITE® Silver Ti2N 600 2300 0,4 1-4 silver

silver
SUNITE® Chrominum CrN 700 1750 0,5 1-5 metallic

metallic
SUNITE® UniversAl TiAlN 800 3000 0,4 1-4 violet

violet
SUNITE® Futura TiAlN 800 3000 0,4 2-6 grey-violet

grey-violet
SUNITE® X.Treme TiAlN 800 3500 0,4 1-3 grey-violet

grey-violer
TiAlN 2600 TiAlN
SUNITE® Hardlube 800 - 1000 0,2 2-6 dark grey
WC/C 1000 WC/C
SUNITE® Alcrona AlCrN 1100 3200 0,35 2-5 blue-grey
Comparison of the friction coefficient of steel and steel when dry machining = 0,8
18
Workpiece quality (1)
Gear quality and manufacturing processes
ground
shaved
after heat hobbed

treatment cut with a rack-type cutter
finish machined shaped
milled
shaped
punched
pressed
DIN 3963 - 3963 1 2 3 4 5 6 7 8 9 10 11 12

ISO 1328 1 2 3 4 5 6 7 8 9 10 11 12
AGMA 390.03 15 14 13 12 11 10 9 8 7 6 5
Shaved
Nitriert
ground
work hardened shaved

Before heat small dimensions
treatment large number of pieces
finish machined inductive or flame single tooth hobbed
hardening shaped
work hardened
hobbed
small dimensions
form cut
custom manufactured
19
Workpiece quality (2)
Hob quality Module ranges

classes as per
DIN 3968
1,00 - 1,60 1,00 - 2,00 2,00 - 2,50 2,50 - 3,55 3,55 - 4,00 4,00 - 6,00 6,00 - 6,30 6,30 - 10,00 10,00 - 16,00 16,00 - 25,00 25,00 - 40,00
8 8 8 10 10 12 12 16 20 25 32
AA 6 6 6 6 6 6 5 6 6 6 6
8 8 10 10 12 12 12 16 22 28 36
14 16 16 18 18 20 20 25 32 40 50
A 8 8 8 8 7 8 7 8 8 7 7
16 16 20 20 18 25 22 32 40 40 56
Fe 28 32 32 36 36 40 40 50 63 80 100
B 10 10 10 10 9 10 9 10 10 9 9
16 16 20 20 18 25 22 32 40 40 56
56 63 63 71 71 80 80 100 125 160 200
C 11 12 11 11 11 11 11 11 11 11 11
56 90 71 71 90 90 110 110 140 200 250
attainable gear quality

according to DIN 3962 - 8.78 (Ff) Overall profile deviation
As a total deviation, the contact pitch Fe within a contact area on the hob is the most meaningful
dimension by which to evaluate hob quality.
It is therefore sensible to compare the contact pitch Fe on the hob with the overall profile error Ff
on the gear.
20
Technology – Climb hobbing
In climb hobbing the workpiece shifts in the
same direction as the tooth cutting
movement. The comma-shaped chip which
begins to detach itself from the gear is cut off
at the beginning of contact. The advantages
of this process are good chip formation, a low
level of burr formation and about 50% higher
potential cutting speeds. The disadvantage is
the so-called “chattering-effect“ caused by the
backlash of the hobbing machine feed spindle
whereby the horizontal force of the workpiece
tries to drag the hob. To eliminate this type of
problem, modern hobbing machines are
equipped with preloaded ricirculating ball
screws. With climb hobbing the surface finish
obtained is regular and dull.
Direction of movement
Relative movement of the workpiece
to the hob
21
Technology – Conventional hobbing
With conventional hobbing there is no
precise chip formation point since the cutting
edges generate only very thin chips. With
this method the hob tooth slides across the
previously machined workpiece surfaces
leading to cold work hardening of the same
since the hob teeth only press and rub at the
start of stroke. This cold work hardening can
have negative consequences in subsequent
operations and especially in heat treatment.
Furthermore this pressing-sliding action
heats workpiece surfaces up even more,
causing the hob teeth to lose hardness at
high temperatures and flank wear to increase
significantly. This explains why such high
cutting speeds are possible with climb
hobbing. With conventional hobbing the
surface finish obtained is shiny.
Direction of movement
Relative movement of the workpiece
to the hob
22
Technology – Climb direction – Conventional direction
Climb hobbing
Helix direction Helix direction

Hob: right --- Workpiece: right Hob: left --- workpiece: left
Conventional
hobbing
Helix direction Helix direction

Hob: right --- Workpiece: left Hob: left --- Workpiece: right
23
Technology – Penetration curve (1)
The penetration curve
Contact between the tool and the workpiece can only take
place in the penetration curve of the tip cylinders of the hob
and the gear.
The penetration zone is marked by a three dimensional
curve i.e. the cutting line. If we project the cutting line on a
plane which is parallel to the tool and workpiece axes, we
obtain the penetration curve. The penetration curve is
therefore a symmetrical curve.
To calculate this curve exactly, we need to know

the length of the hob work zone,
 the setting length and
 the axial approach travel. 0 - Hob
2 - Gear
Calculation of the penetration curve

The cutting edges of the hob only break off chips from the
Penetration of the hob and the gear
workpiece tooth vanes along a part of the penetration
curve. The area which is machined is known as the work
area LA0 and it lies on the hob axis. As a result of the axial
feed fa the hob, and consequently the penetration curve, is
fed in the direction of the workpiece axis with each
workpiece rotation.
24
The penetration curve may be calculated by formula (2).
The form of the penetration curve depends on the
diameter of the tool and the workpiece, the cutting depth
and the swivel angle. The position of the penetration curve
is determined by the machining process used and by the
direction (left or right hand) of the gear and the hob.
2 2
 da2  d 
On the Y-Z-plane we    y   a2  z 
2
have:  2   2 
2
d d 
which gives z  a2   a2   y 2
2  2 
*
r1
On the X-Y-plane we x   y  tan  (1)
cos 
have:
2 2 Design of the penetration curve
Using the A-A cut we  a0   r1*2   a0  h  z 
d d
have:  2   2 
2
2  2 
 da0   da0 da2  da2  2 
r1     h    y 
*
which gives:
 2  2 2  2 
 
