Gear Shaving

By dr. Gianfranco Bianco

www.gianfrancobianco.com
Gear Shaving

Gear shaving is the most common and the

cheapest finishing system of the cylindrical gear

With this presentation we will give the basic

information about the shaving process
 Gear Shaving

Advantage of shaving against grinding

 Easy application of involute profile and lead modification

 Short cycle time

 Possibility to finish gears close to shoulders

 Reasonable set-up time
 Low tool cost per piece
 Low investment for the purchase of a shaving machine
 Easy procurement of tools
 Easy automatization
 Gear Shaving

Disadvantage of shaving against grinding

 Shaving process must be applied before heat treatment.

 Heat treatment distortions result in errors.

 The shaving result is highly dependent by the qualityof the workpiece.

 Occasionally impossible to use the shaving tool on gears with a small

number of teeth.
Gear Shaving

What can you obtain through shaving?

 Profile improvement of 2–3 DIN classes.

 Helix improvement of 2 - 3 DIN classes.

 Indexing improvement of 1 – 2 DIN classes.

 A run out error can be transformed into a

 cumulative pitch error.

 You can get rid of hobbing scallop and other irregularities left by hobbing
operations.

 It is possible to obtain a surface finish almost as good as obtained by

grinding (Ra = 0,4 – 0,6 micron).

You can even obtain class 4 (DIN 3962) gear, but this requires a properly
performed preshaving operation, a lot of attention when shaving, long shaving
times and the general characteristics of the workpiece must be suitable for
shaving.
 Gear Shaving

Even contact points

Even contact points

Odd contact points

The most commonly used shaving cutter design system is the so-called even
contact method. There is always an even number of contact points.
Gear Shaving

Even contact forces

Balanced forces

Unbalanced forces

With even contact points the forces are balanced.

With odd contact points the forces are unbalaced.
 Gear Shaving

Typical profile error generated by the non-fullfillment of even contact

Area with odd contact points

 Gear Shaving

User diagram of shaving cutter

A = Root diameter

B = Beginning of root filet

C = Even contacts

D \ E = Start of active profile

(SAP)

F = Outside diameter of gear

Wz = Thickness over Z teeth

Gear Shaving

Influence of the protuberance relief on

the balance of forces

The contact point of the outside

diameter of the shaving cutter
(5) is unstable.
It’s influenced by the stock
removal, by the protuberance’s
tollerance, by the wear of the
hob
Gear Shaving

Limitation of the even contact method

 There are no points of contact but more or less wide contact areas.

 The contact occurs along an oblique path of variable length.

 The fact that the contact is at an even number of points is respected but the
actual number of points is rarely constant.

 The cutting action depends on the pressure not on the force.

 The pressure depends on the curvature of the surface (continuosly variable).

 Every contact point has a different cutting condition

 Gear Shaving

Schematics of the contact area width

With the same force

Larger area

Lower pressure
Gear Shaving

Cross angle

How to obtain sliding on the tooth

flanks in crossed axis mating

 = cross angle
Gear Shaving

Cross angle

Cross angle  normally must have a value between 10 and 15 degree

This range is valid if we work gears in steel with a resistance

between 600 and 700 N/ mm2

For cast iron or light alloys it’s possible to use a cross angle of 20
degree

In some case it’s not possible to use the above cross angle because of
obstacles interfere with the cutter. But it’s impossible to work with angles
lower that 3 degree.
Gear Shaving

Shaving methods

•Parallel shaving

• Diagonal shaving

• Underpass shaving

• Plunge shaving
 Gear Shaving

Parallel shaving

You can shave gears with very large face

width.

There is no relationship between gear

width and cutter width.

Longer stroke means longer cycle time.

The cutter works only with a limited

contact area.

Shorter cutter life.

Gear Shaving

Diagonal shaving

You can shave gears with a face

width larger than the cutter face
width ( max 100 mm).

Stroke is shorter than with

parallel shaving and depends on
the cross of axes angle, from the
diagonal angle and from the gear
face width.

