A brief introduction to the subject of Thin Film Coatings and their application to gear hobs and shaper cutters is followed by a detailed description of the Chemical Vapor Deposition Process and the Physical Vapor Deposition Process. Advantages and disadvantages of each of these processes is discussed. Emphasis is placed upon: application engineering of coated gear tools based on laboratory and field test results. Recommendations are suggested for tool design improvements and optimization of gear cutting operations using coated tools. Productivity improvements potentially available by properly utilizing coated tools are considered in terms of both tool cost and machining cost.

Borazon is a superabrasive material originally developed by General Electric in 1969. It is a high performance material for machining of high alloy ferrous and super alloy materials. Borazon CBN - Cubic Born Nitride - is manufactured with a high temperature, high pressure process similar to that utilized with man-made diamond. Borazon is, next to diamond, the hardest abrasive known; it is more than twice as hard as aluminum oxide. It has an extremely high thermal strength compared to diamond. It is also much less chemically reactive with iron, cobalt or nickel alloys.

Presumably, everyone who would be interested in this subject is already somewhat familiar with testing of gears by traditional means. Three types of gear inspection are in common use: 1) measurement of gear elements and relationships, 2) tooth contact pattern checks and 3) rolling composite checks. Single Flank testing falls into this last category, as does the more familiar Double Flank test.