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Gear Cutting Tools GEAR CUTTING TOOLS www.tizimplements.eu GEAR CUTTING TOOLS CONTENTS Quality assurance system ................................. 3 Services .............................................................. 22 Products ............................................................. 4 Heat Treatment ........................................................... 22 Re-Sharpening - Hobs & Shaving Cutters .......... 22 Hobs ................................................................................ 4 Gear And Involute Spline Hob ......................... 4 Guidance ............................................................ 23 Straight Sided Spline Hob ................................. 5 Hob Nomenclature .................................................... 23 Sprocket Hob ......................................................... 6 Hobbing Principle ...................................................... 23 Silent Chain Sprocket Hob ................................ 7 Basic Rack Tooth Profile (Din 3972) ...................... 24 Serration Hob ........................................................ 7 Finishing stock ............................................................ 24 Ratchet Hob ........................................................... 8 Addendum Modification Coefficient .................. 25 Timing Pulley Hob ............................................... 8 Timing Belt Profile ...................................................... 26 Timing Belt Profile ............................................... 9 Tool Wear ....................................................................... 26 Worm Wheel Hob ................................................. 11 Effect of sharpening errors ..................................... 27 Solid Carbide Hobs .............................................. 13 The effect of hob mounting errors ...................... 29 Gear cutting tools ...................................................... 14 Ordering details ................................................. 30 Form Relieved Milling Cutters ......................... 14 Hobs ................................................................................ 30 Hi-Bite Mills, "Do-all" Cutters ........................... 15 Spline Gauges .............................................................. 31 Special Tools........................................................... 15 Gear Shaving Cutters .......................................... 16 Tolerances as per DIN 3968 (In Microns) .......... 32 Gear Shaping Cutters ......................................... 16 Manufacturing and testing facilities ................ 36 Gear Deburring Cutters ..................................... 17 Gear Chamfering Cutters .................................. 17 Spline Rollers ......................................................... 18 Forming Rollers ..................................................... 18 Swaging Cutters ................................................... 19 Power Skiving Cutters ........................................ 19 Broaches ........................................................................ 20 Surface Broaches .................................................. 20 Helical Broaches ................................................... 21 Spline Punches ...................................................... 21 2 www.tizimplements.eu GEAR CUTTING TOOLS QUALITY ASSURANCE SYSTEM QUALITY ASSURANCE SYSTEM MATERIAL PROCUREMENT The material is procured directly from world-renowned manufacturers like Bohler Era Steel, Nachi etc MATERIAL IDENTIFICATION The stored raw materials are identified by color code by applying colors on the face as well as the length of stored material. In addition to the color code, every raw material bar is given a unique identification number. The record of the identification number is maintained to facilitate identification of supplier as well as material. The unique identi- fication number of the bar is kept intact until the whole length of the bar is consumed. SHELF LIFE The raw material is stored in iron racks. Since the inventory of the material is maximum three months there is no need for any measures for control of shelf life etc. Prior to finishing, tools are sand-blasted to remove any rusting agents. After grinding and finishing tools are applied rust preventives and are securely packed in polythene bags and cardboard boxes. CALIBRATION Periodic calibration of the measuring instruments and testing equipment done as per BIS with the help of master gauges and meters or from some outside agencies PROCESS CONTROL (HEAT TREATMENT) The temperature of the heat treatment furnace is being controlled with the help of Digital Temperature Indicators and Controllers, Infrared Radiation Pyrometers and Optical Pyrometers. INTERNAL INSPECTION The inspection of the tool to be produced is being done at every stage of machining by keeping necessary Finish- ing/ Grinding margins and expansion tolerances during heat treatment. After heat treatment, the tools are ground to close tolerances as per standard specifications or as per specific requirement of the customer as per drawings etc. MAINTENANCE OF QUALITY RECORDS The maintenance of quality records for special as well as standard tools manufactured as per customers drawings and specifications are being maintained by preparing drawings and by keeping a record of the same by giving spe- cific job/reference number to facilitate repeated orders. 