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FOR PRECISION
INVOLUTE GEARS:
PART I
The following paper outlines the
gear-hobbing machines.
By Stephen P. Radzevich, Ph.D.
Nomenclature
C g / h = center distance do.h = outside diameter of the involute hob
Dg = pitch diameter of the gear ht. g = gear tooth whole depth
Do.g = outside diameter of the gear
m = gear modulus
G = gear tooth surface being machining p b.h = base pitch of the involute hob
N g = number of gear teeth
tc = normal tooth thickness
Nh = number of starts of the involute hob
O g = gear axis of rotation Greek Symbols
Oh = hob axis of rotation = cross-axis angle
dh = gear hob pitch diameter R = auxiliary phantom rack of the gear hob
g Og
2: The Generation Surface T on an Involute Hob A
VR
Determination of the generation surface of a cutting tool is the start
point for designing the tool. We refer to the generation (i.e. to the
machining) surface of a cutting tool as to a surface that is conjugate
Eg
to the surface being machined [1], [6]. Concerning a gear hobbing
operation, the generating surface T of an involute hob is represented
by a screw involute surface that is conjugate to the gear tooth sur- B
face being machined. Parameters of shape of the surface T can be
expressed in terms of (a) parameters of shape of the gear tooth sur-
face G, and (b) parameters of relative motion of the hob with respect R WR R g FR Fg
to the gear. FIG. 1. THE AUXILIARY PHANTOM RACK R OF AN INVOLUTE HOB.
Several methods for generation of the surface T of a cutting tool
g
X g .1
Dg
Og X g .0
VR
XR .0
Y g .0 Y g .1 XR .1
WR l
YR .0 YR .1
2.3.
The generating surface T of an involute hob. The surface T of an 2 3
f2 e2 b2 s2
involute hob can be generated as enveloping surface to consecutive
f1 c2 b1 d 1 1 f3 s3
positions of the auxiliary phantom rack R in its screw motion rela- 1 a1
tive to the hob axis. In order to get a comprehensive understanding c1 e1
4
of the involute hob geometry, it is helpful to consider two different R 4
approaches for determining of the surface T . The first approach is b.h
H2
a descriptive-geometry-based approach to which we refer to as the
DGB-approach3. The second approach is an analytical one. It is usu- Q1
ally referred to as the DG/K-approach4. The DGBapproach gives a a4
A1 R 1 g1
fruitful insight to the development of the DG/K-approach. It could be
considered as a perfect filter for the elimination of rough errors h n
of the analysis. Both the approaches complement one another, and s1
b.h
together they provide the user with profound understanding of the
involute hob geometry and kinematics of the surface T generation
[8], [11], [12]. FIG. 3. DETERMINING OF BASE HELIX ANGLE B.H
OF AN INVOLUTE
HOB.
2.3.1. computation of b.h can be derived. Using the above solution (Fig. 3),
The DGB-approach of the surface T generation. It is convenient to one can come up with the equation [1], [13], [14].
subdivide the problem of generation of the gear hob surface T onto cos b.h = cos n cos h
several sub-problems.
Base helix angle. For solving of the problem of determining of the Equation (6) could also be represented in the form
hob base helix angle, actual values of normal pressure angle n and
the hob-setting angel h are required been known. sin 2 n + tan 2 h
tan b.h =
The solution to the problem under consideration is represented cos n
in the system of three planes of projections. They are 1, 2 and 3
respectively. An auxiliary plane of projections 4 is also used. Here is designated
In order to determine the hob base helix angle b.h using DG- n
= normal pressure angle
based method, the lateral tooth surface of the auxiliary rack R is h
= hob-setting angle
required been constructed. Lets start from an arbitrary plane A that Base lead angle b.h can be computed from the equation b.h
=90 b.h
.
is orthogonal to the axis of projections 1 2 (Fig. 3). The plane A
is specified by the traces A1 and A2 . After being turned about the Base diameter of an involute hob. The generating surface T of a
trace A2 through the hob-setting angle h the plane A occupies the gear hob can be represented as an enveloping surface to consecutive
position of the plane Q . The plane Q is specified by the traces Q1 positions of the plane R that is performing a screw motion around
and Q2 . Then the plane Q is turned about the trace Q1 through the the hob axis of rotation.
normal pressure angle n of the hob tooth. In this final location, the Consider the plane R in a system of planes of projections 123
plane is designated as R , and it is specified by the traces R1 and (Fig. 4). The plane R is performing a translational motion along the
R2 respectively. axis 1/2 with a certain velocity VR . Simultaneously, the plane R is
In order to construct the hob base helix angle b.h in this particular rotating about that same axis 1/2 with an angular velocity R .
