EJ/Customized
High Speed Steal
Gear Shaving
TiN,TiAlN,TiCN,AlCrN and so on
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Product Description
Material: Gear shaving cutters are typically made from high-speed steel (HSS), carbide, or cermet materials. These materials offer high wear resistance and can withstand the forces and temperatures generated during the cutting process.
Profile: The cutting profile of gear shaving cutters is carefully designed to match the desired tooth profile of the gears being produced. This profile ensures that the cutter removes the correct amount of material from the gear teeth to achieve the required dimensions and surface finish.
Number of Teeth: Gear shaving cutters can have a varying number of teeth depending on the specific application and the size of the gear being produced. The number of teeth on the cutter affects the cutting speed and the quality of the finished gear.
Pitch Diameter: The pitch diameter of the gear shaving cutter is crucial for determining the size and spacing of the gear teeth. It is carefully calculated to ensure proper meshing with the gear being shaved.
Pressure Angle: The pressure angle of the gear shaving cutter determines the shape of the gear teeth and influences the smoothness of the gear operation. Common pressure angles include 14.5°, 20°, and 30°, depending on the application.
Helix Angle: The helix angle of the cutter refers to the angle formed by the cutting edges relative to the axis of rotation. It helps in achieving smooth chip removal and reducing cutting forces during the shaving process.
Coating: Some gear shaving cutters may be coated with a thin layer of titanium nitride (TiN), titanium carbonitride (TiCN), or other coatings to enhance wear resistance and prolong tool life.
Shaving Process: Gear shaving cutters are used in a shaving process where they remove a small amount of material from the gear teeth. This process helps to improve the surface finish, accuracy, and noise level of the gears.
Accuracy and Tolerance: Gear shaving cutters are manufactured to very high levels of accuracy and tolerance to ensure precise gear tooth profiles and dimensions.
Compatibility: Gear shaving cutters need to be compatible with the specific type of gear shaving machine being used, ensuring proper fit and performance during the shaving process.
Module or Diametral Pitch (DP): Gear shaving cutters are often specified based on the module (for metric gears) or diametral pitch (for imperial gears) of the gears they are intended to shave. This specification determines the size and spacing of the gear teeth.
Number of Teeth: The number of teeth on the gear shaving cutter is determined based on factors such as the gear module or diametral pitch and the desired tooth profile.
Pressure Angle: The pressure angle of the gear shaving cutter should match the pressure angle of the gears being shaved. Common pressure angles include 14.5°, 20°, and 30°.
Helix Angle: The helix angle of the gear shaving cutter refers to the angle formed by the cutting edges relative to the axis of rotation. It helps in achieving smooth chip removal and reducing cutting forces during the shaving process.
Pitch Diameter: The pitch diameter of the gear shaving cutter is crucial for determining the size and spacing of the gear teeth. It is carefully calculated to ensure proper meshing with the gear being shaved.
Material: Gear shaving cutters are typically made from high-speed steel (HSS), carbide, or cermet materials. The choice of material depends on factors such as the material being shaved, the cutting speed, and the desired tool life.
Coating: Some gear shaving cutters may be coated with a thin layer of titanium nitride (TiN), titanium carbonitride (TiCN), or other coatings to enhance wear resistance and prolong tool life.
Overall Dimensions: This includes the diameter and width of the cutter, as well as any other dimensions necessary for proper fit and compatibility with the gear shaving machine.
Tolerance and Accuracy: Gear shaving cutters are manufactured to very high levels of accuracy and tolerance to ensure precise gear tooth profiles and dimensions.
Shaving Process: Specifications may also include details about the shaving process itself, such as recommended cutting speeds, feeds, and depths of cut.
Physical Cutter: The primary item is the gear shaving cutter itself. This is the cutting tool specifically designed for shaving the teeth of gears. The cutter will have the required tooth profile, dimensions, and material properties to suit the intended application.