25
By adding r1* to the formula (1) we obtain the general

formula with which to calculate the penetration curve
on the X-Y-plane.
By choosing y-values, the relative x coordinates of the
2
 da0   da0 
penetration curve can be calculated as per formula (2). 2 2
 da 2 
  y 2 
1 da 2
x  y  tan       h  
With formula (2) all points on the penetration curve cos   2  2 2  2 
 
may be calculated. The hob setting angle can be
calculated for climb hobbing with the following formula.
(2)
  2   0
The work process used determines which of the two

extremities will mark the work area on the penetration
curve. With climb hobbing it is the upper point while
with conventional hobbing it is the lower point. (see
also Penetration curve).
26
With climb hobbing (where the left or right hand direction of
the gear and the workpiece is the same) and with
conventional hobbing (where the left or right hand direction
of the hob and the workpiece is different) the work area
depends on the axial feed. This means that as the feed
increases, the number of tip cutting edges that actually work
gets bigger. In this case, depending on the established xm-
value, the dimension of the axial feed decreases. By
extracting the coordinates of the X-Y axial system it is now
possible to mark or to calculate the work area of the hob tip
cutting edges.
The length of the hob work area can be determined by the
formula (3).
The profile is generated by those hob teeth that lie within the
profile formation zone, in the middle of which are the central L AV  y1  cos   x1  sin (3)
teeth (formula 4).
The area which is machined just outside the profile formation ha0  x p  mn
zone is known as the roughing zone LAZ. This does not LP 0  2   cos  0 (4)
mean, however, that all roughing work takes place in the tan n
roughing zone. Depending on the hobbing process used the
roughing zone is situated either on the hob approach side or LP0
on the hob exit side (formula 5). L AZ  L AV  (5)
2
The roughing zone and the profile formation zone both give
the same hob work area according to formula (6).
LP 0
L A 0  L AV  (6)
2
27
According to Pfauter the main position of the work area is Hob: Right-handed Hob: Left-handed
clarified by the following diagram. Gear: right-handed Gear: left-handed Gear: right-handed Gear: left-handed
Climb hobbing
Spur gear Spur gear
Only with Only with

relatively large relatively large
feed is feed is
Gear: right-handed Gear: left-handed Gear: right-handed Gear: left-handed
Conventional hobbing
Spur gear Spur gear
Already with Already with

relatively small relatively small
feed is feed is
28
Technology – Cutting speed (1)
Contrary to traditional machining processes, like Zugfetigkeit
Denomination as per DIN Bearbeit-
turning for example, hobbing is not exclusively Material group Heat treatment Rm in
17006 17007 barkeit in %
determined by the entity of cutting speed, feed and N/mm²
St 50 0530 normally heated 550 63
setting parameters. It is in fact influenced by many St 60 0543 normally heated 650 70
more parameters. St 70 0632 normally heated 800 55
This multitude of additional parameters which have C 22 0402 normally heated 530 62
Carbon steels C 22 0402 tempered & hardened 600 68
to be considered is due to the different hobbing
C 45 0503 tempered & hardened 720 65
processes available, the tool and workpiece C 45 0503 tempered & hardened 800 57
geometry and the general generation principle. The Ck 45 1191 normally heated 720 65
affects of these vast interrelationships on the Ck 45 1191 tempered & hardened 800 60
15 Cr Ni 6 5919 normally heated 750 58
process are very difficult to summarise. 36 Ni Cr 6 5710 normally heated 720 55
A rough recommendation when setting cutting speed Chromium-
36 Ni Cr 6 5710 tempered & hardened 850 47
is to take the machinability of the gear material into 14 Ni Cr 14 5752 normally heated 760 53
Nickel steels
14 Ni Cr 14 5752 tempered & hardened 1200 25
consideration. The machinability depends on 14 Ni Cr 18 5860 normally heated 830 50
material type, alloying elements and on any 14 Ni Cr 18 5860 tempered & hardened 1300 20
remachining work performed on the material. A Chromium- 34 Cr Ni Mo 6 6582 normally heated 820 48
Nickel- 34 Cr Ni Mo 6 6582 tempered & hardened 1200 24
chromium-nickel steel 14 Ni Cr 14, for example, Molybdenum 30 Cr Ni Mo 8 V 6590 tempered & hardened 1300 20
which has been normally heated and which has a 25 Cr Mo 4 7218 normally heated 750 65
tensile strength of Rm = 760 N/mm² and a Chromium-
25 Cr Mo 4 7218 tempered & hardened 950 53
42 Cr Mo 4 7225 normally heated 750 65
machinability of 53% in terms of cementation, will Molybdenum
42 Cr Mo 4 7225 tempered & hardened 1050 43
have a tensile strength of Rm = 1200 N/mm² and steels
50 Cr Mo 4 7228 normally heated 820 63
machinability value of 25% if the same steel is 50 Cr Mo 4 7228 tempered & hardened 1300 20
Chromium- 50 Cr V 4 8159 normally heated 820 50
tempered and hardened.
vanadium 50 Cr V 4 8159 tempered & hardened 1000 42
37 Mn Si 5 5122 normally heated 750 50
37 Mn Si 5 5122 tempered & hardened 1050 30
Manganese-
silicon steels
46 Mn Si 4 5121 tempered & hardened 1050 30
29
If we classify machinability into 3 main groups it is Cutting speed recommendations
possible to give the following cutting speed for M35 with TiN coating in relation to
recommendations, depending on the module and machinability
material of the hob.
A material is good or bad to machine depending on
whether it is possible to machine it at high or low Machinability
cutting speeds with adequate tool life and width of good medium bad
tensile strength tensile strength tensile strength
wear land. up to 700 N/mm² up to 900 N/mm² up to 1200 N/mm²
Ck 45, C 60, 18 Cr Ni 8, 34 Cr Ni Mo 6 V,
16 Mn Cr 5, C 15, C35,
42 Cr Mo 4, 37 Mn Si 5, 30 Cr Mo V9 V,
20 Mn Cr 5, 15 Cr Ni 6
18 Cr Ni 8, 17 Cr Ni Mo 40 Ni Cr Mo 7
good medium bad
module m/min m/min m/min
roughing finishing roughing finishing roughing finishing
<2 100 125 74 88 45 53
2 92 115 69 81 41 48
3 84 105 63 73 39 45
4 76 95 57 67 35 41
5 68 85 51 59 31 36
6 60 75 45 53 29 34
7 56 70 43 50 28 33
8 53 67 40 47 27 31
9 51 63 39 45 25 30
10 49 62 37 44 24 28
12 45 57 35 41 23 27
14 43 53 32 38 21 25
16 40 50 31 36 20 23
18 36 45 27 31 19 22
30
max. chip Possible

Hob material Possible cutting speeds Recoating
thickness coatings
(N) 0,00 (N) (N) (N)

