Page 447 - Gear Technology Solutions

30.7.1 Coniflex Straight Bevel Gear Blade Summary Calculation for
Case 1 and Case 2

Certain items of the original Coniflex blade summary for the original size cutter
head (virtual cutter) have to be adjusted for the preparation of the Uniflex
blades. The calculation of the most relevant values is done by the blade grind-
ing summary program and shown in the section “UNIFLEX PENTAC BLADE
DATA” (see the blue marked section in Figure 20).

In this section a 9” cutter is proposed. All values which have to change due to
the application of the UNIFLEX process are included in this section. If the use
of a 15” cutter is preferred, then the cutter point radius has to be changed to
190.50mm. Blade width and blade thickness have to be changed to 19.68mm
and 15.24mm.

It is recommended to rename the original blade grinding summary (Figure 20),
which is for example for a cutter with a 2000mm diameter from JOB1.BFN to
JOB1_AUX.BFN (see Figure 21). The red framed items have to be changed in
order to accommodate the smaller cutter and the Uniflex process. These items
are: Summary text, cutter diameter, cutter number, pressure and clearance
angle, blade distance and top width as well as blade width and blade thick-
ness. Other profile geometry related items or process angles should remain.
All calculated values for the changed items can be found in the blue framed
section of Figure 20 (last section in the original blade grinding summary).

Uniflex can be applied with Cubic Boron Nitride (CBN) coated steel grinding
wheels. Either grinding from solid instead of cutting or grinding as hard finish-
ing operation is possible. The values in the green framed section “UNIFLEX C
B N GRINDING WHEEL DESIGN DATA” in Figure 20 reflect the adjusted pro-
file definitions for a grinding wheel which is capable to perform the UNIFLEX
process. Commonly the grinding wheel design is done by Gleason R&D.

The conversion from the virtual cutter to a 9” (or 15”) cutter, performed by the
program is explained with formulas and graphics below, such that a gear engi-
neer can improvise and alter the values in case problems are encountered.

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