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Research Papers

Serration Design for a Gear Plunge Shaving Cutter

[+] Author and Article Information
Ruei-Hung Hsu

Department of Mechanical Engineering, National Chung Cheng University, 168 University Road, Minhsiung Township, Chiayi County 62102, Taiwan, ROC

Zhang-Hua Fong

Department of Mechanical Engineering, National Chung Cheng University, 168 University Road, Minhsiung Township, Chiayi County 62102, Taiwan, ROCimezhf@ccu.edu.tw

J. Manuf. Sci. Eng 133(2), 021004 (Mar 11, 2011) (11 pages) doi:10.1115/1.4003613 History: Received October 26, 2009; Revised January 21, 2011; Published March 11, 2011; Online March 11, 2011

The surface roughness of the work gear after plunge shaving is affected primarily by the arrangement of the serrations. Given the two possible shaving conditions—up cutting and down cutting—this surface roughness can be improved by arranging the serrations’ cutting edge to perform as much up cutting as possible. Hence, this paper provides guidance on choosing the serration helix and the displacement of the plunge shaving cutter and then validates these suggestions experimentally.

Copyright © 2011 by American Society of Mechanical Engineers
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References

Figures

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Figure 1

Diagram of the shaving cutter and work gear

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Figure 2

Diagram of a shaving cutter with helix-staggered serrations

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Figure 3

Velocity of the shaving cutter at point P of the tangency of the operation pitch cylinder

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Figure 4

Sliding velocity of the shaving cutter and work gear

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Figure 5

Sliding velocity of the shaving cutter and work gear

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Figure 6

Trace of the cutting edge on the work gear

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Figure 7

Simulation of repeated cutting in a range

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Figure 8

End cuts for the simulated first cutting cycle

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Figure 9

Start of the simulated second cutting cycle for up cutting

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Figure 10

Start of the simulated second cutting cycle for down cutting

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Figure 11

Work gear for Example 1, Case A

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Figure 12

Work gear for Example 1, Case B

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Figure 13

Work gear for Example 2, Case C

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Figure 14

Picture of a work gear and measurement result for Example 3, Case D

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Figure 15

Picture of a work gear and measurement result for Example 3, Case E

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Figure 16

Picture of a work gear and measurement result for Example 3, Case F

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