Gear Cutting Tools: Fundamentals of Design and Computation
This book presents the DG/K-based method of surface generation, a novel and practical mathematical method for designing gear cutting tools with optimal parameters. The author, an industry leader for the past 30 years, proposes a scientific classification for all possible kinds of the gear machining meshes before discussing optimal designs of gear cutting tools. This classification makes it possible to consider all possible designs of gear cutting tools, including those currently used in...
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This book presents the DG/K-based method of surface generation, a novel and practical mathematical method for designing gear cutting tools with optimal parameters. The author, an industry leader for the past 30 years, proposes a scientific classification for all possible kinds of the gear machining meshes before discussing optimal designs of gear cutting tools. This classification makes it possible to consider all possible designs of gear cutting tools, including those currently used in practice and those expected to be used in the future. It also allows the author to develop scientific predictions and optimal designs. In most cases, solutions appear in analytical form and/or graphical form.
Part I: BasicsGears: Geometry of the Tooth FlanksBasic Kinds of Gears Analytical Description of Gear Tooth Flanks Gear Tooth Surfaces those Allowing Sliding Over ThemPrincipal Kinematics of Gear Machining OperationsRelative Motions in Gear Machining Rolling of the Conjugate SurfacesKinematics of Continuously Indexing Methods of Gear Machining ProcessesVectorial Representation of the Gear Machining Mesh Kinematic Relationships for the Gear Machining Mesh Configuration of the Vectors of Relative Motions Kinematics of Gear Machining ProcessesElements of Coordinate Systems TransformationsCoordinate Systems Transformation Conversion of the Coordinate System Orientation Direct Transformation of Surfaces Fundamental FormsPart II: Form Gear Cutting ToolsGear Broaching ToolsKinematics of the Gear Broaching Process Generating Surface of a Gear Broach Cutting Edges of the Gear Broaching Tools Chip Removal Diagrams Sharpening of Gear Broaches A Concept of Precision Gear Broaching Tool for Machining Involute Gears Application of Gear Broaching Tools Shear-Speed Cutting Rotary Broaches: Slater Tools Broaching Bevel Gear TeethEnd-Type Gear Milling CuttersKinematics of Gear Cutting with End-Type Milling Cutter Generating Surface of the End-Type Gear Milling Cutter Cutting Edge of the End-Type Gear Milling Cutter Accuracy of the Gear Tooth Flanks Machined with End-Type Milling Cutter Application of the End-Type Gear Milling CuttersDisk-Type Gear Milling CuttersKinematics of Gear Cutting with Disk-Type Milling Cutter Generating Surface of the Disk-Type Gear Milling Cutter Cutting Edges of the Disk-Type Gear Milling Cutter Profiling of the Disk-Type Gear Milling Cutters Cutting Edge Geometry of the Disk-Type Milling Cutter Disk-Type Milling Cutters for Roughing of Gears Accuracy of the Gear Tooth Flanks Machined with the Disk-Type Milling Cutters Application of Disk-Type Gear Milling CuttersNontraditional Methods of Gear Machining with Form Cutting ToolsPlurality of Single-Parametric Motions Implementation of the Single-Parametric Motions for Designing of Form Gear Cutting Tool Diversity of Form Tools for Machining a Given Gear On Classification of Form Gear ToolsPart III: Cutting Tools for Gear GeneratingParallel-Axis Gear Machining Mesh Kinematics of the Parallel-Axis Gear Machining MeshRack Cutters for Planing of Gears Generating Surface of Rack Cutter On the Variety of Feasible Tooth Profiles of the Rack Cutters Cutting Edges of the Rack Cutter Profiling of the Rack Cutters Cutting Edge Geometry of the Rack Cutter Chip Thickness Cut by Cutting Edges of the Rack Cutter Tooth Accuracy of the Machined Gear Application of the Rack Cutters Potential Methods of Gear Cutting and Designs of Rack-Type Gear Cutting ToolsGear Shaper Cutters I: External Gear Machining MeshKinematics of Gear Shaping Operation Generating Surface of Gear Shaper Cutter Cutting Edges of the Shaper Cutter Profiling of Shaper Cutters Critical Distance to the Nominal Cross-Section of the Shaper Cutter The Cutting Edge Geometry of a Shaper Cutter Tooth Desired Corrections to the Shaper