The base diameter db.h of the involute hob tic E it is required to select those points of
is equal to the shortest distance of approach the plane R at which the resultant speed 2.3.2.
between the characteristic E and the axis of the plane points is perpendicular to the The DG/K-approach of generation of the surface
1/2. In order to determine the characteris- normal vector NR to the plane R itself. For T of an involute hob. Equation of the generating
The generating surface T of the involute gear hob can be analytically 3.1.
described by the set of two equations The DGB-approach of determining of orientation of the rake-face. The DGB-
solution to the problem of determining of orientation of the rake-face of the
rR .t = rR .t (UR ,VR , t ) involute hob teeth is depicted in Fig. 6.
T rR .t For solving of the problem of determining of orientation of the hob tooth
(UR ,VR , t ) = 0
t rake-face, the following parameters of design of the hob are required to be
known: the hob tooth modulus m , normal pressure angle n , the hob-set-
After substituting of Eq. (4), the Eq. (11) casts into ting angel h , number of starts of the hob Nh , the hob outside diameter
Do.h , and the hob base diameter db.h.
0.5 db.h sin Vh U h sin b.h cos Vh The solution to the problem under consideration is represented in the
0.5 db.h cos Vh + U h sin b.h sin Vh system of three planes of projections 1, 2 and 3 respectively. Two auxil-
T : r h (U h , Vh ) = iary planes of projections, say 4 and 5, are also used. The auxiliary axis
p hVh U h cos s b.h
of projections 1/4 makes the hob-setting angle h with the axis of projec-
1 tions 1/2. The axis of projections 1/5 is parallel to the axis 1/4. Use
3.2. do.h dh d f .h
b ht
The DG/K-approach of determining of orientation of the rake-face. Figure R
6 provides a clear understanding of the geometry of the precision involute
n5 l5
gear hob with straight-line lateral cutting edges. Understanding features l4 n4
of the hob geometry (see sub-section 3.1) is very helpful for derivation d 4 e4 tr
A4 tc Sc a
of equations for computation of major parameters of the gear hob of the
developed design. Pn
3.2.2.
The angle r between the lateral cutting edges of the hob tooth. Prior to
D
deriving the equation for computation of the angle r that make the lateral R C h
cutting edges of the gear hob tooth, it is convenient to derive an equation
for computation of projection of the angle r onto the coordinate plane n Er
B
XhYh.
The projections of the lateral cutting edges of the involute tooth onto the r Zh
coordinate plane XhYh make an angle . g
El
For computation of the actual value of the angle , the following expres-
D
sion can be used
tan =
db.h E
4 R 2
db2.h db.h
f
Then, consider three unity vectors A, B, and C. These vectors yield the
Xh
following analytical representation
A = [cos h 0 sin h 1] T
B = [sin n sin h cos n sin n cos h 1] T FIG. 7. ORIENTATION OF RAKE-FACE OF THE PRECISION GEAR HOB.
db.h L
db.h cot
0.5 do.h
~ 0.6
Zh
0.5 d h
0.5 d h
h
n E A
tc A Xh d b.h
Er
Prxy C tr d w.h
A r
B A
do.h
db.h
El
Here h designates the hob-setting angle of the involute hob. The angle
h
is measured in the auxiliary rack R pitch plane. It is the angle that FIG. 10. THE INVOLUTE GEAR HOB AFTER BEEN REGROUND.
makes a perpendicular to the rack R tooth and axis of rotation of the hob
(Fig. 9) [8],[14] After exploding of the determinant, and after the necessary formulae
Required for further computations, the hob-setting angle h can be cho- transformations are performed, one can come up with the equation of two
sen by a designer of the gear hob. Usually it is recommended to assign unknowns, namely of r and .
the actual value of the hob-setting angle h equal to the pitch helix angle
of the hob. As it is proven in our earlier work [14], in order to satisfy the
3.2.3.
h
equality h= h (this condition is the best possible) the actual value of the
hob-setting angle is required to be computed from the equation. The angle of intersection of the rake-face and of the hob axis of rotation.
Rake-face of the involute hob is inclined to the hob axis at a certain angle
m Nh
tan h = . In order to determine the required value of the angle , the following
(d o.h 2 1.25 m do.h ) 2 m 2 N h2 three unity vectors C, D, and E were used. For the vectors D and E Fig. 8
yields
Here do.h designates reduction of the hob outside diameter do.h due to
D = [0 1 0 1] T
re-sharpening of the worn gear hob (Fig. 10). Figure 10 yields very simple
formula for computation of do.h = (do(new)
.h
(worn)
do.h ). E = [sin 0 cos 1] T
R
Og Face As of the vectors C, D, and E are located within the rake-face of the hob
0
Oh Oh tooth, therefore the following identity CD E 0 observes. This yields a
determinant
R + + h
Oh
FR
C cos r tan cos r sin r cos
0 1 0 =0
sin 0 cos
R Face WR h After exploding of the determinant, and after the necessary formula
transformations are performed, one can come up with the one more equa-
FIG. 9. HOB-SETTING ANGLE OF AN INVOLUTE HOB.
tion of two unknowns, namely of r and .
h
The design of gear hob with the computed parameters (Table 1) satis- it satisfies the fifth necessary condition of proper surface generating
fies all the necessary and sufficient conditions of proper surface generat- [10]. The conclusion of this article will appear in the May issue of Gear
ing on machine tool [1], [4], [6] and, what is especially of importance, Solutions magazine. CONTINUED ON PAGE 50 >
REFERENCES:
[1] Radzevich, S.P., Fundamentals of Surface Generation. Monograph, Kiev, Rastan, 2001, 592p. Copy
of the monograph is available from The Library of Congress.
