UNIFO RM WITH THIS VOL UME

C O MMER C I A L EN G I N EER I N G
BY

A GE NE R A L MA NA GE R
( A L FR ED j u v a n sn n c z ,
.

A uthor qf Engin eering Es tima tes , Costs a nd A ccoun ts.

THE p rimary aim of th s w o rk is to en eavo ur to i that fill d

gpa w hic h e xis ts in e v e ry sc he me o f ro f ess on a o r u p
s n ess i l b i
i i g
t ra n n : that is to say, the n terv a i
et w een co e e o r l b ll g
app i ip
re n t cesh , a n d act v e an d res o n s i e p ibl p i i
a rtic pat on in
b ius n ess .

The cha tersp d ea n li g

w th the w o r s mar et s fo r
’
i ld k
engi i g p d
n eer n ro uct on s sho u i ld
be o f great v a ue to the l
b i i i g
man o f us n ess a m n to co n serve an d fo rt fy an e x stin i i g
i p
con n ect o n o r to O en up n ew o n es .

g l
The en era scheme o f the wo r is to ma e a certain k k
i k
co n cen tra t o n o f n o w e l dg
e, wh ch has n o t h th e rto e eni i b
p d i
attem t e , in co n n e ct o n w th o n e o f th e most i m o rtan t i p
i d i
n ustr e s o f the co un tr , a n d to y
re sen t it in a co n c se an d p i
access i bl f m e or .

Ev e ry p age may be re a d w ith p ro fit Cas sier s Maga zin e — ’

. .

The grea t me ri t o f t he boo k is its co mp re he n s ive n ess an d le ve l

headedn ess TI
.re Tin ees E ngin eerrn g S ujjlemen t .

De my 8v o ; 369 p a ge s ; n et.

T HE
FI TT I N G A ND
ER ECT I N G O F EN G I N ES
B

C L E SL I E B R O WNE
.

b k
THI S oo has b i
w r tte n w t h the o j
e en i
e ct o f ass st n b i i g
y g gi
o un en i p i l
n eers k ld
in the r ract ca w o r , an d shou be o f
id bl
co n s e ra h lp e e to t he fitte r, as t he ra is on d étre o f the
’

i u p tic i fully pl i d d fu th lu id t d by
v ar o s rac es s ex a ne an r er e c a e
th e aid f umo u di g m
n e ro s a ra s.

Th i f m ti p e t d i th ugh ly u ful
n or a on resen e s o ro se
an d p ti
rac l d w h pl u i c mm di g thi
ca , an e av e e as re n re o en n s
volum e E gi
.
—
g R i w
n n een n
°

ev e .

D e my 8v o ; 153 p ages an d 114 ill ustra tio n s ; n e t.

MA NC HESTE R : E M MOTT CO .
, LI M I TED
65 KIN G STR EET

L O ND O N zo BE D FO R D STR EET, WC . .
G EA R C U T T ING
IN THEO R Y A ND P RA C TI C E

JO SEP H G . HO R NER ,

A . M I MECH E
. . . .

MANC H E STE R
E M M O TT CC .
, L I M I TE D
6 5 K ING STR EET

LO ND O N : 20 B ED FO R D STR EET, WC . .

19 14

[ A 11 R ig}:is R eserved "

 P R EFA C E

WHEN ferin g a
of n ew boo k on Gear C tt u i ng to the public , the
e ons
r as doi g so may be stated
fo r n .

Ma y books ha e been written on the subjec t o f gears dealin g

n v ,

with the design s o f teeth an d gi i g so me accou n t o f the s p v n

practic e conn ected with the formation o f the tooth shapes B ut .

n one that I know o f covers all the later developme ts i a reaso ably n n n

co mp rehen siv e man n e Eith er theo ry is treated apart from practic e

r.
,

o r the w o rk o f the shop s is deal t w i th in a to o summary f ashion .

D uri n g say ten years past shop prac tice has b e e pro foundly
, n

modi fi ed by the gro wth o f form pl i g an d ge erati g planin g an n , n n

method s chiefly appli ed to the b eve l gears an d by the rapid e ten sion , x

o f the mode o f g e erati g spu r g e rs by bo bbi

n n N w m chi
g e a e s a n . n

ha e b ee de eloped a d co me i to assured f our These are

v n v n n av .

illustrated an d treated at le gth in thi s book by the help both o f n

detailed drawin gs a d o f pho tog aph s n r .

The g o wth o f auto mobile practic e an d the d e elopmen ts o f the

r v

all g-
eared machin e tool s h e b oug ht the high carbo teels a d the
av r n s n

allo y steel s to the f ro t These a d the ec essity fo r harde i g o f

n . n n n n

the gea s have had a f

r a eachi g i flue c e o the method s n o t only
rr
-
n n n n

o f the g ear cutte but al so o the whol e sequenc e o f the productio n

r, n

of g ea s f ro m the s lec tio o f the materi al s t o the fi al testi A

r e n
g n n .

con de sed accoun t h s bee gi e o f these d etails

n a n v n .

A s it is n o t po ssible to u dersta d the method o f operatio n n n

of machi e from photogr phs alone e amples o f all the g eat

a n a ,
x r

types o f gear cutti g machi es are illu strat ed by detail ed d awings

-
n n r .

I so me i n sta c es al so full e amples are gi e

n n o f t he si i n g an d
x v n z

cu tti g o f g
n ears fro m shop O p eratio sh eets in association wi th the n ,

machines to which they ha e eference It is hoped that these

'
v r .

drawi gs an d e amples will pro e o f speci l value to the men i

n x v a n

the machi e shop n .

The large numb er o f illu st ati s al l spe cially p repared fo the r on — r

w o rk —will be help ful to the stud e t n .

P o rtions o f the wo rk ha e app a ed pre iou sly i ticl es o f mi e

v e r v n ar n

vii
v iii P R EFA CE

in M d mn ieal World an d the sec tion o n double helical gears

the ,
-

was writte n origin al ly fo r the E ngin eering R eview.

My ac kno wledgments are due to the firms whose names appear

in conn ection with the accoun ts o f th ei r machi n e s . I am spec ially
indebted to the B rown 8: Sharpe _Man u facturin g Co mpan y fo r the
use o f fo rmulae an d table s which wer e originally wo rked o ut fo r an d
printed in their handbook .

JOSE P H H O R NER.

B A TH 9 4 , 1 1 .
 C O NTENTS

SE CT I O N I— P R I N C I P L ES O F D ES I GN
.