M35 90 m/min (N) all No
0,25
(N)
(N) 0,00 (N) (N)
ASP 30 100 m/min (N) all No
0,25
(N) (N) (T) (N) (N)
125 m/min 0,00 | 0,10 all No
S 390
180 m/min (T) 0,30 (N) | 0,25 (T) TiAlN / AlCrN (T) Yes (T)
130 m/min (N) 0,00 (N) | 0,10 (T) all (N) No (N)
Rex 76
165 m/min (T) 0,30 (N) | 0,25 (T) TiAlN / AlCrN (T) Yes (T)
135 m/min (N) 0,00 (N) | 0,10 (T) all (N) No (N)
Rex 121 (T) (N) (T) (T) (T)
170 m/min 0,30 | 0,25 TiAlN / AlCrN Yes
130 m/min (N) 0,00 (N) | 0,10 (T) all (N) No (N)
ASP 80 (T) (N) (T) (T) (T)
180 m/min 0,30 | 0,25 TiAlN / AlCrN Yes
The values given refer to a tensile strength of the workpiece material of Key
(N)
about 700 N/mm² and a normal module of about 2,0 = Wet cutting
(T)
= Dry cutting
31
Technology – Shifting
After running for a certain amount of time or after workpiece
machining a certain number of workpieces, the hob
is automatically fed by a programmable entity in the
axial direction. This movement is known as shifting.
The hob and workpiece are therefore no longer in
contact. Gear rotary
direction
To use a hob economically, not only is the width of
wear land fundamental but wear distribution is also
of extreme importance. This is influenced by the
shifting strategy and by the shift increment.
After each shift more teeth on the approach side of Shift Hob rotary
the hob participate in the cut, relieving the strain on direction direction
the exit side. The purpose of this shift is to either
increase hob life or to maintain tool life constant but
use enhanced cutting parameters. The shift travel
Ls is a part of the usable hob length Ln. The
correlation between the two is clear from the figure
(2,0 bis 2,5) x mn (2,0 bis 2,5) x mn
on the right.
The amount of 2,0 x mn to 2,5 x mn serves as a
safety margin in order to ensure that the tooth vane
is properly formed. If the contact ratio is known, it is
possible to reduce this safety margin even further.
Shifting area on the hob
(Hob and gear both left-handed)
32
Technology – the shift strategy
The direction of the shift can be opposite to the
table rotary direction or in the same direction
as table rotation. It is more common, however,
that it is set in the opposite direction. Start position
Shifting in the opposite direction to table
Shift area
rotation workpiece
Hob
This means that the hob is fed from the exiting
profile formation area to the approaching profile
formation area. This ensures that the profile is End position
always formed by “new“ cutting edges.
Shifting in the same direction as table rotation

This shifting is mainly used for finish cutting.
Shifting in the opposite direction to the
With this method “new“ hob teeth always work table rotary direction
in the roughing zone which results in a clean
cut and low heat diffusion.
33
Technology – the shift increment (1)
With older generation machines, it is not
possible to shift the hob in small increments
(due to the inaccurate drive systems used for
0 1...n 1...n 1...n 1...n
the tangential movement of the hob). In each
shift position one or more workpieces (stack) 1...n = Number of machined workpieces in
one shift position
are machined and the shift increment is around
the same size as the module.
Thanks to the introduction of CNC technology

on hobbing machines, it is now possible to
perform small, accurate hob shifts. It is in fact
customary to perform a small shift after each
machined workpiece or stack.
It has proven advantageous with TiN coated
0 1 1 1 1 1 1 1 1 1
hobs to shift hobs more times across the total
length until the maximum width of wear land
has been reached.
The shift increment should be between 0,2 mm
and 0,6 mm.
34
Furthermore current research shows that if
the rough shifting method is used with TiN
coated high-performance hobs, it is possible
to attain further improvement in terms of
overall tool life.
With this method the hob shift increment is
relatively large after each workpiece or 4. Start off-set, 5. repeat shift
stack. During repeat shifting, the area 3. Start off-set, 4. repeat shift
between the shift centre distances is used 2. Start off-set, 3. repeat shift
1. Start off-set, 2. repeat shift
which creates a small start off-set. This Start, 1. repeat shift
procedure reduces hob heating. The start
off-set is around 0,1 mm to 0,2 mm in entity.
Modern CNC machines also support this
shift strategy with suitable control
equipment.
35
The graph below shows the wear distribution along a gash in relation to different numbers of machined workpieces.
Ls 0,5 = 1296 workpieces
Ls 1,0* = 1800 workpieces {* - rough shifting}
Max wear in mm/tooth
Tooth number
36
Technology – Calculation of hobbing time (1)
It is very important to know the axial travel since it is h
possible to decrease hobbing time if this travel is
reduced.
Approach and exit travels in hobbing can be
determined with the aid of the penetration curve. The
A1
da
approach travel E1 can be calculated with formula 7.
0
In this formula the oblique position of the hob has
bZW
been taken into consideration. For this reason it is
only applicable for hobbing with the Pfauter process.
b2
The overrun travel A1 in gear hobbing presupposes
b2
that the hob is still in contact with the gear after
cutting the final gear face. When working with the
Pfauter process it is possible to calculate overrun
E1
travel with formula 8.
Overall hobbing time can be calculated by the

quotients of the axial travel and the axial speed Approach and exit travels in hobbing
(formula 9).
The axial travel can be calculated by formula 10.
 d 
E1  tan   h   a20  da2  h  (7)
 sin  
A1  ha0  cot n  sin (8)
37
Technology – Calculation of hobbing time (2)
If we insert the formulae 10 and 11 in the hobbing time
formula 9, we get the hobbing time as per formula 12. lx
tH  (9)
The hob diameter can be inserted in this formula over vx
the cutting speed as per formula 13.
Following all of these insertions we get the hobbing
lx  E1  (b2  nWst  bzw )  A1 (10)
time calculation formula as per formula 15.
According to formula 15, hobbing times decrease as
the hob diameter decreases. With small tool diameters z0  n0  fa
the axial approach travel E1 is therefore also smaller vx  (11)
z2
(see formula 7).
As regards manufacturing times, it is therefore better
to use a tool with as small a diameter as possible. This tH 
E1  (b2  nWst  bzw )  A1   z2 (12)
statement would only be valid, however, if the cutting z0  n0  fa
speed and the feed were not dependent on the hob
diameter.
da0    n0
It is not possible to view these separately since the vc  m/min (13)
entities of cutting speed, feed and tool diameter are all 1000
closely interrelated. For reasons of wear, it is therefore
v c  1000
necessary to adapt cutting speed and / or feed in
n0  1/min (14)
certain circumstances to decreasing hob diameters. da0  
tH 
E1  (b2  nWst  bzw )  A1   z2  da0   min (15)
z 0  fa  v c  1000
38
Technology – Calculation of hobbing time / Graph (1)
th as f(fa) at variable cutting speeds
8,00
7,00
6,00
5,00
th in min
4,00
3,00
2,00
1,00
0,00
1 1,5 2 2,5 3 3,5 4 4,5 5 5,5 6 6,5 7 7,5 8
fa in mm/WU
vc=130 m/min vc=120 m/min vc=110 m/min vc=100 m/min vc=90 m/min vc=80 m/min
The graph shows the behaviour of cutting time at different cutting speeds
39
Technology – Calculation of hobbing time / Graph (2)
th as f(v c) with variable axial feeds

