Page 416 - Gear Technology Solutions

original settings and consolidated settings are only in the 20-micron range.
However, the combination of these small basic setting changes prevents the
flank form and tooth thickness differences which would be expected by using
the consolidated cutter instead of the original cutter. Only the combination of
the consolidated, unified cutter head with the individually adjusted basic set-
tings prevents significant changes in flank form of the consolidated jobs.

Figure 11: Comparison of original cutting summary and summary after
consolidation

The tooth contact analysis (TCA) results of the original Job No. 102 and the
consolidated Job No. 102C is represented in Figure 12. The small differences
which can be detected are marked with green arrows in the two TCA graphics.
The small visible differences are insignificant, and the two sequences of TCA
results appear to be identical.

Similar consolidations like the one shown in this paragraph have been done
with real gearset families in an industrial environment. The number of jobs per
consolidation was up to 13. In some cases, more than 20 jobs were consoli-
dated with 5 to 10 existing jobs. In these cases, it was possible to utilize exist-
ing pinion and gear cutters and find the most suitable members from the new

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