C H AP TE R I
EL E M ENTS O F TO O TH FO R MS

C ycloicial and l
l n vo ute Fo r
m$

C HA PTE R II

TO O T H C U R V ES
G e n e ra t n i g C i l
rc e s— O d o n to g ph I f
ra s— n t er e re n ces in Lo w -n um be d re In vo
lut e s— Co rre ct on si
— The L i mi t i g Numb
n e r o fTee th

C H A P TE R 111

P I TC HES

Ci rcul ar, Di m t l M dul

a e ra , o e— Me tri c— Co m p ia r so n s— Man chester Pi t ch

Cho r d l Pit h
a c

CHA PTE R IV

TO O TH P R O P O R TI O NS

T o o th P p i ro o rt on s d erived fro m t he i
P tches— Chan g es P p d P
ro o se — re ssure

A n gl e s-h Shorten ed Tee th

C H A PTE R V

G EA R S L
R E A TED TO THE SP UR S
In te rn a l Ge s
a r — Too th Fo rms— S pi l
ra Gears— Pi t h
c es an d An gl es — Heli cal
Sp urs— Wo rm Gears l
— E eme n ts— Und e ut—
rc Ho ll o w - faced Gears
Hi n dl ey Gears — G l b id
o o Gears— V ar ai bl G e ea rs
1x
 C ONTENTS

C H A PTE R V I

B EV EL GE A RS

P A GE
Ele men ts of Bev e l Gears— P p ti
ro o r o ns — A b n or mal Gears— R ul es fo r Sk e w
Bev e l s

SE CT I O N II .
—
M E T HO D S O F C UTTIN G

C HA PTE R V II

FO R M C U TT E RS

The M etho d s of Cutt i g n — R an g e of D i sc Cu r

tt e s— Cutters for Circu ar l an d

D i a me tra l P itch — G es ash n i g— Cutte rs fo r S pi l

ra Gears— En d Mi ll s
Cutters f B or lGeve ears

C HA PTE R V I I I

FO R M P LA NI N G A ND G ENER A T NG M ETHO DS I

The Fo rm The Rac

— i fG ti k
Th F ll w Cutt
-to ot h Bas s o e n e ra on — e e o s er

Th Su d l d R ck h p d C ut t — Th Si g l R ck t th Typ
e n e r an a -s a e er e n e a - oo e

H bo— T h isA cti — O bj t i t

e r — P d uct i onf H b — G ti g ec on s o ro on o o s en era n

by Milli g Th Ch mb H b Th G t M chi — Th W
— n e a on o — e ran a ne e a rren

Cutt Th B l Cutt
e rs— e ea e ers

SE CT I O N I I I .
— M A C HI N ES

C HA PTE R IX

M A C H NES U S NGI I FO R M C UTTER S

Fo r Spurs : B ro wn Shar p e, li g S ll G uld
Loew e , D ar n e ers, o E be rhar t d
R ac k -
cutters : Walco tt W d R k cutti g A tt ch m
oo — ac -
n a en t to Millin g
M hiac ne— In tern a Gears l

HA PTE R X C

M A CH NES U S NG FO R M CU ITER S ( co ti ued)

I I
’ ‘

n n

For W m dR l t dG
or an Sp i l Si g l h li l G
e a e — Pl i g Spi l
ea rs— ra or n e- e ca ears an n ra s

— D ub l h li l — Stu kg ld P t t— Th L M hi ’
o G e- e ca ears c o s a en e ore n z ac ne
 C ONTENTS xi

C HA PTE R XI

M A C H NES U S NG
I I FO R M C U TTE RS
( con tin ued
)
PA G E
Fo r B ev e l Gears B ro w n Shar p e, The B i rch Machin e , Go u ld b
E e rha r t d
D ou bl e -
he li l
ca B ev e l s Pl o an o w s ki P a ten ts— wast Machi n e us i g
n En d
Cutters — P o w er Pl an t Co .
’
s M hi ac Ci t
n e— ro e n Machi n es

C HA PTE R X II

FO R M P LA NI N G
Sp urs a n d Bev e s : The e w t o l
n M a ch n e — N
The G easo n Machin c The i l h

lik
O e r o n Ma ch n e— The G re en w o o an d Bat e Mach n e — The B o uhe
i d ly i y
Ma ch n e i

C HA PTE R XI I I

M A C HI NES TH T A G ENER A TE BY P L A NI N G TO O LS
Sp urs The Sun d l
er an d— The Fe ll o w s— The B ilg ra m fo r S ur Gea rsp

C HA PTE R X IV

M A C HI NES T HA T G ENER A TE B EV E‘S BY P L A NIN G

T he Bi lg ram— The Ro b ey Sm t
- h— TheiSun d l d
e r an — The G l easo n

C HA PTE R XV

ENER A T ING B Y HO B B I N G
Sp urs , S pi l ra s an d Wo rms TheWa ll w o rk M ach in e
— The Go u ld E b dt
e rhar

— The Schuchar t d Schu e The Wa ll w o rk

t t — fo r Wo r m g -
ea r H bbi g
o n

T he Wiist Machi n e fo r D oubl e h e l i cal -

p
S urs

C H A PTE R XV I

G ENER A T NG I BY M LL NG
I I

B ro w n Shar p e A t tachme n t —
Th e B eale Machi n e
xfi C ONTENTS

SE CT I O N IV M A TE R I A L S M A N UFA CT U RE ,

S TRE N GT H

C HA PT ER XV I I

T HE M A NU F CTU R E A OF G EA R S
PA G E

Materi al s : The A l T tm ll yo Stee s —

rea en ts : Hard en i n g Furn aces— P p
re a ra

t i on o f Bl k G hi g Sp d
an s —
as n —
ee s an d Fe eds fo r Cuttin g — Sel ecti o n s fro m
Prac ti c
e — T th u di g
oo Gfi di -ro n n — n ng
— Test i g
n

C HA PTE R XV I I I

T HE ST R EN T H O F G G EA RS

Wil fred Le w i s Fo rm ul a— The G l ea so n R u e — l The Fe ll l

o ws R ue — The Ba rth
l
R u e — A rms — Co n c us l i on

A P P END I X

I NDEX
 G EA R C U T T IN G
IN T HEO R Y A ND P R A CTIC E

S EC T IO N I .
— P R INC IP L ES O F D ES IGN

CHA P TER I
ELEM ENTS O F T OOTH FORM S
HIS TO R ICA L . M0re progress has been m ade in the cutting of toothed
—

ge ar s du ring twenty or twent y fiv e ye ars pas t than in the two or

-

three centu ries previous The first men who cut ge ars were the
.

horologists an d as tronomical instrument m akers an d their wo rk w as

-
,

done in the lathe an d without much regard to the correct sh apes of

t he teeth . The book by Camus who died in 1 768 w as the first in
, ,

which the subject w as treated at length There is not an y exam ple .

in this of double curv ed teeth though the con struction of intern al

,

an d extern al cycloids is illu strated an d des c ribed A ll the illustra .

tion s are either of involute teeth or l antern ge ars or of the vas tly
, ,

predo min ating design in which epicycloid al curves are combined

wit h radi al flanks below pitch line Or altern atively the fl anks
.

above pitch line are semicircles like knuckle ge ars but the fl anks ,

belo w are inv ari ably radi al True contact therefore could onl y
.
, ,

occur at an d in the immediate vicinity of the pitch circles Though .

the con struction o fthe hypocycloid or intern al cycloidal curves

w as ill us trated they were not applied to the form s of the teet h shown
in th at work A l so though the teeth were produced by cutting
.
, ,

there w as a large amount of flank clearance allowed A llusion is .

m ade to inequ al ity an d other defects in the teeth A pinion is also .

said to be preferable to a l antern for driving There is much of this

.

kind of curious in terest in this book with which the present subject
A I
2 GEAR CU TTI NG
isnot concerned But the m athematic al bas es of the two fo rms of
.

tee th used to day are explained at len gth an d may be studied the re
-
,

with advant age an d interest .

