Some results of evaluation by this method in the automotive industry.

There are great advantages in dry hobbing, not only for friendliness toward the environment, but also for increasing productivity and for decreasing manufacturing cost. Dry hobbing, however, often causes failures in hob cutting edges or problems with the surface quality of gear tooth flanks. These difficulties are not present when hobbing with cutting oil. Pinching and crushing of generated chips between the hob cutting edge and the work gear tooth flank is considered a major cause of those problems.

The seemingly simple process of placing a uniform chamfer on the face ends of spur and helical gears, at least for the aerospace industry, has never been a satisfactory or cost effective process.

To meet the future goals of higher productivity and lower production costs, the cutting speeds and feeds in modern gear hobbing applications have to increase further. In several cases, coated carbide tools have replaced the commonly used high speed steel (HSS) tools.

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Load-carrying capacity of gears, especially the surface durability, is influenced by their tooth surface roughness in addition to their tooth profiles and tooth traces.

Almost any external tooth form that is uniformly spaced around a center can be hobbed. Hobbing is recognized as an economical means of producing spur and helical gears with involute tooth profiles.

In the past, the blades of universal face hobbing cutters had to be resharpened on three faces. Those three faces formed the active part of the blade. In face hobbing, the effective cutting direction changes dramatically with respect to the shank of the blade. Depending on the individual ratio, it was found that optimal conditions for the chip removal action (side rake, side relief and hook angle) could just be established by adjusting all major parameters independently. This, in turn, results automatically in the need for the grinding or resharpening of the front face and the two relief surfaces in order to control side rake, hook angle and the relief and the relief angles of the cutting and clearance side.

Complete Product News for May/June 2003.