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MATS shaving cutter is a high precision tool in the form
of a disc type helical gear with slots running down the flank, forming
cutting edges. The helix angle of its teeth is different from the helix
angle of the work gears to facilitate the smooth finishing (shaving) of the
flanks of the works gears.
Gear shaving cutters are designed to suit the specific finishing
requirements of work gears. Therefore complete details of work gears along
with cutter details, if available, are required to design and manufacture
shaving cutters. The cutters are normally manufactured in PCD 150 mm to 300
mm with suitable face width and bore as per requirements.
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| The Process:
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The gear shaving process improves the surface finish of
gear flanks to great extent and reduces tooth profile error, index error &
lead error on work gears manufactured by hobbing and shaping operations. The
requirement of crowned tooth form or taper tooth form to avoid end bearing
condition is achieved by the shaving process.
The process of shaving involves running the shaving cutter in tight mesh
with the work gears at high speed on the gear shaving machine. During
rotation, the cutting edges sweep over the work gear flanks and remove fine
hair like chips.
The cutter drives the work, which is fixed, between the two live centers and
the work (gear) reciprocates transversely or diagonally or by the plunged
method.
Work gears with hardness upto 30 RC on the gear teeth can be shaved to
achieve a high grade of surface finish and reduced error in index, helix
angle, tooth profile & eccentricity. The shaving operation is carried out
with suitable cutting oil.
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| Advantages & Applications:
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With reduction in various errors of gear teeth and
improvement in surface finish, gear noise is reduced to a great extent while
transmitting high power at high speed. The life of gears is also enhanced.
Modification of tooth form to crowned or taper shape by shaving eliminates
tooth end load concentration in surface and increases the factor of safety.
Shaving is done at high speed, involving a very low operation time. This is
the fastest and most economical method of producing quality gears; since the
cutter can be resharpened, the total no. of gears that can be finished by a
cutter is quite substantial.
Gear shaving is thus extremely useful in the mass production of highly
accurate gears for automobile industries at reasonably low cost and at a
high rate of production.
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| Key Parameters:
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Improved surface finish of flanks and accuracies
of profile
Produce high accurate gear at low cost.
Range : 170 mm to 260 mm PCD.
Material : M2 & M3 (II) type of HSS material.
Also carry out resharpening with profile correction
Module : 0.8 M to 6.35 M.
Special design for lower than 1.50 modules.
Used for finishing operation of Gears for Automobile Transmission & other
similar Engg. Industry.
Each Item tested on Hoffler Gear Tester.
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