Cutter Tooth Profile Thickness of Chip Cut by Shaper Cutter Tooth Accuracy of Gears Cut with the Shaper Cutter Application of Gear Shaper CuttersGear Shaper Cutters II: Internal Gear Machining MeshKinematics of Shaping Operation of an Internal Gear Design of Shaper Cutters Thickness of Chip Cut by the Gear Shaper Cutter Tooth Accuracy of the Shaped Internal Gears Enveloping Gear Shaper Cutters Application of Gear Shaper CuttersPart IV: Cutting Tools for Gear GenerationIntersecting-Axis Gear Machining Mesh Kinematics of the Intersecting-Axis Gear Machining MeshGear Shapers with Tilted Axis of Rotation Kinematics of Gear Shaping Operation with the Shaping Cutters Having Tilted Axis of Rotation Determination of Generating Surface of a Shaper having Tilted Axis of Rotation Illustration of Capabilities of the External Intersecting-Axis Gear Machining MeshGear Cutting Tools for Machining Bevel GearsPrincipal Elements of Kinematics of Bevel Gear Generation Geometry of the Interacting Tooth Surfaces Peculiarities of Generation of Straight Bevel Gears with Offset Teeth Generation of Straight Bevel Gear Teeth Peculiarities of Straight Bevel Gear Cutting Milling of Straight Bevel Gears Machining of Bevel Gears having Curved TeethGear Shaper Cutters Having Tilted Axis of Rotation: Internal Gear Machining MeshPrincipal Kinematics of Internal Gear Machining Mesh Peculiarities of Design of Gear Cutting ToolsPart V: CUTTING TOOLS FOR GENERATING OF GEARS: Spatial Gear Machining MeshSection V-A: Design of Gear Cutting Tools: External Gear Machining MeshGenerating Surface of the Gear Cutting Tool Kinematics of External Spatial Gear Machining Mesh Auxiliary Generating Surface of the Gear Cutting Tool Examples of Possible Kinds of Auxiliary Generating Surfaces of Gear Cutting Tools Generation of Generating Surface of a Gear Cutting Tool Use of the DG-Based Methods for the Determination of the Design Parameters of Generating Surfaces of the Gear Cutting Tools Possible Kinds of Generating Surfaces of Gear Cutting Tools Constraints on the Design Parameters of Generating Surface of a Gear Cutting ToolHobs for Machining GearsTransformation of the Generating Surface into a Workable Gear Cutting Tool Geometry and Generation of Rake Surface of a Gear Hob Geometry and Generation of Clearance Surfaces of Gear Hobs Accuracy of Hobs for Machining of Involute Gears Design of Gear Hobs The Cutting Edge Geometry of a Gear Hob Tooth Constraints on the Parameters of Modification of the Hob Tooth Profile Application of Hobs for Machining GearsGear Shaving CuttersTransformation of Generating Surface into a Workable Gear Shaving Cutter Design of Gear Shaving Cutters Axial Method of Gear Shaving Process Diagonal Method of Gear Shaving Process Tangential Method of Gear Shaving Process Plunge Method of Gear Shaving Process Advances in Design of Shaving Cutter Peculiarities of Gear Shaving ProcessExamples of Implementation of the Classification of Kinds of the Gear Machining MeshesA Hob for Tangential Gear Hobbing A Hob for Plunge Gear Hobbing Hobbing of a Face Gear A Worm-Type Gear Cutting Tool Having the Continuous HS-Cutting Edge Cutting Tools for Scudding Gears A Shaper Cutter with the Tilted Axis of Rotation for Shaping Cylindrical Gears A Gear Cutting Tool for Machining a Worm in Continuously Indexing Method Rack Shaving Cutters A Tool for Reinforcement of a Gear by Surface Plastic Deformation Conical Hob for Palloid Method of Gear Cutting Section V-B: Design of Gear Cutting Tools: Quasi-Planar Gear Machining MeshKinematics of Quasi-Planar Gear Machining MeshGear Cutting Tools for Machining Bevel Gears Design of a Gear Cutting Tool for Plunge Method of Machining of Bevel Gears Face Hob for Cutting Bevel Gear More Possibilities for Designing Gear Cutting Tools Based on Quasi-Planar Gear Machining MeshSection V-C: Internal Work-Gear to Cutting Tool MeshKinematics of Internal Spatial Work-Gear to Cutting Tool MeshGear Cutting Tools Featuring Enveloping Generating Surface Gear Cutting Tools having a Cylindrical Generating Surface Gear Cutting Tools having Conical Generating Surface Gear Cutting Tools having a Toroidal Generating SurfaceGear Cutting Tools for Machining Internal GearsPrincipal Design Parameters of a Gear Cutting Tool for Machining an Internal Gear Examples of Gear Cutting Tool for Machining an Internal GearConclusion Appendices References Index
