Page 407 - Gear Technology Solutions

• Blade radii of pinion inside and outside blades are calculated from the
blade radii of the consolidation variety by altering them in order to ar-
chive semi-balanced amounts of deeper or shallower cutting. Semi-
balanced means in this connection that deeper cutting of 80% and shal-
lower cutting of 20% of the variation range is optimal for roll conditions
and strength:

Rw1Cons = Rw1WPmin – DSlot/2 * Fspp (1)

Rw2Cons = Rw2WPmin + DSlot/2 * Fspp (2)
where:
Rw1Cons… Radius of inside blade of consolidated cutter
Rw2Cons… Radius of outside blade of consolidated cutter
Rw1WPmin… Radius of inside blade of job with smallest pinion slot width
Rw2WPmin… Radius of outside blade of job with smallest pinion slot width
DSlot… Difference between the widest and the smallest slot with
Fspp… Factor for semi-balancing, e.g. 0.80

• If blade pressure angles from one particular cutter are used for the virtu-
al master, then the blade angles of the pinion and gear have to come
from the same job, even though none of the other cutter data of this par-
ticular job are used.

• The symmetry vector between the outside and inside blades of each in-
dividual member is compared to the master job and machine setting cor-
rections are used to minimize the difference in tooth profile of the original
jobs and the consolidated version of those jobs.

If it is required, in order to achieve good consolidation results, to use an effec-
tive point radius which results in a larger (or smaller) flank lead curvature, for
example, on certain gear members, then the consolidation strategy considers
that the mating pinion will also receive a larger (or smaller) lead curvature in
order to maintain the original Ease-Off and tooth contact pattern within the lim-
its of the physical possibilities.

29.5 Detailed Explanation of a Universal Cutter Consolidation

The combination of the different possibilities in a customized cutter consolida-
tion process leads to a complex flow chart which is summarized in Figure 7
and explained in detail. The explanations in this section should give gear engi-
neers the information required to set up a most optimal cutter consolidation
process which fits the needs of a specific manufacturer with a particular part
portfolio. Although the default setting will generally deliver very good results,

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