Optimum design of gear shaper cutters

Results obtained from the analysis of the profile deviations in the present shaper design are shown, and a new approach to the design is presented. The new design permits high rake and relief angles in the cutter, and thereby increases the cutting efficiency without any profile deviation in the generated gear. Investigation are carried out to determine the effects of multiple resharpenings on the active profiles of both the conventional and the new design of cutter, and on the profiles of the generated gear. Methods are also suggested for modifying the new cutter to generate gear tooth relief, if required.;Changes in the cutter corner radius after multiple resharpening of the cutter are simulated, and their effects on the generated gear fillet are found. Finally, methods are suggested for minimizing the changes in the fillet of the generated gear. (Abstract shortened by UMI.).;Devices for practically manufacturing the new cutter shape are also suggested. A modification is outlined that will be required to the small and medium size grinding machine for incorporating the additional kinematic group that is necessary for generating the new cutter shape.