A cutter wich exploit its whole

length is ideal.
sen
l1  L 2 
sen   
Gear Shaving

Underpass shaving

It can be used with shoulder

gears with a minimun crossing
angle of 3°.

Cutter face width is larger than

gear face width.

Very short stroke.

Offset serrations.

' L2
L 
1
cos 
Gear Shaving

Plunge shaving
Stroke length
roughly 1 mm

Shortest stroke and cycle time.

Cutter face width is larger than gear

face width.

Offset serration.

Cutter helix has to be modified to

achieve the correction required on
the gear.

CNC machine required.

Gear Shaving

Offset serration

(a): Serration for conventional shaving cutters.

(b) – (c): Underpass and plunge shaving cutters
 Gear Shaving

Design of serration
Normal module Serrations pitch
mn Pc Notes

Up to 1,50 From 1,80 to 2,00 Provided module is the

same, if stock removal Serrations pitch in
increases ,serrations function of the module
From 1,50 to pitch will be bigger. E.g.
From 1,90 to 2,19 if you pass from a stock
2,75
removal of 0.04 to one of
0.08 mm per flank,
From 2,75
From 2,00 to 2,20 serrations pitch
onward increases of ca. 10%
 Gear Shaving

Serrations sizing Design of serration

Serrations Width of solid Serration space
pitch Pc Serration Pp Pv
1,80 1,05 0,75
1,85 1,10 0,75
1,90 1,15 0,75
1,95 1,15 0,80
2,00 1,10 (or 1,20) 0,90 (or 0,80)
2,05 1,10 0,85
2,10 1,10 0,90
2,15 1,20 0,95
2,20 1,20 1,00
 Gear Shaving

Design of serration

Each resharpening
reduces the serration’s
depth of roughly from
0,02 mm to 0,04 mm

0,20 min

Normal Pressure Angle Serration Depth

Up to 17° 30’ Min = 0,20 + 0,22 mn

Max = 0,20 + 0,28 mn
from 17° 30’ to 22° 30’ Min = 0,20 + 0,28 mn
Max = 0,20 + 0,32 mn
from 22° 30’ onward Min = 0,20 + 0,25 mn
Max = 0,20 + 0,28 mn

Shaving cutter can not work normally if the depth of the serration are less
than 0,20 mm
 Gear Shaving

Offset serration

Z = N° of teeth of gear
Z1 = N° of teeth of shaving
cutter
Pc = Pitch of serration
Sf = Offset of serration tooth
Pi = Overlap value

P i = Z S f – n Pc

n Pc ≤ Z Sf ≤ (n + 1) Pc

Pi = 0,15 – 0,25 mm
 Gear Shaving

Offset serration

S f  Z1
 f
Pc

Integer number

Choose as f the integer number closest to

S f  Z1
the ratio
Pc

f  Pc
Sf  Recalculate the
Z1 value of Sf
 Gear Shaving

Lightening
holes

Offset serration
Gear Shaving

Working condition

•Shaving stock removal

• Stroke length

• Number of passes

• Cutting speed

• Cutting feed

• Lubrication and cooling

 Gear Shaving

Speed vectors in the various points of the tooth

Outside diameter
Max cutting speed

V = Cutting speed vector

Vs = Radial vector
Va + Vl = Axial vector

Rolling Pitch diameter

Min cutting speed
Gear Shaving

Example of working traces with different directions

Gear Shaving

Working condition
Recommended peripheral speed on cutter pitch diameter (m/min)

Steel resistance in Kg/mm2 Module = 2 Module = 4 Module = 6

50 200 – 120 180 - 110 160 - 105

60 180 –115 160 -105 140 - 100

70 160 – 110 140 -100 120 - 90

80 140 – 100 120 - 90 100 - 80

90 120 – 90 100 - 80 90 - 70

100 100 – 75 90 – 70 80 - 60

Feed : Ag = 0,2 – 0,7 mm/ gear revolution

 Few teeth Ag Lower (example Z = 12 ; Ag = 0,3 mm/rev.)
 More teeth Ag Higher (example Z = 40 ; Ag = 0,6 – 0,7 mm/rev.)
Gear Shaving

Working condition

Number of passes

For parallel and diagonal methods:

General rule:
 1 pass every 0,01 mm of stock removal

For plonge method:

 Special feed cycle
 Gear Shaving

Feed scheme in the case of plunge shaving

Point A: Meshing size. Center

distance 0,8 mm larger than the
final center distance.