5,00
4,00
3,00
th in min
2,00
1,00
0,00
70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150
vc in m/min
fa=2 mm/WU fa=3 mm/WU fa=4 mm/WU fa=5 mm/WU fa=6 mm/WU fa=7 mm/WU
The graph shows the behaviour of cutting time with different axial feeds
40
Gear quality – feed marks (1)
Gear quality primarily depends on the accuracy of the
hobbing machine and on the stability of the clamping
equipment used. Other criteria are the quality of the hob,
the quality of gear preparation and the clamping of the hob
and the workpiece on the machine. In terms of clamping it
is important to ensure that there is good true and axial 2
 f  sinn
running.  x   a   mm (16)
In terms of the hob, the form of the outside diameter, the  cos 2  4  da0
number of gashes and the number of threads all influence
the quality of the gear.
Feed marks - x
As the hob diameter decreases, the depth of the lead and
profile errors x which are dependent on the feed
increases as per formula 16 (see picture). If the number of
gashes were increased, it would be possible to work with
higher feeds. This, however, would increase the depth of
feed marks even further. In some subsequent
manufacturing processes, such as shaving for example,
large feed marks are desirable. It is necessary to make
sure that there are always at least two available feed
centres on a tooth flank. If this is not the case, the shaving
cutter may tend sideways, culminating in poor shaving
quality.
Illustration of feed marks
41
60,00
Hob outside
Hob outside diameter diameter
50,00 decreasing in the chordal direction]
30
40,00
Depth of feedmarks
40
50
60
30,00
70
80
90
20,00
100
110
120
10,00
130
140
0,00
0,25 0,75 1,25 1,75 2,25 2,75 3,25 3,75 4,25 4,75 5,25 5,75
axial feed [mm/WU]
The feed marks from the axial feed depend on the variation in outside diameter
42
Examples of feed marks on different workpieces

43
Feed mark depth

tolerances
minimum (µm) maximum (µm)
Finish hobbed 0 - 3
Hobbed for honing 5 - 10
Hobbed for rolling 5 - 10
Hobbed for shaving 10 - 35
Hobbed for form grinding 5 - 20
Hobbed for generating grinding 5 - 15
44
Gear quality – Enveloping cut deviations (1)
Enveloping cut deviations - y
As the number of gashes increases, the
number of enveloping cuts which form the
involute curve also increases.
Enveloping cut deviations (see picture) on the
theoretically exact involute curve y are
calculated according to the formula (17):
2  z0  mn  sinn
2
y  mm (17)
4  z 2  i0
2
Illustration of enveloping cut deviations
45
2 starts with 12 gashes 1 start with 24 gashes
Illustration of the maximum chip thickness
46
Number of
gashes
3,000
10
12
Enveloping cut deviations on the pitch circles [µm]
2,500 14
16
Number of gashes 18
2,000 [decreasing in the chordal direction
20
22
1,500 24
26
1,000 28
30
32
0,500
0,000
10 20 30 40 50 60 70 80 90 100 110 120 130
Number of gear teeth
Enveloping cut marks depend on the number of workpiece teeth
47
Technology – Wear
During machining, the intense metallic contact between the tool teeth, the workpiece and chips causes
significant mechanical and thermal stress for the hob. Wear basically covers anything which results in
the cutting edges losing their geometrically defined form, whether this be caused directly or indirectly.
Wear is a fundamental criteria in the economic use of hobs due to the high proportionate tool costs.
Aside from the cutting parameters, the characteristics of the gear material, the cutting angle, the metal
cutting geometry and the coolant all influence hob wear formation.
Rounding off of the

cutting edges
Flank wear
Cutting edge
chipping
Crater-type wear
Flank wear
48
Technology – maximum width of wear land (1)
Knowledge about wear formation is necessary in order to
determine an economically convenient maximum width of
wear land. This corresponds to the amount of material
removed in resharpening.
If the wear on the hob teeth becomes too large, it will
quickly result in increased cutting force due to the
intensified friction of the hob cutting edges. This
generates poor machining quality on the workpiece.
Errors caused by a specific cutting edge will generate
more heat energy within the workpiece which can prove
negative for subsequent gear heat treatment.
Wear development establishes most quickly on shifted

hobs since with these types of hobs more stacks or
workpieces are hobbed in one shift position. After a
predetermined number the hob is removed and
measured. In such procedures the maximum wear is
usually only on 2-4 teeth. For this reason before removing
the hob from the machine, its position on the spindle must
be marked to avoid distortion of the measurements taken.
49
Technology – maximum width of wear land (2)
The upper curve in the graph below corresponds to a typical course of wear land formation. It must also be noted that
this wear land is not proportional to the number of hobbed stacks. The lower curve illustrates the proportional increase in
wear during hobbing of 10 stacks at a time. A minimum of 150 stacks is available here and with this minimum the
maximum width of wear land is 0,278 mm.
The best width of wear land is therefore just before wear formation begins to increase rapidly.
The maximum width of wear level is 0,3 mm.
2 workpieces per stack