A S the v aried designs of the ge ar cutters depend upon an d are ,

deri ved from the fundamental principles of the design of the teeth
,

of gears it is essential to give some prelimin ary attention to the

,

elemen ts of gear tooth construction Machines must be so design ed

-
.

th at m athematic al accuracy in all the gear elements Shal l be em

bodied in the action of the m achin e s This is seen at its highest .

development in the generating m achines in some of which no ,

form ed cutter is used at all but a tool with a plane face or a n arrow
,

edge only does the cutting the generating elements being em bodied,

in the m achine The action of some of these m achin es can only be

.

understood if the fundament al principles of the form ation of the

sh ape s of the ge ar teeth are grasped .

D efin itio s
n —Gears derive their v arious n ames prim arily from
.

their axes of rot ation an d pitch surfaces Cylinders h aving their axes .

parall el an d teeth paral lel with the axes are sp ur gears They may have .

intern al teeth Cylin ders the axes of which are not parallel but set
.
,

at an angle h ave teeth w hich cl as s them as sp iral or properly screw

,

ge ars R acks are either Spur or spiral (screw) ge ars of infinite radiu s
.
, .

Worm gears are a type of screw gears a screw engaging with a wheel , ,

in which the ax es are usu all y though not essenti ally at exact right , ,

angles —
hence often te rmed t angent wheels Conic frus tra h aving .

their axes in the sam e pl ane an d intersecting have teeth the bound , ,

ing lines of which would if prolonged meet at the common apex of

their cones These are bevel gears The axes of skew bevels are not
. .

in the same pl ane These clas sific ations say nothing about the forms
.

of the teeth A n d whatever the section al shapes of the teeth which

.

are adopted they vary in outline s an d dimensions with every

,

vari ation in the character an d dimensions of the pitch surfaces an d ,

with the relative dimen sions of the ge ars in cont act an d al so with ,

the dire ction in which the teeth are arranged on their pitch sur
faces This fact is very pronounced in the wo rm gears an d
.

Spiral ge ars .

The Ideal Gems The pitch lines (Fig 1 ) R D P D are cut by the
— .
, .

line of centres which joins the centres or axes of revolution of ge ars

in mutu al engagement This is divided at the point where the pitch
.

surfac es are in cont act the p itch p oin t 0 This occurs at a dist ance
, , .

b e t ween the centre s of revolution inve rse ly proportion al to th e radii ,

 ELEMENTS o r T OOTH FORM S 3

diameters or circumferences of the gears in cont act The line ar

,
.

velocity being alike in each of a pair the angular velocity varies ,

inversely as the di ameters This assumes t hat no slip occu rs between

.

the su rfaces The fact th at thi s might happen between smooth

.

fri ctional surfaces is the re as on why interlocking teeth are used an d ,

then the ide al is so to design the teeth that the ge ars will transmit
,

motion as uniform ly an d smoothly as th at which would be produced

by the simple frictional cont act of smooth surfaces It is around .

this ide al th at the whole practice O fge ar tooth design an d cutting has -

been developed P ractice only t akes account of two simple kinds of

.

teeth the cycloidal an d the involute The principle s which underlie

, .

those as well as al l other form s of teeth are these :

The Common Normal The law which governs correct tooth con
.
—

t act by virtue o f which ge ars transmit motion as though by the

,

cont act of smooth surfaces is t his : The common norm al of pressure to,

the tooth cu rves in cont act must pass through the pitch point This .

permits of the choice of several possible curves as well as st raight or ,

curved faces in the case of racks B ased on this law several systems .
,

of ge ar tooth cu rves have been pro posed an d demonstrations given

-
,

Sh o w ing how h aving the curve of one tooth given th at of its fellow
, ,

can be constructed Though intere sting they are of little practic al

.
,

v alue But the fundament al fact is of first import ance bec ause if it
.
,

is not embodied in ge ar wheel teeth the engagement wil l not be -

m utu al regul a r an d correct

, In the older teeth perfect cont act w as.

igno red as in the knuckle gears an d those which have straight flanks
,

below the pitch line Some slipping occurs in these cases which does
.

not happen when the teeth are m ade to ful fil the condition just now
s t ate d .

A templet can be m ade of wood ( Fig 2 ) to demon strate the accu .

racy of the st atement that the common norm al must always p as s

through the pitch point Cut the edges of two pieces of wood to .

re present arcs of b ase circles of involute teeth an d bore a hole at the ,

ce ntre of each to pivot them around Cut two pieces with involut e .

curves struck from the base circles using centres a b an d screw them , , ,

on the first pieces On centres a b pivot a link having a centre line

.
,

co nnecting the pivots Then on moving the tooth edges in cont act
.
,

the centre line of the link in its movement will al w ays cut t he pitch
po int 0 in the lin e O f centres .

The curves of teeth may be of an y fo rm so long as they fulfi l

the conditions just st ated P ractical considerations of m anufacture .
4 GEAR CUTTI NG

limit these to regular curves such as can be struck from cent res with
compasses or which can be re adily generated .

In order to en sure smoothness of engagement it is essential that

there shal l be no break of cont act at an y st age of the action In other
.

words the path of cont act must be continuous an d from every

, ,

point in the path of cont act no rm als carried therefrom from both
cu rves must pass through the pitch point This fa ct lies at the b as is
.

of tooth profiles The path of cont act may travel either al ong curves
.

or along a straight di agon al path But in an y c ase the sam e

.

curves or the s ame di agon al path will be traversed by the teeth of

, ,

e ach gear in engagement Thi s is a most import ant fact bec ause it
.
,

renders the interch angeability of gears a simple m atter It is only

.

necessary first to determine the n ature of the path of cont act an d ,

then all teeth of the same pitch shaped by that will engage correctly .

Or h aving the tooth curve s of on e wheel l aid down those of others to

,

gear with it can be desc ribed It is possible though not workable

.
, ,

to use othe r curves besides those of the circle for gene rating tooth
curves The gener ating elements may be of segment al or of
.
 ELEM ENTS O F T OOTH FO RM S 5

p arabolic fo rm but ,
the difficulties of applying them would be too
great .

F riction o
f The obliquity of
Teeth
action of teeth is con
— sidered

obj ection able due not only to the vari ation in the angle of p ressure
,

f rom the t angent to the line of cent res but al so bec ause of the gre ater ,

a mount of sliding friction which occurs The action along the tan .

gent Fig I when cont act t akes pl ace at the pitch point is rolling
, .
,

s imply Elsewhere it is th at of rubbing or sliding This is a mo st

. .

import ant difference which gives occ as ion to the designs of the
h elic al teeth an d of trundle an d knuck le gears The friction along
,
.

the arc of appro ach a 0 Fig 1 the uppe r gear being the driver an d
, , .
,

the lower one t he driven is more injurious than that al ong the arc ,

of recess 0 b Henc e in designing st andard gears the aim is to

.

lessen the obliquity as far as is practic able without the sac rifice of
other adv an t ages The angles included by 0 a o b are the angles of
.
, ,

a ppro ach an d recess res pectively .

In order to ensure perfect action cont act should occur both ,

above an d be low the pitch line t hough a few ge ars are m ade which do ,

not fulfi l this condition The po rtion of the tooth above pitch line .

is te rmed the face that below is the flan k It is not essential in order
, .
,

to the correct cont act of one pair of ge ars that the path of cont act ,

sh al l follow the sam e curves above an d below pitch line but it is ,

essential if all ge ars O f the same pitch are to interch ange B evel .

ge ars which work only in pairs might obviously h ave different cu rve s
of cont act above an d below pitch line which is done occasion ally to ,

avoid a we ak pinion B ut for convenience an d economy of m anu

.

facture there is usually no difference m ade in these .

