Chamfering of Cylindrical Gears - Innovative New Cutting Solutions for Efficient Gear Production
Cylindrical gear chamfering and deburring is a rather ‘unloved’ process that adds cost but without delivering readily apparent improvements in gear quality. However, the chamfer process, when performed correctly, provides significant advantages for downstream handling and processing. This is why manufacturers of automotive- and truck-sized gears are increasingly exploring new technologies to chamfer their gears.
Two major chamfer technologies are used: forming and cutting. While chamfer rolling is a highly proven forming process that has been used for decades mainly in mass production, cutting chamfer technologies are of increasing market interest due to cost reduction and increased quality requirements; especially in dry cutting conditions.
This paper will cover new chamfer cutting processes: Chamfer Contour Milling and Chamfer Hobbing and compare them with the existing chamfer roll technology.
Chamfer Contour Milling uses a universal fly cutter tool with indexable carbide inserts. Chamfer angle and chamfer size depend on programmable machine movements. Therefore, this process provides highest flexibility for coarse pitch gears – even with different modules, pressure angles or number of teeth.
Chamfer Hobbing has been developed for modern gear production focusing on low tool cost per part with dry cutting and short cycle times in mass production. As for the left and right gear flank, separate and dedicated chamfer hobs are used to meet most customer specifications in the market.
By comparing the advantages and limits of the aforementioned chamfer processes in gear production for workpieces up to 400 mm diameter and module 8 mm, it is possible to select the right process depending on the specific requirements.
Author: Gottfried Klein
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