3 www.tizimplements.eu GEAR CUTTING TOOLS HOBS GEAR AND INVOLUTE SPLINE HOB sizes as per DIN-8002B Outside dia Length Bore diameter Module Hub length Gashes øD L ød 1 22 50 31 3 14 1.25 (3/4") 1.5 22 56 38 3 12 1.75 (3/4") 2 63 46 27 (1") 3 12 2.25 2.5 70 56 27 (1") 3 12 2.75 3 3.25 89 69 32 (1 1/4") 3 12 3.5 3.75 90 78 32 (1 1/4") 4 12 4 4.5 90 78 32 (1 1/4") 4 10 5 100 88 32 (1 1/4") 4 10 5.5 6 6.5 110 108 32 (1 1/4") 4 10 7 8 125 138 40 (1 1/2") 4 10 9 10 140 170 40 (1 1/2") 5 10 11 160 180 50 (2") 5 9 12 170 195 50 (2") 5 9 13 180 210 50 (2") 5 9 14 190 225 50 (2") 5 9 15 200 235 60 (2 1/4") 5 9 16 210 248 60 (2 1/4") 5 9 18 230 270 60 (2 1/4") 5 9 20 250 296 60 (2 1/4") 5 9 4 www.tizimplements.eu GEAR CUTTING TOOLS HOBS STRAIGHT SIDED SPLINE HOB Dimension of Each Spline Type Specification of HOB Title of I Type II Type Spline Outer Full Number Minor Major Chamfer- Number Minor Major Chamfer- Inner Width Width of Diameter Length of Splines Diameter Diameter ing of Splines Diameter Diameter ing Diameter B B øD L N d D g N d D g 11 11 14 3 13 13 16 3.5 60 60 19.05 16 16 20 4 0.3 18 18 22 5 21 21 25 5 23 23 26 6 23 28 6 26 26 30 6 26 32 6 27 28 75 75 28 32 7 28 34 7 (25.4) 32 32 36 8 0.3 32 38 8 0.4 6 36 36 40 8 36 42 8 42 42 46 10 42 48 10 46 6 46 50 12 46 54 11 95 95 52 32 52 58 14 52 60 14 56 (31.75) 56 62 14 56 65 14 115 115 62 62 68 16 62 72 16 0.5 72 72 78 18 72 82 18 135 175 40 82 82 88 20 82 92 20 (38.1) 0.4 92 145 190 92 98 22 92 102 22 32 32 36 6 32 38 6 36 75 75 27 (26.988) 36 40 7 36 42 7 0.4 42 42 46 8 42 48 8 46 8 46 50 9 8 46 54 9 52 52 58 10 52 60 10 56 95 90 56 62 10 56 65 10 62 62 68 12 62 72 12 32 72 72 78 12 72 82 12 0.5 (31.75) 0.5 82 82 88 12 82 92 12 92 10 92 98 14 10 92 102 14 115 115 102 102 108 16 102 112 16 112 112 120 18 112 125 18 The values of Tip width (f), undercut width (e) and lug diameter (d’) are decided as per DIN-5462, DIN-5463 or DIN-5464. 5 www.tizimplements.eu GEAR CUTTING TOOLS HOBS SPROCKET HOB [mm] Types of Chain Sprocket HOB Dimensions Outer Diam- Inner Diameter (d) KS, Full Length CP RD eter ASA I & II L D A [m] B [in] RS25 6.35 (1/4”) 3.3 60 60 35 9.525 (3/8”) 5.08 65 65 22 22.225 35 9.525 (3/8”) 6.35 65 65 40 12.7 (1/2”) 7.77 75 75 40 12.7(1/4”) 7.95 75 75 40 12.7 (1/2”) 8.5 75 75 27 25.4 (26.988) 50 15.875 (5/8”) 10.16 85 90 60 19.05 (3/4”) 11.907 90 105 80 25.4(1”) 15.875 110 125 100 31.75(1 1/4”) 19.05 120 140 32 31.75 120 38.1 (1 1/2”) 22.225 130 170 140 44.45 (1 3/4”) 25.4 160 190 160 50.8 (2”) 28.575 170 210 40 38.1 180 57.15 (2 1/4”) 35.72 190 240 200 63.5 (2 1/2”) 39.688 210 260 50 50.8 240 76.2 (3”) 47.625 240 3100 CHAIN AND HOB TOOTH PROFILE (NORMAL ANGLE) KS-U Type KS-S Type Pn = Normal pitch of hob = 1.011 X Chain Pitch U = 0 Ds = Minimum diameter of basic coverture of tooth bottom = 1.005 x Roller + 0.08 U = 0.07 (Chain Pitch-Roller diameter) + 0.051 6 www.tizimplements.eu GEAR CUTTING TOOLS HOBS SILENT CHAIN SPROCKET HOB For tooth profile; ASA B29.2-1950 and UDC NO.621.855 Standard Number of Range of Tooth Profile Chain Pitch Hob Number Teeth of Hob SC3 = .375” 1 20 17-23 SC4 = .500” 2 28 24-32 SC5 = .625” 3 38 33-43 SC6 = .750” 4 51 44-58 SC8 = 1.000” 5 69 59-79 SC10 = 1.250” 6 95 80-110 Sc16 = 2.000” 7 100 111-150 SERRATION HOB Following is standard tooth profile of KS-B-2007 Involute Serration. ORDER SPECIFICATION Order specifications for Involute Serration Hob are the same as that of In- volute Spline Hop. For overall dimensions, please refer to Involute Spline Hop described in page page 4. Basic formula of each part are as follows. Calculation Formula of Serration Item Symbol Part Module Teeth Pressure Angle Tooth Height Shift Major Diameter Pitch Pitch Diameter (Pitch Circle Diameter) Major Diameter Minor Diameter Limit Diameter of Involute Addendum Serration Dedendum Inner Diameter Width of Arc of Groove on PCD Major Diameter Minor Diameter Limit Diameter of Involute Addendum Serration Dedendum Outer Diameter Diameter Outer Thickness of Arc of Tooth on PCD 7 www.tizimplements.eu GEAR CUTTING TOOLS HOBS RATCHET HOB The importance o designing ratchet should be recognized consid- ering its indispensable functions. Following are to be considered in designing ratchet. • Force impacted on the sustaining point of the pawl must be min- imal. • Angle (Θ) of contacting side of pawl when it stops must be larger than fractional angle. Under normal dry ambience Θ=12-20° Under lubrication Θ=10-15° Things to accompany with Order When ordering Ratchet Hob, please provide following data: • Detailed Drawing of Ratchet Profile • Overall dimensions of Hob (Outer Diameter x Inner Diameter x Length) • Specification of Hob - Number of Threads and Blades, etc.
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