Documentation: This may include technical specifications, operating instructions, and safety guidelines. It's important to understand how to use the cutter properly to achieve the desired results efficiently and safely.
Quality Assurance Certificate: Especially for high-precision machining tools like gear shaving cutters, a certificate of quality assurance may be provided. This certifies that the cutter has undergone specific quality control measures and meets certain standards.
Optional Coatings: Depending on the manufacturer and specific requirements, the gear shaving cutter might come with optional coatings such as titanium nitride (TiN) or titanium carbonitride (TiCN) to enhance durability and performance.
Packaging: The cutter is typically packaged securely to prevent damage during transportation and storage. This could include protective coatings, plastic caps, or foam inserts to keep the cutter safe.
Support: Some suppliers or manufacturers may offer technical support or assistance in choosing the right cutter for your application. They might provide guidance on tool selection, machining parameters, or troubleshooting.
Customization Options: Depending on the manufacturer, there might be options for customizing certain aspects of the cutter, such as the tooth profile, diameter, or coating type, to better suit your specific needs.
Accessories: In some cases, additional accessories might be included, such as tool holders or adapters, to facilitate mounting and use of the cutter on your gear shaving machine.
Warranty: Manufacturers may offer a warranty on their gear shaving cutters, guaranteeing against defects in materials or workmanship for a certain period. This provides assurance to the buyer regarding the quality and reliability of the product.
Training: For complex or specialized applications, manufacturers might offer training sessions or resources to help operators and technicians understand how to use the gear shaving cutter effectively and efficiently.
Cutter Design: Understanding the design principles behind gear shaving cutters, including the geometry of the cutting edges, tooth profile, helix angle, and other factors that influence their effectiveness in shaving gear teeth.
Material Science: Knowledge about the materials used in gear shaving cutter manufacturing, such as high-speed steel (HSS), carbide, and cermet materials. This includes understanding their properties, advantages, and limitations.
Manufacturing Process: Insight into the manufacturing processes involved in producing gear shaving cutters, including cutting, grinding, heat treatment, and coating processes. Understanding these processes is crucial for ensuring the quality and performance of the cutters.
Gear Shaving Process: Familiarity with the gear shaving process itself, including the principles of gear shaving, machine setup, cutting parameters (such as speed, feed, and depth of cut), and troubleshooting common issues.
Tool Selection: Knowledge about selecting the appropriate gear shaving cutter for a given application based on factors such as gear module, material, tooth profile requirements, and desired surface finish.
Quality Control: Understanding quality control measures and inspection techniques used to ensure the accuracy, precision, and surface finish of gear shaving cutters. This includes dimensional inspection, surface roughness measurement, and tool wear analysis.
Applications: Awareness of the various industries and applications where gear shaving cutters are used, such as automotive, aerospace, machinery, and more. Understanding the specific requirements and challenges of each application helps in optimizing cutter design and performance.
Maintenance and Sharpening: Knowledge about maintenance procedures and sharpening techniques to extend the service life of gear shaving cutters. This includes proper storage, handling, and reconditioning methods.
Emerging Technologies: Keeping up-to-date with advancements in gear shaving cutter technology, such as new materials, coatings, and manufacturing processes, to stay competitive and enhance productivity.
Safety: Awareness of safety precautions and best practices when operating gear shaving machines and handling cutting tools to prevent accidents and ensure a safe working environment.
Personal Injury: Always wear appropriate personal protective equipment, including safety glasses, gloves, and hearing protection. Avoid contact with rotating cutter edges and moving machine parts to prevent cuts, crush injuries, or entanglement.
Machine Damage: Incorrect setup or operation of gear shaving cutters can cause damage to the gear shaving machine or workpiece. Ensure the cutter is securely mounted and aligned according to manufacturer specifications before starting the shaving process.
