Page 409 - Gear Technology Solutions

• Protuberance from master or average protuberance is calculated or certain
Percentage of maximum protuberance is used

• Edge radius from master or average edge radius is calculated or certain
percentage of maximum edge radius is used

The calculation program begins to read the basic setting data files of the des-
ignated jobs and stores all required key data in data arrays. The first calcula-
tion “3” is the computation of the slot width at the toe of each pinion and gear
of the consolidation variety. The smallest slot width will determine which cutter
of the consolidation variety can be used in order to cut all consolidation jobs
without blade interference and tooth surface mutilation.

The next calculation “4” is computing the average values and the maximal and
minimal values of the following parameters:

• Spiral Angles
• Whole Depths
• Face Widths
• Blade Pressure Angles
• Slot Widths
• Cutter Radii Blade Dedendums
• Blade Offsets
• Blade Spacing Angles
• Blade Edge Radii
• Blade Curvatures
• Protuberances

If the range between min and max values is larger than recommended for a
consolidation, the program part “5” prompts a warning. If the range of values is
acceptable, then the program defines in part “6” the master job as the pinion
and gear job with the smallest slot width at the toe or uses the master jobs
which are forced by the input. Box “7” in Figure 7 is the address where the
program has to skip after a virtual master has been defined (will be explained
later).

The next step “8” is the calculation of the cutter radii, blade offsets and blade
pressure angles. In case of an input forced pinion and gear master, cutter radii,
blade offsets and pressure angles from the selected masters are used without
any calculation.

The following section “9” in the consolidation procedure defines the blade edge
radii, the main cutting-edge curvature radii and the protuberance parameters
for the consolidated pinion and gear cutter head. Certain features of the mas-

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