Point B: Cutter/gear contact size.

Centre distance 0,1 larger than the
final center distance.

Point C: End of roughing size.

Center distance 0,02 larger than
the final center distance.

Point D: Final center distance

 Gear Shaving

Feed cycle in the case of plunge shaving

From A to B: fast feed 200 mm/min

From B to C: roughing feed 1,5–2 mm/min

From C to D: finishing feed 0,75–1 mm/min

T1: pause time (2-5 seconds) only with rotation

and no feed

From D to C: fast return and rotation direction

reversal

From C to D: finishing feed 0,75-1 mm/min

T2: pause time slightly longer than T1

From D to A: fast return to initial meshing size

 Gear Shaving

When do you have to replace the shaving cutter ?

Range of
tollerance

Profile obtained
Profile obtained

B B

A
A

Situation with Situation after a

resharpened cutter certain N° of pieces
Gear Shaving

Power shaving

Shaving process with Nowadays all shaving cutter

synchronized axes is a
new method to use shaving
cutters
Theoretically the accuracy and the
speed of shaving operation can be
improved a lot.
But practically the situation is quite
different
machines are managed by a
powerful CNC and therefore it’s
possible to synchronize, with
high accuracy, the rotation of
the gear in accordance with the
shaving cutter rotation

This system was born mainly for to increase the

stock removed during each pass and for to reduce
drastically the index errors. After some years of
experience, we can affirm that the index error can be
reduced roughly 10 – 15% and also the feed can be
increased of 10 – 15 %.
Gear Shaving

The reason of this poor results is that the power of the

electrical motor applied to the gear axis cannot be very high.
The max torque can be approximately 65 N/m

Example of a shaving
cutter with diameter of
200 mm and PA 20°

In a normal shaving operation the tangential force,

in the same condition, are roughly 3000 N, that
is 10 times more.
Gear Shaving

How to carry out profile modification

example

P1 = SAP = 16,5 --- ---

P2 = 21,5 T2 = 0.008 E2 =-0,005

P3 = 26,5 T3 = 0,008 E3 = 0,005

P4 = 31,5 T4 = 0 E4 = -0,005

P5 = 36.5 T5 = -0,008 E5 = 0,005

Gear Shaving

Special helix modification with mixed cycles

obtainable by interpolation of the machine CNC axes

a)- Crowning more stressed at the end

b)- More crowning at the end and tapering correction
c)- Axismetric crowning with different radius
d)- Double tapering
Gear Shaving

Profile error

Profile error generated by the non fullfillment of the

conditions of the even contact method.
Gear Shaving

Excessive material at tooth tip with presence of stripping

The cutting speed Vs (component in radial direction) is too high or

the cross of axes angle is too small
Gear Shaving

Traces of serrations on tooth shaved surface

The shifting of the contact between the cutter and the

gear is equal to the pitch of serrations.
Gear Shaving

Noticeable burrs on the teeth and partially glossy surface

This defect is due to shaving cutter wear or to an

insufficient cross of axes angle.
Gear Shaving

Hollow helix

 Insufficient table stroke length.

 In plunge shaving the error is caused by bad
shaving cutter resharpening
Gear Shaving

Excessive material on helix close to a reference face

 The table stroke being too shorth on the side of the shoulder.
 Wrong cutter setting
Gear Shaving

Thank you for your

attention

By Dr. Bianco Gianfranco www.gianfrancobianco.com