Gear Shaping
Gear shaping is a generating process in which a gear-shaped cutter performs a combined stroking and rolling motion to cut the gear teeth into the workpiece. Unlike gear hobbing, it is also suitable for internal gears, stepped gears, and gears with restricted clearance.
Operating Principle
The cutter gear performs a stroking motion (axial) that produces the actual cut, while rotating synchronously with the workpiece (generating motion). The combined motion progressively generates the tooth profile on the workpiece. The cutter gear and workpiece are geometrically related: the cutter is itself a gear with the module of the gear to be produced. Depending on the face width, multiple strokes are needed.
Applications and Comparison with Gear Hobbing
The decisive unique feature of gear shaping is its ability to produce internal gears — which is not possible with a hob. Similarly, stepped gears (gears with an axial collar) and short shoulder gears at shaft ends are accessible, as the cutter gear requires no axial run-out. The disadvantage compared to gear hobbing is lower productivity, as the process works in strokes rather than continuously. The achievable quality matches that of gear hobbing (Q 7–9 rough, Q 5–7 after grinding).
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