Page 412 - Gear Technology Solutions

1. In case of a forced master (or virtual a master in the second run) the pro-
gram writes in “13” all basic settings and cutter definitions and archives
in step “16” each consolidated JOBj under the new name JOBjC.

2. In case the virtual master is chosen (and first run) the program continues
at “12” in a subroutine “14” which is devoted to creating the ideal virtual
master.

For the inventive virtual master, cutter radius and blade dedendums are based
on the pinion and gear geometry with the smallest root slot width at the toe.
Cutter radius and blade dedendums are now modified using the precise radius
values at the individual blade reference points used in equation (4). At this
point the precise deeper cutting amounts are calculated, and the blade point
radii and blade dedendums are defined. The balance between deeper cutting
and shallower cutting is calculated from the user input. If the user enters 20%
of shallow cutting is allowed, the procedure arranges the range of jobs be-
tween 20% shallower cutting and 80% deeper cutting. The pressure angle of
each blade kind (pinion inside and outside blade, gear inside and outside
blade) are calculated as an average of all individual blade kinds (e.g. the virtu-
al pinion master inside blade pressure angle is the average of all pinion inside
blades pressure angles).

After the virtual master has been defined in “15”, the consolidation process
continues at “7” where the process repeats steps “8”, “9”, “10”, and “11”. In
contrast to the first run, now all calculations are performed with the virtual mas-
ter, leading to a significant improvement of the consolidation success. The
tests with the inventive consolidation method have shown that many job varie-
ties which were not possible to successfully consolidate in the past can now be
consolidated without sacrifice of the physical properties of the individual jobs.
The process passes now through “12” to “13” and “16” concludes the consoli-
dation task.

29.6 Consolidation Job Analysis Output

The consolidation output for the pinion jobs is shown in Figure 8. The ten pos-
sible consolidation jobs are shown next to each other. The lines below summa-
rize the items in Figure 8 in table form:

- Tooth counts
- Hypoid offsets and deviation from average
- Cutting methods
- Cutter head types
- Pinion spiral angles and deviation from average

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