Page 455 - Gear Technology Solutions

clearance cutting edge exists (see the right-side graphic in Figure 25) in order
to achieve a cutting-edge depth which is equal 115% of the jobs whole depth.

With this new summary JOB2_AUX.BFN the blades for the Uniflex cutter can
now be ground. It is recommended to use 3-face ground blades instead of 2-
face blades in all cases when the blade distance is equal to the blade top width
+ 0.5mm. A blade front face grinding with a side rake angle of 4.5° and a prac-
tically unground clearance side increases the capability of the clearance side
to remove chips during plunging and/or during the roll of the first side.

All blade features should be checked after the summary calculation. Slight ad-
justments can be made, for example to Blade Distance, Top Width as well as
the Clearance Angle in cases where the blade width leaves not much room for
the entire blade profile.

The values in the section “C B N GRINDING WHEEL DESIGN DATA” are
submitted to Gleason for the design of a CBN grinding wheel, if either grinding
from solid or grinding as hard finishing operation are the intended manufactur-
ing processes.

30.7.3 Coniface Face Gear Blade Summary Calculation for
Case 4 and Case 5

The original Coniface blade summary for the original size cutter head has to be
altered for the preparation of the Uniflex blades. The calculation of the most
relevant values is done by the blade grinding summary program and shown in
the section “UNIFLEX PENTAC BLADE DATA” (see the blue marked section
in Figure 26).

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 26),
which is for example for a cutter with a 1500mm diameter cutter from
JOB3.BFN to JOB3_AUX.BFN (Figure 27). 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 as well as blade width and blade thickness.
For face gears the blade top width remains as calculated in the original design
summary. Other profile geometry related items or process angles should also

440