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Gear Finishing
For effective and noiseless operation at high speed , it is important
that profile of teeth is accurate , smooth and without irregularities.
In Milling , it may not have accurate profile because of use of limited
cutters.
In Shaping and Hobbing, it composed to tiny flats. This difficulty
achieved by reducing feed rate but it increases cutting time.
In many cases gears are hardened after cutting teeth to improve life
but it introduce slightly distortion or surface roughness.
Finishing operation intended to perform following function :
1) Eliminate after effect of heat treatment.
2) Correct error of profile and pitch.
3) Ensure proper concentricity of Pitch circle and Centre hole.
Gear Shaving
Process of finishing of gear tooth by running it at
very high rpm in mesh with a gear shaving tool.
A gear shaving tool is of a type of rack or pinion
having hardened teeth provided with serrations.
These serrations serve as cutting edges which do a
scrapping operation on the mating faces of gear to
be finished. Both gears in mesh are pressed to
make proper mating contact.
The gear shaving operation is composed by
the simultaneous rotation of
workpiece and cutter as a pair of gears with
crossed axes. The crossed
axes generate a reciprocal sliding action between
the flank, gear tooth and the cutter teeth.
• Soft materials like aluminium alloy, brass, bronze,
cast iron etc. and unhardened steels are mostly
finished by shaving process.
Gear Shaving
Different types of shaving cutters which while their finishing action work apparently
as a spur gear, rack or worm in mesh with the conjugate gears to be finished.
All those gear, rack or worm type shaving cutters are of hard steel or hss and their
teeth are uniformly serrated) to generate sharp cutting edges
Gear Shaving
Most widely used method
For the continuous production of large lots, it represents the best
cost/performance ratio.
The main limit of the gear shaving process is the lack of the chance
to remove the distortion caused by heat treatment.
In the automotive industry, the vast majority of gears used in
gearboxes are suitable for gear shaving.
The productivity of a gear shaving machine is much higher compared to a gear
grinding machine.