Cycloidal Teeth The path of cont act coincides in cycloidal teeth

—

with the circles A B Fig I which are used for generating the tooth
, ,
.
,

curve that is the teeth in engagement travel for h al f the period

s—
,

along the p ath of cont act a 0 de fi ned by o n e circle A to the pitch

’

, , ,

point 0 the are covered being the arc of appro ach an d during the
, ,

s eco n d h alf from the pitch point 0 b al ong the other circle B du ring

the arc of recess The diamete rs of these generating circles are most
.

import ant in an interchange able system of ge ars bec ause sm all ,

circles though perm itting of the employment of sm all pinion s ent ail
, ,

a high angle O f obliquity an d thrust an d very wide fl anks in t he ,

l arger wheels The b asis is commonly either a thi rteen or a fifteen

.

toothed pinion using a generating circle h aving a di ameter equ al to

,

its radius Such a pinion has radi al flan ks

. Sm aller pinion s will .
6 GEAR CUTTI N G

h ave convex flanks much undercut A ll gears larger t h an the b as e .

will have concave fl anks the width at the b as e increasing with in

,

cre ase in diameter The b asi s therefore of this system is the gen e
.
, ,

rating circle O f half the diameter of the b ase pinion of the series
, .

A lthough the cycloid describ ed by the rollin g of a generatin g

‘

circle on a b ase is not a regul ar cu rve a very close approxim ation is ,

struck with comp as se s The di fference is negligible in sm all ge ars

. .

But there is a m arked difference in teeth of co arse pitch .

Sin gle Cn rve Teeth Single curve teeth the involutes (Fig
—
,
.

have no conc ave faces the cu rves of the teeth in e ach of a pair bein g
,

convex The curves are produced by un win din ga cord from an arc
.
,

Fig 4 or by roll ing a st rip with a needle point round the arc Fig 5
.
, ,
. .

A n approxim ation the reto is obt ained by striking the curves from
a single centre The path of cont act is a straight lin e which is a
.

t an gent to the b ase circles Fig 3 of wheel an d pinion an d the pres , .

, ,

sure coincides with the p ath o f cont act The b ase in this system is .

not a pinion as in the cycloid al but a rack Fig 6 In determining , ,

. .

the b as e the angle of the path of cont act is fi rst selected the object
, ,

sought being b esides interch ange able ge ars the employment of an

, ,

an gle without too high obliquity with con se quent inju r i ous thrust ,

on journ als an d bearings The angle usu ally t aken varies from I4§.
0

to 2 0 to the t angent to the pitch circle 1 4 5 or 1 5 having been

°
,
° °

common until recently preference being often now given to higher

,

angles ( see p Then this determin es the angle of the faces of the
.

rack teeth which f aces are perpendicular to them ; hence the rack is
,

the b asi s of this system as the sm allest pinion is th at of the cycloidal

,

system The involute rack has straight faces (in theory) ; the
.

cycloid al rack has double curves whence import ant results arise ,

w hen the que s tion of cutting ;accurate ge ars is under con s ider atio n .
8 GEA R CU TTI NG

concern s both cut an d c ast ge ars an d in both c as es vested inte rest s

,

are a formid able objection to a system of uniformity A large set of

.

patterns an d tooth blocks o r of cutte rs may e asily h ave cost several

, ,

hundreds of pounds It may be accepted as a settled fact that the

.

question of the best st and ard gear will not be determin ed by m athe
m atical consideration s as the met ric system w as but by purely
, ,

practic al an d wo rking ones The simple r the system adopted the

.

bette r ; an d there seem s no re as on to entert ain the thought of dis

c arding eithe r the cycloidal o r the involute systems al re ady est ab
lished. They fulfil all requirem ents an d are e as ily understood an d
,

worked out by practic al m en who are not m athem atici ans .

 CHA PTER II
OOTH C U RV ES
T

D R A WING TOO TH Gun m The formation of o n e tooth curve to

an —

s uit an othe r though po ssible by point con struction is not a p ract i

, ,

c able method It would be too tedious an d error creeps in besides

.
, ,

which it would h ave to be repe ated for every ge ar A more practic able .

method is to cut a piece of sheet met al to the shape of the tooth to

which it is desired to m atch a ge ar centre this an d the intended ge ar
, ,

roll them together an d from the edges of the met al templet m ark a
,

succession of tooth outlines from the time of entering to th at of le av

ing ge ar The boundin g outline s common to al l these curves give

.

the conjugate out lines Of the wheel teeth required .

B ut the actu al m arking O ftooth outlines is seldom done by a de

v elo men t of e ach tooth from its m ating tooth In strik ing out teeth
p .

for working drawin gs arcs are obt ained which are as approximately
,

correct as it is possible to get them to the m athem atic al tooth curves .

Then a Circle or circles are st ruck from the centre of the gear through
the centre obt ained for the tooth arc an d on this circle so obt ained
,

the centres of all the tooth cu rves will be loc ated .

The double cu rved or cycloidal teeth are struck either by rolling

generating circles directly or by an odontograph or by constructions
, ,

which are b as ed on the employment of either circles or an odonto

graph The first is absolutely correct the second two are app roxi
.
,

m ately so .

Cycloidal Cn rves The usu al method of m arking out cycloidal

.
-

tooth curves directly is shown in Figs 7 8 an d 9 Having adopted .

, .

a cert ain size of desc ribing circle templet s are m ade with convex
,

an d conc ave edges cut to the same cu rvatures res pectively as the

pitch circles a of the wheel an d b of the pinion The circles A B being .

,

provided with a needle po int will when rolled on the extern al an d

, ,

intern al templet edges of wheel an d pinion generate the tooth p ro ,

files indicated an d these will when in cont act fulfil the conditions
, , ,

of accurate engagement st ated in the first Ch apt er R adii are .

ad apted to the cu rve s which su f fi ciently approxim ate to the actual

curves Through the cent res of the arcs thus found circles o r c ars
.
,

9
IO GEAR CU TTI NG

are s truck concentric with the pitch circle an d these form line s of ,

centres whence all the teeth are st ruck Two such arcs are shown
.

at c d for the fl anks in the fig

, ure s The centres for the faces happen
.

to come on the pitch lines a b in these c ases Fig 9 shows the same
,
. .

process applied to the rack which is a spur gear of in fin ite radius

,
‘

Here the arcs are al ike above an d below pitch line .

The cycloidal curves can be drawn without using templet circles

by adopting the stepping round process Circles or arcs are struck
-
.

repre senting successive positions of the rolling of the generating

circles an d Short dist an ces are stepped round The cu rv es drawn
, .

through the points thus obt ained will be practic ally correct .

There are several methods of con struction which give app roxima

Fig . 8 .

tions to these curves illustrated in works on ge ars Some afford

, .

re aso n ably correct Shapes others do not It seems unnecessa ry to

, .

employ these when the employment of rolling circles against t emplet

curves give absolutely correct shapes This rem ark applies in a
.

lesser degree to the adoption of odontograph sc al es an d to con struc

tion s b ased Upon them A lthough three or four such sc ales h ave been
.

proposed only one has been generally employed that of P rofessor

, ,

Willi s Its basis is the selection of a definite angle O f pressure an d

.
,

its principle lies in the movement s of link work .