[2] Bregi, B.F., Erxleben, R.F., Tersch, R.W., et al, Modern Methods of Gear Manufacture, 4th Edition,
National Broach & Machine Division/Lear Siegler, Inc., 5600 St. Jean Ave., Detroit, MI 48213, 1972,
160p.
[3] Townsend, D.P., Dudleys Gear Handbook. The Design, Manufacture, and Application of Gears, 2nd
Edition, McGraw Hill, Inc., New York, 1991.
[4] Radzevich, S.P., Sculptured Surface Machining on Multi-Axis NC Machine, Monograph, Kiev, Vishcha
Shkola Publishing House, 1991, 192p. Copy of the monograph is available from The Library of
Congress.
[5] Radzevich, S.P., Diagonal Shaving of an Involute Pinion: Optimization of Parameters of the Pinion
Finishing Operation, The International Journal of Advanced Manufacturing Technology. (In press).
[6] Radzevich, S.P., Conditions of Proper Sculptured Surface Machining, Computer-Aided Design,
Vol.34, No 10, September 2002, pp.727-740.
[7] Olivier, T., Theorie Geometrique des Engrenages, Paris, 1842.
[8] Radzevich, S.P., About Hob Idle Distance in Gear Hobbing Operation, ASME J. of Mechanical Design,
December, 2002, Vol. 124, Issue 4, pp.772-786.
[9] Radzevich, S.P., Design of Shaving Cutter for Plunge Shaving a Topologically Modified Involute Pinion,
ASME J. of Mechanical Design, September 2003, Vol. 125, Issue 3, pp.632-639.
[10] Radzevich, S.P., A Novel Approach for Computation of Constraints on Parameters of Modification
of the Tooth Addendum of Precision Involute Hob, ASME J. of Mechanical Design, July 2006, Vol.
128, Issue 6, pp.000-000.
[11] Buckingham, E., Analytical Mechanics of Gears, Dover Publications, Inc., New York, 1963, 546p.
[12] Radzevich, S.P., A Descriptive-Geometry-Based-Solution to a Geometrical Problem in Rotary
Shaving of Shoulder Pinion, ASME J. of Manufacturing Science and Engineering, November, 2005,
Vol. 127, Issue 4, pp. 893-900.
[13] Radzevich, S.P., Design and Investigation of Skiving Hobs for Finishing Hardened Gears, Ph.D. Thesis,
Kiev Polytechnic Institute, 1982, 286p.
[14] Radzevich, S.P., Cutting Tools for Machining Hardened Gears, Moscow, VNIITEMR, 1992, 60p.
[15] Pat. No. 990.445 (USSR), A Precision Involute Hob./S.P. Radzevich, Filed: October 08, 1981, Int.
Cl. B23F 21/16.
[16] Pat. No. 1.114.505 (USSR), A Precision Involute Hob./S.P. Radzevich, Filed: October 18, 1982, Int.
Cl. B23F 21/16.
[17] Pat. No. 2.040.376 (Russia), A Precision Involute Hob./S.P. Radzevich et al, Filed: January 03, 1992,
Int. Cl. B23F 21/16.
[18] FETTE. Gear Cutting Tools: Hobbing, Gear Milling, Leitz Metalworking Technology Group, 196p.
FOOTNOTES:
1) The DG/K-approach is based on fundamental results obtained in differential geometry of surfaces, and
in kinematics of multi-parametric motion of a rigid body in E3 space (For details see (i) Radzevich, S.P.,
Sculptured Surface Machining on Multi-Axis NC Machine. Monograph, Kiev, Vishcha Shkola Publishers,
1991, 192p Copy of the monograph is available from The Library of Congress [4]; and (ii) Radzevich,
S.P., Fundamentals of Surface Generation. Monograph, Kiev, Rastan, 2001, 592p Copy of the mono-
graph is available from The Library of Congress [1]). A perfect example of application of the DG/K-
approach is disclosed in the paper: Radzevich, S.P., Diagonal Shaving of an Involute Pinion: Optimization
of Parameters of the Pinion Finishing Operation, The International Journal of Advanced Manufacturing
Technology. (In press) [5].
2) Olivier, T. disclosed two principal methods of generation of enveloping surfaces in his work published
as early as in
3) The DGB-approach proved to be useful for solving variety of gear related problems (see, for example, the
monograph by Buckingham [11], as well as more recent publications [8] [12]).
4) The DG/K-approach is based on fundamental results obtained in differential geometry of surfaces, and
in kinematics of multi-parametric motion of a rigid body in E3 space. The method is disclosed in two
monographs [1], [4] by the author. Both the monographs are available form the Library of Congress.