Page 411 - Gear Technology Solutions

the time of cutting. Because the cutter radii of the master cutter have to ac-
commodate the correct slot width for the individual consolidation jobs, an axial
cutter correction DH2j is calculated with:

DH2j = – [(RW2Cons – RW1Cons) – (RW2-j – RW1-j)] / [tan(a 2Cons) – tan(a 1Cons)] (4)

where:
DH2j… Individual blade point radius correction
Rw1Cons… Consolidated inside blade radius
Rw2Cons… Consolidated outside blade radius
a 1Cons… Inside pressure angle of consolidated blade
a 2Cons… Outside pressure angle of consolidated blade

The third element of tooth thickness correction in “10” results from the blade
spacing differences Dj c in Figure 3 between individual consolidation cutter and
the master cutter. Blade spacing errors have only an influence on the tooth
thickness in the continuous indexing face hobbing process. Figure 4 shows
that Dj c leads to a tooth thickness error Ne.

Ne = Dj c * Rc * sind w (5)
where:
Rc…Blade radius in cutter
d w… kinematic blade offset angle

An equivalent axial cutter correction DH3i to eliminate the blade position relat-
ed tooth thickness error Ne is calculated with:

DH3j = – Ne / [tan(a 2Cons) + tan(a 1Cons)] (6)
where:
DH3j… Individual blade spacing correction

In order to achieve correct tooth thicknesses an axial cutter head correction of
DHj is calculated as follows:

DHj = DH1j + DH2j + DH3j (7)

The master cutter head is now axially shifted in section “11” for each of the
consolidation jobs j by the amount DHj along its axis vector. A simplified graph-
ical explanation of the axial cutter and blade profile move is given in Figure 5.

At this point the consolidation procedure splits in “12” in either of the two pos-
sibilities:

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