P rin cip le ofWillis s Odon tograp h If in Fig 1 0 round the fi xed

’
—
. .
, ,

cent res A an d B the links A c an d B d rot ate an d are connected by ,

the rigid link 0 d then whatever the positions t aken by A c an d B d

, ,

they will be always norm al or perpendicular for an inst ant to the

urve which they desc ribe If these perpendicul ars are prolonged
.
 OOTH CU RVES
T II

the y w ill meet at c around which 0 d is for the in stant mov ing e is
, .

term ed t he inst ant aneous or virtu al centre A line dropped from e

.

perpendicular to the link 0 d

cuts A B in o where the line of
centres A B is divided The .

points 0 an d d are the centres

in the odontograph from which
tooth curves are struck Suc .

cessiv e movement s of the links

A c B d are indic ated by the

,

dotted lines an d in each posi

,

tion the link 0 d cut s the line

of centres A B in points not far
removed from o The link 0 d .

forms with the other lines a

s e ries of equ al tri angles by virtue of which the angul ar motions of
,

A c B d are to e ach othe r inversely as the Seg

, m ent s into which the
link 0 d divides the l in e of centres A B In other w ordS the angul ar
.
,
~

v elocity of A c divided by the angul ar velocity of B d equ als B 0

di v ided by A 0 Thus to obt ain unifo rm ratios the triangles on each

.
, ,

s ide O f the pitch point

0 must be similar ,

which can only occur

when the link 0 d in
te rse ct s the line of
cent res A B in the point
0 in the proportion of

the required velocity

ratios of the arcs A c ,

Bd .

In Fig 1 0 the im
.

ag in ary link 0 d divides

the line of c entres A B
exactly at 0 If now
.

radii be struck from

an y point s in the lin e Fig 10 . ,

c d wheels with centres

,

at A an d B will be d riven p reci sely as by the movement of the lin k

0 d absolutely correctly when at the point of intersection o an d

, ,

nearly so in positions a little above an d below that point when the

IZ GEAR C UTTING
pe rpendicul ar from 6 falls to one side of o It is upon these facts an d .
,
‘

the coincidence of the point 0 with the velocity ratio th at the con ,

stru ction of the odontograph is b ased .

It should be mentioned here that it is not necessary that the cu rves

should be struck at 0 They may be loc ated on either side of th at
.

point or even out side the link an d they may be both alike convex
, , ,

or convex an d conc ave Or two cu rves may be employed The . .

essenti al is that the loc ation of their centres shall be in the line of the
lin k 0 d .

The line 0 d is the angle of p ressure an d in fix ing this a mean ,

h as to be struck Willis first fi xed upon this at

. which he
selected after v arious t ri als as being one which avoids too much

rounding of the teeth on the one h and an d too oblique a pressure ,

on the other .

A gain the position of the tooth cu rv es in relation to the point 0

,

may vary In single curve teeth the best loc ation is fixed at the point
.

0 which Corre sponds with the momerit of p as sing the lin e of centre s .

B ut with double cu rve teeth the p assing of the line of centres should
Co rres pond with the point of cont act of the arcs forming the faces an d

flanks of the tooth The elements of t his are given in Fig II Let
. . .

A B be the centres of a wheel an d pinion in cont act at the pitch

,

point 0 in the line of centres A B From 0 draw the line C o D at the .

angle dete rmined on From 0 draw the perpendicular o E A ssume

. .

a centre a in the line C D whence the circul ar arc b of a tooth for the

wheel A shall be struck To find the corre spondin g centre for the
.

wheel B join A a an d produce the line to meet 0 E in E Join E B

,
.

an d produc e to meet 0 D in c 0 will be t he cent re for the tooth cu rve

.

of pinion B .

If in Fig 1 1 the point E is supposed to be situated at an infinite

.

dist an ce the points a an d c not being given then the lin es A a E c B E

, , ,

will be p aral lel with o E an d perpendicul ar to C o D If therefore .

,

( Fig . line s a re dr awn from A an d B pe rpendicul ar to C D then a ,

an d b will be centre s from which arc s m ay be struck at 0 which will

engage correctly A n d an y wheel of a set in which the angle A o C

.

rem ains const ant will work correctly if the arcs are st ruck through
the point 0 This is the b asis of the sin gle curve system A n d if
. .

new radii are sub stituted as c e d f radii struck from c an d f through , ,

the point 0 will engage correctly B ut it is essenti al that the arcs .

be struck through the point 0 The objection which Professor Willis .

m ade to this system w as th at the cont act w as point cont act only "
,
 TO OTH CU RVES I3
0

strictl y e xact at the moment of passing the line of centres For this
.

re a s o n he gave the preference to the double curve teeth the arcs of

,

w h i ch are struck on oppo site side s of the pitch point 0 A n d the

.

Fig . 11 .

a rc s a re so se t out th at the point s of mutu al action of faces an d

fl ank s Shal l t ake pl ace one ne arly in the middle of the arc of motion
,

b efore the line of centres is re ached an d the other about the middle
,

Fig 1 2
. .

of the arc of motion that lies beyond the line of cent res an d between
that an d the quitting of cont act .

Figs I3 an d 1 4 Show the const ruction for a set of gears for inter
.

changeability A B is the line of centres divided at the pitch point 0

.
14 GEAR CU TTING
o the line O faction of
C is an d c o is pe rpendicul ar to o C The two .

points e e on t he lines C 0 are set Off at equal dist an ces from o in

, , ,

each diagram The centres O f the convex arcs are found by joining
.

t he centres of e ach wheel in both fi gures A with the point c which lies —

on the opposite side of the line C o of the wheel A in Fig 1 3 B with .

,

t he point c in Fig 1 4 The point of intersection of these lines with

. .

C o is the centre of the arc In Fig 1 3 a is the centre of the conve x . .

,

arc b an d in Fig 1 4 a is the centre of the convex arc b

, .
, .

The centres for the conc av e arcs are found by joining the centre
of each wheel with the point e which lies between it an d the line C 0 .

Thus in Fig 1 3 d is the centre of the concave arc e in Fig 1 4 d

.
,
.
,

is the cent re of the conc ave arc e The whole of these arcs are struck .

through a point lying beyond 0 uniformly t aken at one h al f the pitch .

This with the con st ant dist ance 0 c ensures interchangeability in a set .

In such a ge ar the angle of the line of pressure is not const ant as ,

in the involute design but varies as the teet h traverse the paths of ,

cont act It is highest when sm all generating circles are at the basis
.

of construction The angle of 75 in the Willis system leaves 1 5

.
° °

as it s complement These angles are only correct for an inst ant

.

when on e side of the tooth is at the line of centres Twelve teeth is the .

b asis pinion in the Willis system ; fifteen teeth in the B rown Sharpe .

Odontographs m ay be in st rument s or c alcul ated t ables only , .

In each c ase they cryst all ize into a h andy form the l abours of the
m athem atici an or of the practic al m an who has obt ained st and ard
,

teeth by more l abo rious methods When an instrument is used error .