Tool Breakage: Excessive cutting forces, improper feeds and speeds, or using dull or damaged cutters can lead to tool breakage. Inspect the cutter for signs of wear or damage before use, and replace if necessary to prevent accidents or damage to the workpiece.
Fire Hazard: Certain cutting operations may generate heat or produce sparks. Take precautions to prevent the accumulation of flammable materials and ensure adequate ventilation in the work area to minimize the risk of fire.
Chemical Exposure: Some coatings or materials used in gear shaving cutters may pose health hazards if ingested or inhaled. Handle cutters with care and avoid exposure to cutting fluids, coatings, or dust by using appropriate ventilation and protective equipment.
Improper Storage: Store gear shaving cutters in a dry, clean environment away from moisture, corrosive substances, and extreme temperatures. Improper storage conditions can lead to corrosion, deterioration, or reduced tool life.
Training Requirement: Only trained and qualified personnel should operate gear shaving machines and handle cutting tools. Lack of proper training and experience can result in accidents, injuries, or damage to equipment.
Regular Maintenance: Perform regular maintenance and inspection of gear shaving cutters and associated equipment according to manufacturer recommendations. Failure to maintain equipment in good working condition can lead to decreased performance, premature wear, or catastrophic failure.
Consult Manufacturer: If you are unsure about any aspect of gear shaving cutter operation, maintenance, or safety, consult the manufacturer or a qualified expert for guidance.
Risk Assessment: Conduct a risk assessment before each cutting operation to identify potential hazards and implement appropriate control measures to mitigate risks.
1.What is a gear shaving cutter?
A gear shaving cutter is a specialized cutting tool used in the gear manufacturing process to improve the surface finish and accuracy of gear teeth by removing a small amount of material from their surface.
2.How does a gear shaving cutter work?
Gear shaving cutters work by rotating against the surface of gear teeth, removing a thin layer of material to achieve the desired tooth profile and surface finish. This process results in smoother, quieter gear operation.
3.What are the benefits of using gear shaving cutters?
Gear shaving cutters improve the surface finish and accuracy of gear teeth, resulting in quieter operation, reduced vibration, and increased load-carrying capacity of gears. They also help to correct minor errors in tooth profile and spacing.
4.What types of gears can be shaved using gear shaving cutters?
Gear shaving cutters are commonly used for shaving spur gears, helical gears, and internal gears. They are suitable for a wide range of gear materials, including steel, cast iron, and non-ferrous alloys.
5.How do I choose the right gear shaving cutter for my application?
The selection of a gear shaving cutter depends on factors such as the module or diametral pitch of the gears, the material being shaved, the desired tooth profile, and the surface finish requirements. Consulting with a gear cutting expert or the cutter manufacturer can help in selecting the appropriate cutter.
6.What is the difference between gear shaving and gear hobbing?
Gear shaving and gear hobbing are both gear manufacturing processes, but they serve different purposes. Gear shaving is primarily used for finishing gears to improve their surface finish and accuracy, while gear hobbing is used for roughing out gear teeth from a blank.
7.How can I maintain gear shaving cutters for optimal performance?
Proper maintenance of gear shaving cutters involves regular inspection for wear or damage, keeping them clean and free from chips or debris, storing them in a dry environment, and following recommended sharpening or reconditioning procedures.
8.Can gear shaving cutters be resharpened?
Yes, many gear shaving cutters can be resharpened or reconditioned to extend their service life. However, this process should be performed by experienced professionals using appropriate equipment and techniques.
9.Are there any safety precautions I should take when using gear shaving cutters?
Yes, always wear appropriate personal protective equipment (PPE), follow manufacturer guidelines for machine setup and operation, and ensure proper training and supervision of operators to prevent accidents or injuries.
10.Where can I purchase gear shaving cutters?
Gear shaving cutters can be purchased from specialized tool suppliers, machinery manufacturers, or directly from cutter manufacturers. It's essential to choose a reputable supplier with expertise in gear cutting tools.
