In gear finishing, a variety of tools are utilized depending on the nature of the gear as well as the amount of precision desired. Of these, gear-shaving cutters are universally applied across different sectors. The cutters provide an excellent finish and also ensure the enhancement of gear performance. But how do they stand in comparison with other tools for gear finishing? Let’s compare the key points that reveal the difference.
What Are Gear Shaving Cutters?
Gear shaving cutters are employed to shave off a thin layer of metal from the gear tooth surface. This is done to correct small errors following hobbing or shaping. The tool operates based on the rolling contact principle. It enhances the surface and renders the gear quieter. It also enables the gear to have a longer lifespan.
Gear shaving is mostly applied to medium and high-volume production. It is primarily applied in the automotive and machine tool industries. It is very popular as it delivers quick and precise outcomes. However, it has few restrictions as compared to other tools.
Common Gear Finishing Tools
Some of the other gear-finishing tools are gear grinding, gear honing, lapping, and skiving. Each of them has its own application and advantages.
- Gear Grinding – It is a slow but highly accurate process. It is employed when the gear requires very high accuracy. It provides a fine surface finish. However, the procedure is time-consuming. The cost is more.
- Gear Lapping – Here, two gears are operated together with an abrasive. It makes the surface smooth but is not applied for large production numbers.
- Gear Skiving – This is a new technique. It is quick and suitable for both inner and outer gears. But it requires special machines and configurations.
Key Differences
Let’s compare the techniques based on some key points.
- Surface Finish—Gear grinding provides the best surface. However, shaving also provides a good finish in less time.
- Speed and Cost—Shaving is quicker and less expensive. Grinding requires more time and money.
- The volume of production—shaving is suitable for medium and high volumes. Honing and lapping are suitable for small or special work.
- Machine Setup—Gear shaving requires specific machines, but they are less costly compared to grinding machines.
- Accuracy—Grinding provides higher accuracy. Shaving remains acceptable for most ordinary applications.
Case Example
In a single auto gear factory, a gear grinding to shaving change decreased production time by 30%. The factory saved approximately 20% of the cost as well. Gear quality was not decreased by making this change. Instead, the gears were smoother and lasted longer. This change was made possible due to assistance from professional gear shaving cutter suppliers who provided the appropriate tools and expertise.
Final Words
All the gear finishing tools are used for specific purposes. Shaving cutters are a good choice for a lot of work. They are quick, provide decent results, and save money. But for extremely high-precision applications, grinding can still be the way to go. The decision will depend on the job, the type of gear, and the desired quality. Knowing these tools allows engineers to make the right decision and achieve improved results.