,

m ay creep in by its c areless applic ation to the p rim a ry lines of the

wheel ; when a t able of dime nsions is used erro r may al so be present ,

in application More than that O dontographs are not abso lutely

.
,

correct bec ause they general ly m ake use of single circle arcs an d
, ,

t rue tooth cu rves are not arcs of circles They are extremely close .

approxim ation s an d the re sult s are often within the limit s of average
,

workshop requirements an d c ap abil ities Wil lis s odontograph is an .

’

a pproxim ation only but the same is true also of set s of cutt ers each
, ,

o f which has to do duty for a ran ge of teeth greater or less in the , ,

c ase of high an d low numbered ge ars respectively .

eren ces in In roln tes

In terf A lthough the involute rack produces '
.
—

a pe rfect involute curve in wheels which it gene rates thi s cu rve c annot ,

be continued below the b ase circle on which lies what is termed the ,

interference point The line of action is t an gent to the b ase circle

.
,

an d the inte rference point occurs at the point of t an gency on which

I6 GEA R C U TTI NG

t ke the pitch circle P L pitch it round an d div ide each pitch

S ri , .
,

into equal parts to give the tooth thickness an d space Strike the .

lines for the addendum A the working depth W D an d the root line
, .
,

for bottom clearance corresponding with the whole depth of tooth

,
.

From a pitch point on a line joining the point to the centre describe a .

se mici rcle B equ al to the radius of the pitch di am eter Take one .

fourth of this radiu s an d step it b ack from the pitch point to the
semicircle at a Through the point of intersection desc ribe a circle
.

concentric with the pitch circle This is the base circle B C With
. . .

a radius equ al to one fourth of the radius of the pitch circle an d

-
,

compass set on the point a in the b ase circle desc ribe the tooth ,

arcs The tooth fill ets

.

by which these curves

merge into the bottoms
of the tooth Spaces are
struck with a radiu s

equal to one Six th

Fig 15
. .

of the widest part of the tooth Space or at the addendum

circle .

A S the rack tooth has flanks an d faces of 7 55 of angle this gives

°
,

the construction at once for a no rm al rack ( Fig The addendum

.

line the wo rking depth an d the bottom Clearance lin e are set out
, , ,

as proportioned for a circul ar g ear an d the pitch is Set out an d divided

,

e qu al ly A line is then d rawn through an y pitch point p e rpendicul ar

.

t th e pitch line
o From the pitch point an arc is struck an d on
.
,

it angles of 7 55 are se t o ffto right an d left of the pe rp endicular an d

°
,

diagon als drawn through these from the pitch point These lines .

re pre sent the p ath of cont act an d angle s of pre ssure an d t he tooth ,

sides are drawn at ex act ri ght angles with these This completes the
.

essenti al tooth form s but fi llet s are in serted in t he bottom e qu al to

,

o n e sixth of the width of s p ace s of the rack teeth at the addendum line
-
.
 T OOTH CURVES I7

Correction s below 30 Teeth — The interference of rack teeth with

low numbered ge r th at is, those be low 30 t eeth— is
-
a s— such th at

cert ain corrections an d adjustments have to be m ade both in the

rack an d pinion teeth Straight faced rack teeth will as previously
.
-
,

st ated cut into the fl anks of the teeth of Sm all pinion s not only
, ,

below the pitch line but to a little dist ance above t hat line So
, .

that al though the straight rack teeth are correct in theory they
, ,

have to be modified in an interch ange able system which has to in

clude pinion s below 3 0 teeth The teeth of the racks are therefore
.

alw ays s lightly rounded o f f using a cutter for 1 00 or 1 3 5 teeth

, .

In the Brown Sharpe system the racks are st ruck with a

slightly rounding f ace as in

Fig 1 8 so that they will

.
,

gear with sm all pinions with

out interference The teeth .

o i the sm aller pin ions a e

r
designed in a m anner which
is b as ed on experiment s
m ade with templet s In .

ge ars bel ow 2 0 teeth a cer

t ain proportio n of the tooth
len gth below pitch line is
m ade parallel ( Fig 1 8) vary .

ing in amount from one thi rd -

to o n e Sixth of the diametral

-

pitch as the gears are l arger

,
Fig 1 7 . .

or smal le r A radius is then

.

t aken from the centre of a tooth to a parallel line an d an arc ,

struck to meet the fi llet h aving a r adiu s equ al to one sixth of the
,
-

widt h o f the Space at the addendum circle as seen in Fig 1 8 ,

. .

If the rule given for st riking the curves of a ge ar above 30 teeth

were adopted in low numbered ge ars the teeth would be too rounded
-
, ,

too n arrow at the point s an d would not t ake much bearing away
,

from the pitch line The curves of the faces of the teeth of the
.

sm all e r ge ars are the refore obt ained by a succession of t angent line s

an d radii as in Fig 1 8 The co struction is simil ar to that which

. . n

would be produced by the unwinding of a co rd Four t angent lines .

are t aken in the fi gu res The successive point s 1 2 3 4 are centres

. , , , , ,

of short radii fro m t angent line to t angent line the arcs of which ,

are a suflicien tl
y clos e a pproxim ation to an involute .

B
18 GEAR CU TTI NG

The foregoing relates to a highly developed system by which

goo d gears can be produce d It has been most exten sively adopted
.

an d is the generally accepted st and ard But it involves the accept

.

an ce of m inute approxim ation s whic h would be elimin ated in a good

g en e r ating system .

The Grant System A nother system which is used to a more

—

limited e x tent is that of George B Grant who fixed the limit of

.
,

a ge ar w ithout correction at 3 6 teet h H e compiled .i n volute

odontograph t ables by st rik ing out ve ry large teeth of about
8 in long
. .

Co rrec tions were m ade by ro un ding the poin ts so that they

Fig 18
. .

woul d cle ar the radial flanks of a 1 2 toothed pinion— the sm all est
-

in the set ; an d cent res we re found by t rial o n the b as e line which ,

would agree with the true involute up to the limit po int an d cle ar
t he corrected po in t The radii are embodied in a t able for given
.

numbers of teeth an d these radii are av ailable for different pitches

,

by multiplying them by the ci rcular pitch or dividing them by the ,

di ametral pitch Two radii are required up to 36 teeth but on e

.
,

curve only afterw ards In this system the rack teeth are rounded
.

of fto a con st ant radiu s for e ach pitch to avoid interference

, .

Fig 1 9 illustrates the n ature of a correction as applied to a 1 2

.

t ooth pinion of 2 pitch an d the t able is given on p 2 0

, . .

The addendum line is drawn outside the pitch line at a dist ance
from it equal to one divided by the diam etral pitch or to one third
, ,
-
 T OOTH CU RVES 19

of the circular pitch The dedendum line is inside of the pitch line
.

by the s ame dist ance The clearan ce line is inside of the dedendum
.

line by one eighth of this dist ance The b ase line is drawn inside
-
.

of the p itch line by one sixtieth of the pitch di ameter

-
.

Ha v ing drawn these lines an d divided the pitch equ al ly t he ,

t ab le is consulted Opposite 1 2 teeth is found the face radius

.
,

which divided by the di ametral pitch 2 gives With the

divi de rs set to this face radius draw the faces of the teeth from
centres located on the b ase line If the number of teeth is gre ater
.

than 3 6 or if the pitch is sm all this face radius Should be continued

, ,

to the base line .

