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29.4 The Basic Elements of Cutter Consolidation with
Virtual Master

The new method of job consolidation utilizes a two-step approach which first
defines a temporary master and in a second step creates a virtual master
which is especially well suited for accommodating the requirements of the jobs
in the consolidation variety.

In the first step all jobs of the consolidation variety have been analyzed by a
computation procedure and the first temporary master is defined as one of the
existing jobs of the consolidation variety which cuts the smallest root slot width
of all jobs observed. Then the cutters of all other jobs are more specifically
compared to the temporary master. In particular the normal blade radii RW1-j
and RW1Cons as well as RW1-j and RW1Cons and the spacing between the outside
blades and the inside blades as shown in Figure 3 are compared at equal
blade dedendums for all different jobs. The radial differences between master
cutter and original cutter directly relate to a change in slot width. In face hob-
bing, the additional blade spacing differences will cause the generation of an
equidistant flank. The geometrical quantification of the slot width change
caused by the blade spacing difference is graphically explained in Figure 4
[2,3].

Figure 3: Blade spacing calculation

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