Wear
Number of hobbed stacks
Max. wear in mm Wear increase in mm / 10 pieces
50
Maximum chip thickness according to Hoffmeister
During interrupted cutting processes like hobbing, the hob
teeth are subject to a certain shock load, especially with
climb hobbing. The shock depends on the cutting force
and amongst other things on the chip cross section. t un g
Raddrehrich
The maximum chip thickness h1max of all hob teeth which
cause the large shock load can be calculated by formula Undeformed chip section
Spanungsquerschnitt
18.
0,511
9,2510 3
 2 0,542  0,015x p  f 
h1max  4,9  mn  z 2 e 0,015 2
e   a  
 mn 
E A
8,2510 3
 2 0,225  0,877 0,319
Stelle des
Position of
 d  i   h  Flanken-
  a0    0     (18) verschleißes
flank wear
 2  mn   z0   n
m
To determine the optimum feed for a given chip thickness

the abovementioned formula can be used. See formula 19. Hob tooth
Fräserzahn
1,614510 2
 2 0,773  1,810210 2
 2 1,0607 
fa  h1max  0,0446  mn  z2 
1,9569
1,614510 2
 2  0,4403  1,7162
   da0  i 
 e 2,9410
2
 2
  0  
 2   z0 
2,9410 2
x p 
 h0,6243  e (19)
51
Maximum chip thickness according to Hoffmeister (Examples)
mn = 2,00 mm mn = 2,00 mm
z2 = 50 teeth z2 = 50 teeth
da0 = 86 mm da0 = 86 mm
z0 = 3 starts z0 = 3 starts
i0 = 24 gashes i0 = 24 gashes
fa = 2,00 mm/WU fa = 2,00 mm/WU

h = 5,50 mm h = 5,50 mm
h1 max = 0,13 mm h1 max = 0,21 mm

52
mn = 2,00 mm
z2 = 50 teeth
0 = 20°
2 = 0°
xP = 0 mm
da0 = 100 mm
z0 = 1 start right
i0 = 12 gashes
fa = 3,50 mm/WU
h = 5,50 mm
h1 max = 0,12 mm

53
mn = 2,50 mm
z2 = 14 teeth
0 = 20°
2 = 0°
xP = 1,0 mm
da0 = 100 mm
z0 = 1 start right
h1 max = 0,30 mm i0 = 12 gashes
fa = 5,50 mm/WU
h = 4,50 mm

54
mn = 2,00 mm
z2 = 14 teeth
0 = 20°
2 = 10°
xP = 0,5 mm
da0 = 100 mm
z0 = 1 start right
i0 = 12 gashes
h1 max = 0,22 mm fa = 3,30 mm/WU

h = 5,40 mm

55
Spanungsdicken
0,25
0,20
0,15
hcu [mm]
hcu,max
hcu,mit
0,10
0,05
0,00
-10,00 -8,00 -6,00 -4,00 -2,00 0,00 2,00 4,00 6,00 8,00 10,00
Unwinding of the cutting edges [mm]
Schneidkantenabwicklung
Hob
tooth
Chip thickness over the hob tooth
56
1 mm
1 mm
57
1 mm 1 mm
1 mm
1 mm
mm 1 mm
1 mm
58
Chip forms
3-Flank chips
Tip chips
Flank chips
59
Chip forms (simulation)
Waelzstellung
Generating position-39
-39
0,238-0,250
0,225-0,238
0,213-0,225
0,200-0,213
0,188-0,200
0,175-0,188
0,163-0,175
36 0,150-0,163
0,138-0,150
0,125-0,138
0,113-0,125
22
0,100-0,113
0,088-0,100
rotation angle [°]
0,075-0,088
Werkzeugdrehwinkel
8 0,063-0,075
0,050-0,063
0,038-0,050
-6 0,025-0,038
0,013-0,025
8,1 0,000-0,013
Tool
6,9
5,3
-21 3,7
2,1
0,3
-1,4
-3,1
-35 -4,7 Schneidkantenlänge
Cutting edge length [mm]
-6,3
-7,6
60
Chip forms (simulation)
Generating position -26
Waelzstellung -26
0,238-0,250
0,225-0,238
0,213-0,225
0,200-0,213
0,188-0,200
0,175-0,188
0,163-0,175
36 0,150-0,163
0,138-0,150
0,125-0,138
0,113-0,125
22
0,100-0,113
0,088-0,100
Tool rotation angle [°]
0,075-0,088
Werkzeugdrehwinkel
8 0,063-0,075
0,050-0,063
0,038-0,050
-6 0,025-0,038
0,013-0,025
8,1 0,000-0,013
6,9
5,3
-21 3,7
2,1
0,3
-1,4
-3,1
-35 -4,7 Schneidkantenlänge
Cutting edge length [mm]
-6,3
-7,6
61
Cutting value analysis / cost analysis
Cutting analysis Cost analysis:

Date: TT.06.JJJJ
Date: TT.06.JJJJ
Customer: Example - test customer - place
Customer Example - test customer - place
Drawing number: 1234-5678-90
Drawing number 1234-5678-90
Workpiece data: 0912-3456-78
Workpiece data: 0912-3456-78
Material Rm ca. 600 - 750 N/mm²
Material Rm ca. 600 - 750 N/mm²
Normal module (mn2) 2,1200 mm
Normal module (mn2) 2,1200 mm
Pressure angle (n2) 20,0000 °
Pressure angle (n2) 20,0000 °
Number of teeth (z2) 23
Number of teeth (z2) 23
Helix angle (ß2) straight
Helix angle (ß2) straight
Addendum modification (x*mn2)
Addendum modification (x*mn2) -0,0400 mm
-0,0400 mm
Outside diameter (da2) / root diameter (df2) 64,5300 mm / 54,5000 mm
Outside diameter (da2) / root diameter (df2) 64,5300 mm / 54,5000 mm
Hobbed width (b2) 10,0000 mm Hobbed width (b2) 10,0000 mm
Hob data: S 390 ---TiAlN coating (Futura-Nano)
Hob data: S 390 ---TiAlN coating (Futura-Nano)
Hob quality DIN 3968 class AA Hob quality DIN 3968 class AA
Outside diameter (da0) 80,00 mm Outside diameter (da0) 80,00 mm
Hobbed length (lverz) 140,00 mm Hobbed length (lverz) 140,00 mm
Gashes (i0) 17 Gashes (i0) 17
Number of starts (z0) 2, right Number of starts (z0) 2, right
Addendum (hap0) 2,5000 mm Addendum (hap0) 2,5000 mm
Tooth depth (hw) 5,5165 mm Tooth depth (hw) 5,5165 mm
Lead angle (0) 3,2083° - right Lead angle (0) 3,2083° - right
Technological data: DRY HOBBING Technological data: DRY HOBBING
Manufacturing process: Finish hobbing Manufacturing process: Finish hobbing
1. cut 2. cut stacked - 2 workpieces per stack
Hobbing process: climb hobbing conventional hobbing 1. cut 2. cut
Cutting depth (h) 5,0150 mm Hobbing process: climb hobbing conventional hobbing
Cutting speed (vc) 140 m/min Cutting depth (h) 5,0150 mm
Number of hob rotations (n0) 557 1/min Cutting speed (vc) 140 m/min
Number of workpiece rotations (n2) 48,44 1/min Axial feed (fa) 1,80 mm/WU
Axial feed (fa) 1,80 mm/WU
Hobbing time: 0,4551 min
Approach factor: 1,00 Hobbing time: 0,4551 min
Exit factor: 1,00 Floor-floor time incl. non-productive time 0,6051 min
Hobbing time: 0,4551 min
Feed mark depth 3,89 µm
Cost analysis:
Enveloping cuts 9 Cost of new hob: 900,00 €
Tooth contact frequency 157,83 Hz Number of possible resharpenings: 23 (bei VB = 0,25 mm)
Chip thickness (h1max) 0,1813 mm Stacks / workpieces per resharpening 2776 stacks / 5552 workpieces
Enveloping cut deviations 1,08 µm Stacks per hob / workpieces per hob 66624 stacks / 133248 workpieces
Resharpening time [min]: 44,00 min
Setting data: Okay; Okay; Okay; Okay
Hourly resharpening cost [€/h]: 40,00 €
Swivel angle: 2,8319 ° Approach path: 20,0727 mm Cost per resharpening: 29,33 €
Profiling area: 11,65 mm Overrun travel: -0,3950 mm
Coating costs: 86,00 €
Approach area: 17,28 mm Shift entity: 3,3301 mm (Factor = 0,50)
Overall tool costs: 3.552,59 €
Setting length: 23,10 mm Workpieces per repeat shift: 32 stacks
Tool costs per stack: 0,0267 €
Safety zone: 13,32 mm Number of repeat shifts: 174 repeat shifts
Tool changeover time [min]: 15,00 min
maximum shift path: 103,58 mm Start off-set: 0,0191 mm
tool changeover time per stack: 0,16 sek
Machining time and tool life: Workpiece changeover time 9,00 sek
Workpieces per workholding fixture stacked - 2 workpieces per stack Hobbing cycle time: 0,6078 min
Tool life per hob tooth: 5,00 m Labour costs of machine operator [€/h]: 35,00 €
Usable tip length (approx.): 5,8 mm Number of resharpenings: 23 (bei VB = 0,25 mm) Labour cost per stack [€/h]: 0,7091 €
Machined length per stack: 0,2381 m Number of hob teeth: 357 Zähne (264 Zähne) Hourly machine rate of hobbing machine: 45,00 €
Workpieces per resharpening: 5552 Stück Workpieces per hob: 133248 Stück Machine costs per stack [€/h]: 0,9117 €
Cutting force: 1039 N Hobbing time: 0,4551 min
Main motor power: 2,4241 kW Hobbing time incl. non-productive time 0,6051 min Production costs for the hobbing process per part 1,6474 €
!!! The data shown is only approximate and is consequently not binding !!! Totale production costs per hob: 9.146,37 €
!!! The data shown is only approximate and is consequently not binding !!!
62
Resharpening and resharpening errors (1)
Use-related wear on the hob must be eliminated from the
tool by a resharpening operation since as wear increases,
the cutting force increase and workpiece quality is
reduced.
Hob tooth
The resharpening quality is particularly important since Wälzfräserzahn
The actual hob
Zahnradzahn
Gear tooth
der wirksame Fräser- dieser wird
Becomes am at
thicker
workpiece quality is influenced to a large extent by this tooth becomes
zahn wird länger Kopf
the tip dicker
longer
process.
Since the hob cutting edges lie on the enveloping helix fehlerhafte,
Error, positive positive Spanflächenlage
side face position
which generates the profile of the workpiece teeth, this
must correspond to the relative criteria in terms of position
and pitch. Each profile and position error on the side faces
causes distortions in the cutting wedge form. Pitch
deviations of the gashes lead to contact pitch deviations of Hob tooth
Wälzfräserzahn Zahnradzahn
Gear tooth
The actual hobFräser-
der wirksame dieser wird
Becomes am
thinner
the cutting edges. These deviations cause changes on the zahn becomes
wird kürzer
tooth at Kopf
the tipdünner
gear tooth profile and on the contact pitch. shorter
A depth of roughness (Rz) of 3 - 4 µm on the side faces fehlerhafte, negative Spanflächenlage
Error, negative side face position
should be targeted both to ensure workpiece accuracy and
surface quality and also for reasons or tool life.
Typical resharpening errors are shown in the diagram to
the right. Their influence on the hob profile and on the gear
teeth is also indicated. Wälzfräserzahn
Hob tooth Zahnradzahn
Gear tooth
balliger
crownedFräserzahn
hob tooth hohle gear
hollow Flanke
tooth
Error, crowned
fehlerhafte, side
ballige face position
Spanflächenlage
The dotted lines indicate the geometrically correct profile
63
Resharpening and resharpening errors (2)
After resharpening the following must be checked:
 Side face position and profile errors (error 7 as per
DIN 3968)
 Single indexing error of gashes (error 8 as per DIN
3968)
 Cumulative pitch error of gashes (error 10 as per
DIN 3968)
 Gash direction (left or right) over 100mm of hob
length (error 11 as per DIN 3968)
In any case the hob must also be checked for any

