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Profile Analysis of Spur Gear Shaping Cutters Based on Sharpened Cutting Edges

Spur shaping cutters, the most versatile gear cutting tools, are used to produce gears that are limited in general cutting cases, such as internal gears and stacked gears. The side clearance angle, which is formed by the profile shifting on the tooth surface, and the rake angle, which increases the cutting efficiency and reduces the wearing of the cutting edge, are designed to create better cutting conditions. However, these cutting angles cause errors in the profile of the cutter edge. In this study, mathematical models of the Isoform® shaping cutter generation method and a model of the cutter edge formed by the conical cutter face were derived to verify the profile error of the cutter edge. A mathematical model to determine the profile error through the corresponding cutter enveloping gear is also proposed. Finally, mathematical models were also derived to correct and reduce the profile error at the major cutter face and the results at the other cutter faces. The numerical results, namely, the profile error curves, show that the corrected cutter has better profile accuracy for the normal usable cutter life.