In the t able at 1 2 teeth is found the fl an k radius 96

, .
,

Fig 19 . .

div ided by the diam et ral pitch 2 gives 48 With the dividers set . .

to 48 an d from centres on the b ase line draw in all the fl anks of

.
,

t h e t eeth from the pitch line to the b ase line From the b as e .

lin e continue the flanks of the teeth to the dedendum lin e by

s t raight radial lines an d complete with a radius into the cle aran ce
,

lin e .

To draw the rack draw a straight line at an angle of 1 5 with the

°
,

radius connecting to the centre of the pinion Round the point .

of the tooth from the h al f w ay point a to the point b with an are

-
,

drawn from a centre set on the pitch line with the dividers set to ,

2 1 0in
. divided by the di ametral pitch or 67in multiplied by the
.
, . .

Circul ar pitch .
20 GEA R CU TTING

I NV O L UTE O D O NTOGRA P H .

A A
ST ND RD INTERC HA NG EA EL E TO O TH, CENT R ES ON B ASE L INE .

( By George B . Gra n t )
.

i id
D v e by the Mul tiplyby the
i
D ametra tch l Pi . i
C rcu ar l Pi
t ch .

Tee th .

D ra w t he rac kt o o th by p
the s ecia lm e tho d (p .
 OOTH CURVES
T 21

By methods such as t hese approxim ations to co rrect shape the

,

cutters for system s of ge ars are Shaped Similar approxim ations

.

a re m ade to the double curve or cycloid al teeth

- -
It does not seem
.

necessary to describe these in View of the fact th at they are used

,

to a const antly lessening amount Mo reover the interest in these

.
,

diminishes bec ause of the growth of generating practice Having.

di sposed thus of the subject of tooth curves we will go on to conside r

,

the pitches propo rtions an d v arious dispositions of teeth on thei r

, ,

prim ary or pitch surfaces .

 CHA PTER III
P I TCHES

P ITCHES OR TO O TH CEN TR ES ettlement of so simple a m atter

. The
-
s

as the me asu rement of the cent res of t he teeth of e r w heel s is not

g a

done without vari ations in practice which to say the leas t compli , ,

c ate calculations We fin d four pitches in use the circular the

.
—
,

di ametral the module an d the chord al ; to which may be added that

,

te rm ed the di am eter pitch Each is of v al ue in its own Sphe re ;

.

but e ach must be c ap able of transl ation into its equival ent s in the
other term s The following are the mean ings of these definition s
.
,

an d the s peci al utilities of the di f

fe rent system s
Circular P itch This al so sometimes termed arc pitch is the
—
, ,

division of the circumference of the pitch circle by the number of

teeth in the gear This meas urement therefore t akes pl ace around
.
, ,

the curve of the arc while chordal pitch also b ased on the circ ul ar
, ,

pitch is t aken al ong the chord or Shortest dist an ce between the pitch
,

centres Chordal pitch is rarely used as a b asis of c al cul ation but

.

the chordal thickness of a tooth is an essential measurement in gear

cuttin g an d is t aken account of in me asu ring tooth thicknesses
, .

A rc me asurement the refore being unde rs tood th at t aken round —

the curve an d not al ong the cho rd a Circular pitch equ als the pitch —

di ameter multiplied by an d divided by the tot al number

of teeth or : ,

whe re p = circul ar pitch ,

n = uumber of teeth , 1
) d= p it ch di ameter .

A lso
24 GEAR CUTTI NG

C OM P A R I SO N O F THE D I A M ETR A L MO D UL E A ND , CI R C U L A R
P I TC HES .

C i l Pi t
rcu ar ch C i rcu arl Pit ch .

Mo dul e i
D ame tral
Mod ul e
.

i
P tch .
.

As it is troublesome to h ave fin e fraction al di amet e rs the ne arest ,

even di ameter is general ly t aken an d the pitche s are worked in to

,

suit . Thi s often c auses diffi culty in utilizing exact pitches when
centres are fi xed so th at it sometimes h appens that odd or b ast ard
,

pitches full or b are to exact dimension s have to be tolerated

, , .

D iametral P itch This is the number of teeth which corre

—

s on ds to Tin of di amet e r of the pitch circle

p . H ence if t he pitch .
,

di ameter is divided by the number of teeth in the ge ar the quotient ,

is the di ametral pitch It is al so the module

. .

It is not a dimension st ated in inches or part s of an inch but a ,

ratio Being the number of teeth to an inch of diameter di ametral

. ,

pitches are fractions .

n o
de
'

n o
d"
)

=
W :

n
p d x d
p;

{ d= pit ch di ameter , n = uumber dp= diametral

 P I TCHES 25

Soth at while circular pitch is given in inches an d parts as zin , .

pitch 2 5m pitch etc the di ametral is given by the number which

, .
,

represent s the ratio or number of teeth per inch of di ameter ,

.

2 pitch me an s 2 teeth per inch A wheel 6in di ameter h aving 1 2 . .

teeth would be of 2 pitch .

The Modn le The diametral pitch an d the module are each

.
—

quotient s obt ained by div iding the diameter of the pitch circle by
the number of teeth But while the di amet ral pitch is st ated as a .

ratio the module is given as a dimen sion A lso as the latter is

,
.
,

mo st commonly applied to met ric pitches it h as become generally ,

identified with di ametral pitch measu rements in millimetres See .

the Table p 2 4 This however is not an essenti al distinction

,
. .
, , ,

Since the module is also exp ressed in p art s of an inch an d is thu s ,

embodied in some fo rmulae The di fference between the di ametral .

pitch which is a ratio an d the modul e which is both a ratio

, , ,

an d dimen sion is therefo re a real di ffe rence ; but only one of

, , ,

terms Thus if a gear has say 48 teeth an d the pitch di am eter

.
, , , ,

me asures 1 2in dividing min by 48 teeth gives kin as quotient

.
,
. . .

The module therefore is kin But the di ametral pitch is 4 pitch

, ,
.
,

b ec ause it is convenient to design ate diametral pitches by the de

nomin ato r of the fraction or the reciproc al of the fraction , .

Metric P itches The re ason why the modul e is used much more
.
-

extensively on the Continent th an the di ametral pitch is that measure .

ments are in millimet res an d the millimetre being a fin e dimension , ,

the module is very conveniently exp ressed in millimetres an d

fraction al part s of the sam e Therefore in forming ment al im ages .
,

of these pitches one may work from the ci rcular pitch of a defi nite
, ,

dimension say in inches to the diamet ral pitch which is a ratio

— —
,

only to the circul ar pitch an d to the module which is a defi nite

, , ,

dimension of the di ametral pitch an d related like it to the circular ,

pitch .

These metric pitches are given in modules the equival ents of ,

the B ritish di amet ral pitches only that they are based on the milli ,

metre instead of on the inch A module is the pitch di ameter in .

millimetres divided by the number of teeth in the gear A lso the .

addendum is one module in len g th an d the depth below pitch line ,

is equ al to one module plus the bottom cle aran ce Modules are even .

numbers an d even fraction al ones as 1 mm 1 2 5mm 1 5mm

, , .
, . .

1 7 5mm
. 2 mm etc But the di am et ral pitches which correspond
.
,
.

with them all give un even fract ion s so that the two are not practi ,
 26 GEAR CU TTI NG

c ally translat able . therefore

Simil ar to tho se for n
p d
_
.

p d — n x
'
m ‘

M
m
where
module m
p d pitch diameter ;
n number of teeth .