magnetism. Should the hob be subject to magnetism,
there is the danger that the hobbed chips may stay
attached to the cutting edges. If this occurs the workpiece
surface finish will not be clean and it is even possible for
gear teeth to break off.
64
Skiving hob / process definition
Skive hobbing is a chip removal process used to hob u
gears after heat treatment i.e. hardened gears.
Carbide tools are therefore used for this process, the most l
notable feature of which is a negative rake angle. This
negative rake angle generates the typical skiving-type cut
of the skiving method. In terms of applications this type of
hob is used for finish machining of gears which cannot be
ground for shoulder-interference reasons. Combined
of rotation
Drehrichtung
skiving and grinding processes have also proven to be
economically convenient.
The hardness level of workpieces must be within a range
of 58 - 63 HRC.
Direction
Due to the high edge strength requirements of the cutting
material, carbide from the groups K05 and K10 is normally
used.
The rake angle depends primarily on the module and on
the level of hardness of the workpiece.
It usually ranges between -16° and -30°.
da0
l – rake angle
u – side face centre distance
da0 – outside diameter
Sketch of a skiving hob
65
Skiving hobs / Wear and technology
Wear
Since the tooth tip of the skiving hob will not cut if premachined with protuberance, wear formation
builds up exclusively on the flank backs.
The width of wear land should not surpass a maximum value of 0,15 mm. As a general rule the
maximum level of wear is from 0,05 to 0,10 mm. Since the wear zones on the cutting edges are
relatively small, an optimum shift value is of the utmost importance (rough shifting).
If wear becomes too large, scaly cracks build up on the cutting faces.
Cutting speed
The cutting speed depends on the size of the module and on the hardness level of the gear.
The following approximate values can be considered as reference values:
Module 1,5 to 3,0 ca. 90 m/min - 110 m/min
Module 3,0 to 4,0 ca. 80 m/min - 90 m/min
The higher the cutting speed, the greater the heat absorption of the workpiece and therefore the larger
the structural changes of the workpiece surfaces.
66
Skiving hobs / Accuracy and tool life
Feed
The skiving method is performed exclusively with the climb hobbing process since a certain chip
thickness must be available from the start of stroke.
Feed is set according to the required workpiece quality.
Depending on the attainable and desired quality, it is possible to hob in 2 cuts with the skiving method
(a roughing cut and a finishing cut). The amount of stock removed per flank should not exceed 0,3 mm,
0,1 mm of which should be left for the finishing cut.
Roughing approx. 4,0 - 5,0 mm/WU
Finishing approx. 1,0 - 2,5 mm/WU
Accuracy
Skiving hobs in use today have a quality class of AA according to DIN 3968 or of AAA in cases where
high workpiece quality is required (75% of tolerances are AA).
The accuracy attainable is directly connected with the quality of the machine, the clamping equipment,
the tool, the technological parameters and the preparation and heat treatment of the blank workpiece.
Under suitable conditions it is possible to obtain gears of quality class 6 as per the DIN 3962 normative.
Tool life
Tool life is around 1,0 m and 4,0 m per hob tooth depending on the module and on the level of
workpiece hardness.
67
Comparison of research / tool life
A general analysis of the width of wear land is very limited
since wear depends on many more parameters than just
those examined here.
Even so the analysis of tool life and the number of parts Hobbed gear tooth length
hobbed between hob resharpenings can be useful for

application purposes. b2  z 2  nWT
l2 f 
It is not possible to compare research on different cos 2
workpieces. Information on the length, which a hob tooth
can machine per resharpening, however, enables us to
make better comparisons between different results.
Tool life can be calculated as a quotient of the hobbed l2 f b  z  n    mn
workpiece tooth length l2f and of the number of usable teeth lfz   2 2 WT
of the hob zn0. zn0 cos 2  Ln  i0  cos  0
If we insert the length of available shift areas as the gash
length, we get the hobbed tooth length per hob tooth in the Usable hob teeth
shift area. This value automatically increases as the hobbed
tooth length per hob tooth increases. In my opinion this Ln  i0  z0
z n0 
value is much more realistic since the teeth are only afflicted pz0 Hob lead
by wear to a small extent in the end zone of the profile
formation area (see wear formation).
z0    mn
pz0 
cos  0
68
Research strategies
Tool life
Manufacturing time
Gear quality
Variation in cutting Variation in axial Variation in shift Variation in coating

speed feed increment and in
shifting strategy
69
Process optimisation strategies
Geometry Strategy Technology
Calculation of chip cross Hob design
given gear geometry
section -Hob geometry
Hobbing machine Work conditions
Cutting speed
Assessment of the Feed
cutting process Shift increment
Shifting strategy
Wear measurement
Wear assessment
Wear analysis
Optimisation of cutting
Reduction of wear
conditions
Increase in economy
70
Comparison of tool life between different hob materials
Comparison of tool life with different hob materials
mn2 = 2,88 mm da0 = 90 mm fa = 3,00 mm/WU

3000 alpha n2 = 18° z0 = 2 left vc = 110 m/min
z2 = 17 i0 = 17 VB ca. 0,2
da2 = 63,76 mm ln = 186 mm
VB ca. 0,2
VB ca. 0,4
Number of hobbed gears per resharpening
2500 VB ca. 0,2
VB ca. 0,2
2000
1500 VB ca. 0,25
1000
500
0
M 35 CPM-M 35 ASP 30 S390 neu S390 coater A S390 coater B
71
Data required to order a hob (1)
Roughing or finishing hob
Dimensions
Outside diameter {min. Ø 40 - max. Ø 305}
Total length
Tooth segment length
Bore diameter {min. Ø 16} or precise mounting details
Type of clutch keyway
Number of threads / direction of hand
Number of gashes
With or without taper
Profile
Should you be unable to determine the profile according to a normative or if you are not sure, please send us your workpiece drawing with the
gear data so as to avoid misunderstandings.
Rack profile normative

Hobs for involute gears as per DIN 867, DIN 3972, DIN 58400
or other normative
Module {min. 0,75 - max. 32}
Pressure angle
Splined shaft hobs with involute flanks as per DIN 5480, DIN 5482 or other normative
Module {min. 0,75 - max. 32}
Pressure angle
Hobs for serrated gears as per DIN 5481 or other normative
Nominal diameter of the serration
Hobs for roller chain sprockets as per DIN 8197 or other normative
Pitch
Roller diameter
72
Data required to order a hob (2)
Hobs for splined shafts as per DIN 5462, DIN 5463, DIN 5464, DIN 5471,
DIN 5472, DIN 9611 or other normative
Inside and outside diameters *
Width of splines *
Number of splines *
*) for finish hobbing give the tolerances of the marked measurements,
for roughing indicate the machining allowance
It is important to indicate whether a band should be hobbed and with what diameter.
Any required profile corrections
Semitopping
Semitopping angle and depth of semitopping on the finished workpiece
Protuberance
Entity of protuberance and protuberance angle and depth of protuberance
Tip relief
Pressure angle and depth of tip relief
Topping
Tooth depth
Lugs
For roughing give the machining allowance dimensions per tooth flank
Quality class as per DIN 3968 AA, A, B, C, D (please indicate any restrictions)
Hob material or indication of gear material and hardness level
Type of coating (TiN, TiCN, TiAlN or similar)
Number of pieces
73
Abbreviations and symbols
A1 axial exit travel prP0 Protuberance
da0 tip diameter of hob sP0 Tooth thickness (/2*mn)
da2 tip diameter of workpiece tH Hobbing time
db0 base diameter of hob vc Cutting speed
db2 base diameter of workpiece VB Width of wear land
b2 Workpiece width xP Addendum modification
bzw total space between stacks z0 Number of threads
E1 axial approach travel z2 Number of teeth of workpiece
fa axial feed n normal pressure angle
haP0 Addendum of the rack profile prP0 Protuberance angle
hp Gear profile depth = cutting depth KP0 Pressure angle of the semi-topping flanks
hP0 Addendum 2 Helix angle of workpiece
hNfP0 Usable dedendum of the hob rack profile 0 Helix angle of hob
hprP0 Protuberance depth of the rack profile x Feed mark depth
hFfP0 Usable dedendum of the rack profile x Entity of enveloping cut deviations
h Cutting depth aP0 Tip rounding radius
h1max maximum chip thickness fP0 Root rounding radius
i0 Number of gashes  Hob swivel angle
LV Portion of hob length available for shifting
LAV Length of hob work area in the roughing zone
LAA Length of hob work area on the exit side
LAE Length of hob work area on the approach side
LS Shifting length
Ln usable hob length
LP0 Length of the profile formation area
LAZ Length of the roughing zone
LA0 Length of the hob work area
lverz machined length of hob
mn normal module
n0 Number of hob rotations
nWst Number of tools per stack
74
Overview of DIN normatives and further reading (1)
DIN 867 Basic rack tooth profiles for involute teeth of cylindrical gears for general engineering and heavy engineering
DIN 1825 disc-gear cutters for spur gears
DIN 1826 extended hub gear cutters for spur gears
DIN 1828 shank-gear cutters for spur gears
DIN 1829 Pinion-type cutters for cylindrical gears; Part 1 – Part 2
VDI 3333 Hobbing of spur gears with involute profile
DIN 3960 Definitions, parameters and equations for involute cylindrical gears and gear pairs
DIN 3962 Tolerances for Cylindrical Gear Teeth; Part 1 – Part 3
DIN 3966 Information on Gear Teeth in Drawings; Part 1 – Part 3
DIN 3972 Reference Profiles of Gear-cutting Tools
DIN 3975 Terms and definitions for cylindrical worm gears with shaft angle 90°
DIN 3998 Denominations on Gears and Gear Pairs
DIN 5463 Straight-sided Splines
DIN 5464 Straight-sided Splines
DIN 5471 Spline Shafts and Spline Bore Profiles with 4 Splines, Internal Centering, Dimensions
DIN 5472 Spline Shafts and Spline Bore Profiles with 6 Splines, Internal Centering, Dimensions
DIN 5480 External splines with involute flanks Part 1 – Part 16
DIN 5481 Internal and external serrated shafts, Profile Sheet 1, sheet 5
DIN 5482 Profiles of internal splines and shafts with involute flanks, Dimensions Sheet 1, Sheet 3
DIN 7721 Synchronising belt drives, metric pitch Part 1 – Part 2
75
Overview of DIN normatives and further reading (2)
DIN 8002 Hobs for Spur Gears, with Clutch Drive Slot or Keyway, Modules 1 to 20
DIN 8187 European type roller chains
DIN 8188 American type roller chains
DIN 8196 Toothing of chain wheels for roller chains as specified in DIN 8187 and DIN 8188; profile dimensions; Part 1
– Part 2
DIN 8197 reference profiles of hobs for sprockets for roller chains
DIN 8198 Profiles of tooth space cutters for chain wheels for roller chains
DIN 9611 Splined shafts ISO 500:1991 modified
DIN 58400 Basic rack for involute teeth of cylindrical gears for fine mechanics
DIN 58405 Spur Gear Drives for Fine Mechanics; Sheet 1, Sheet 4
DIN Handbook 106
Antriebstechnik (Drive technology) 1 (ISBN 3-410-10840-8)
DIN Handbook 173
Zahnradfertigung (Gear manufacturing) (ISBN 3-410-12685-6)
DIN Handbook 123
Zahnradfertigung (Gear manufacturing) (ISBN 3-410-13213-9)
Moderne Zahnradfertigung (modern gear manufacturing)
Thomas Bausch u.a.
Kontakt und Studium – Band 175 (Expert Verlag - 1994)
ISBN 3-8169-0980-9
76

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Samputensili Hobbing

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Hobs and gear

It is possible to manufacture such an extensive range of

The growing needs of gear manufacturers in terms of

Hob design primarily depends on the tool holding fixtures

Clamping by means of an arbour which slides into the hob

Hob with special clamping fixture

The type of shank depends on the clamping system of the

 double-sided parallel support shank

The clamping systems on most machines are arranged so

Double bore-type hob with clutch keyway

Back of tooth Cutting

Hobbed length / usable length

• Axial hobbing: During machining the hob only Axial hobbing fa

Tangential hobbing with a tapered hob

Centre distance [mm]

Work areas on the hob

Increasing the number of threads can result in an increase

Number of hob rotations Number of workpiece teeth

Number of flutes  Number of workpiece teeth

For hobbing helical gears, the climb hobbing method is

resharpenable length on tooth tip

Normal module = 2,00

The resharpenable tooth length depends on the number of

Main machining Structural Application

resistance and cutting speed

P50 heavy roughing

resistance and cutting speed

K40 heavy roughing

Relatively high bending

2.500,00 € Material TiN coating TiCN coating TiAlN coating

SUNITE® Gold TiN 600 2500 0,4 1-4 gold-gelb

SUNITE® Carbonium TiCN 450 3300 0,4 1-4 grey blue

SUNITE® Silver Ti2N 600 2300 0,4 1-4 silver

SUNITE® Chrominum CrN 700 1750 0,5 1-5 metallic

SUNITE® UniversAl TiAlN 800 3000 0,4 1-4 violet

SUNITE® Futura TiAlN 800 3000 0,4 2-6 grey-violet

SUNITE® X.Treme TiAlN 800 3500 0,4 1-3 grey-violet

SUNITE® Alcrona AlCrN 1100 3200 0,35 2-5 blue-grey

after heat hobbed

DIN 3963 - 3963 1 2 3 4 5 6 7 8 9 10 11 12

work hardened shaved

Hob quality Module ranges

attainable gear quality

Helix direction Helix direction

Helix direction Helix direction

To calculate this curve exactly, we need to know

Calculation of the penetration curve

By adding r1* to the formula (1) we obtain the general

The work process used determines which of the two

Only with Only with

Gear: right-handed Gear: left-handed Gear: right-handed Gear: left-handed

Spur gear Spur gear

Already with Already with

max. chip Possible

(N) 0,00 (N) (N) (N)

Shifting in the opposite direction to table

Shifting in the same direction as table rotation

Thanks to the introduction of CNC technology

Overall hobbing time can be calculated by the

A1  ha0  cot n  sin (8)

th as f(fa) at variable cutting speeds

th as f(v c) with variable axial feeds

Illustration of feed marks

Examples of feed marks on different workpieces