A study of the figure s in the T able on p 2 4 will Show th at .

neither the di ametral pitch the module nor the circular pitch in
, ,

inches or millime t res agree e ach ent ailing fractions so that they
, ,

are not tr ansl at able into whole numbers for which t he cutt e rs f or ,

di ame tral pitches are m ade .

The P itches comp ared The rel ation s of the circul ar an d dia
—

metral pitches being exactly those of the ratio of circumference

to di ameter or , to 1 a circular pitch o f 3 1 4 1 6in is the
,
. .

equival ent of 1 di ametral pitch or 1 P A n d a ci rcular pitch , .

of 1 in has as its equivalent

. di am etral pitch Hence .
,

the co arser the circular pitch the sm aller is the numbe r which re
presents the ratio oi the di ametral pitch because the co arser pitches ,

w ill not subdivide so much into p art s of Tin of diameter as the .

finer pitches will Thus a circular pitch of 4in co rre sponds with
.
,
.

diametral pitch an d a circul ar pitch of tin with a di amet ral

,
.

pitch of Hence we can usefully remember that high

,

numbers of the latter correspond with fine pitches .

But as the ratio is such th at even numbers c annot be

obt ained by the tran slation of one pitch into the terms of another ,

therefo re it is almost impractic able to work the two in con

junction If the dimensions of one are even then those of the other
. ,

must be fraction al Both diametral an d circular pitches are giv en

.

in in tegers an d in even fractional numbers as hal ves an d qu arters ;

but neither can be translated into Similar even numbers in the other
system . So that cutters m ade for either system c annot be used fo r
the othe r The selection then becomes one of gre ater or less con
.
, ,

v en ien ce .The choice is in favour of the di amet ral because in this , ,

diameters are all even being cal culated di re ctly in terms of pitch
,

an d n u mbers of teet h In the circul ar s ystem on the other h and

.
, ,
 PI TCHES 27

di am eters alm ost invariably ent ail sm all fraction al dimensions ,

be in g cal culated from even circumferences on the bas is of pitch an d

number of teeth This is the real explan ation of the fact th at the
.

diametral system is rapidly displ acing the other But fu rt her the .
,

diametral system Simplifies the proportioning of the teeth bec ause ,

t h e pitch is m ade a b as is for propo rt ioning The length of addendum .

is m ade equ al to one di ametral pitch an d the dedendum also plu s , ,

a b ottom cl e arance equ al to one tenth of a pitch -

.

With regard to the ratio dividing by is the same

as multiplying by bec ause The latter is ,

t h erefore often preferred as a multiplier If the circumference of

, .

t h e pitch ci rcle is multiplied by 3 1 8 3 the product is the pitch ,

di ameter A n d if the circul ar pitch is multiplied by 3 1 83 the pro

. .
,

duct has the same relation to the Circul ar pitch that the di ameter
be a rs to the circumference Henc e the Circul ar pitch multiplied
.
,

by 3 1 83 equ als one diameter p itch an other term which requires —

expl an ation The di ameter pitch e xpresses the modulus or module

.
,

or ratio of the di ameter to the circumferen ce It is the diameter of .

the pitch ci rcle divided by the n irmber of teeth .

Man chester P itch The old Manchester di amet ral pitch used
—

fifty or sixty years ago w as not the same thing as the di ametral
pitch of the present Th at w as wh at we now term the module
. .

If the di ameter of the pitch ci rcle be divided into as m any eqrial

parts as there are teeth in the wheel one of these parts w as termed ,

the diametral pitch (module) ; thus :

D i ameter

A gear in which the relations were 2 teeth to the inch of di ameter

w as c al led 2 pitch ; one h av in g 4 teeth to the inch 4 pitch an d so ,

on In the present diametral system the reciproc al of the old or

.

m odule system is used Thus for ex ample t aking 2 di ametral

.
, ,

pitch which is l in module the g

,
in is dropped an d the denomin ator
.
, .

only is ret ained gin . circul ar pitch

. x .

The following formul ae will afford ex ample s of c al cul ation The .

di ametral pitch as we have said is denoted by the lett e r P If there

, , .

a re 4 teeth to e ach inch of di amete r of the pitch circle the di ametral ,

pitch is 4P To obt ain the circul ar pitch from

. hence
3 4 /4
1.1 6 P = 8
7 54 for the.equiv al ent circul ar pitch Therefore ,

P =4 , an d for the module or one tooth , ,

o r diameter pitch which is u su ally design ated as 3

, A n d conversely .
, ,
28 GEAR CUTTI NG

divided by the module equ al s the number of teeth

o r Tin .

to fl u or the di ametral pitch To obt ain di ametral pitch from .

circular pitch divide

, by the circul ar pitch ,

The simplicity of the di ametral pitch system has not only en abled -

it to t ake the lead eas ily of the circular pitch system but it has re -
,

acted o u the l atter The old sc ales of tooth proportions h ave given
.

w ay to the Simplicity of the di ameter pitch or module for getting

the outside an d root diameters The addendum is equ al to thi s .
,

an d the dedendum al so but plus a root cle arance ,

.

Cho rdal P itch This is hardly ever used now for obt aining the
—

pitch circumference s It is evident that gears in order to imitat e

-
.
,

the action of the smooth fri ction al peripheries of cylinders mus t ,

have their pitches me asured round the arcs of the pitch cylinders ,

an d not al ong the chords The di fference is negligible in large gears

.
,

but it is very apparent in the sm al ler wheels an d pinions an d ,

especi ally in those of co arse pitches But the chord measurement .

is applied to the tooth thickness in cut ge ars in which as there is ,

no flank cle arance at all very slight inexactitude in thicknesse s

,

would either produce engagements too Slack or too tight It is the .

practice therefo re to correct the thicknesses for chord measurement

, , ,

an d eithe r set a vernier c aliper to the thickness or use a s olid gauge , .

Looking at Fig 2 0 the chord dist ance C E is m ade less th an

.
,

h alf the circul ar pitch Thi s mu st be .

so bec ause the chord thickness K I

,
'

meas ured straight across the too th is

less than th at around the arc K D I
of the pitch circle ; an d als o bec ause
the points C an d E will touch the
Sides of the teet h above the pitch

circle bec ause F C= G D an d C E is , , ,

therefore m ade still sm aller than the ,

actu al chord thickness Obviously .

,

too this thickness C E is different even

,

Fig 20
for ge ars of the same pitch but h aving ,

different numbe rs of teeth owing to

. .

di fferences in the cu rvature of their arcs It would not therefore .

, ,

be strictly co rrect to use the same gauge for al l ge ars of the same pitch
from a rack to a pinion Tables are c al culated an d are avail able for
.

the chordal thicknesses of teeth of different pitches an d heights of

am . But practically perfect results can be secu red by using one solid
 PI TCHES 29

ga uge m ade for a ge ar midw ay between a rack an d a Sm all pinion .

This m akes the sm all pinions wit hslightly thicker teeth than st andard ,

an d t he l ar er ge ar s with teeth corre spondingly thinner

g .

Fig 2 1 illustrates the gauges used at the Gleas on Works for a

.

range of gears from 2 D P to 1 6 D P They are m ade from a ge ar

. .

is 7 8 0eiJ
‘
.

"
6 2 01 4 4 57

3 118
‘

14 28
0

”
0 7 14 0 6 25
“

about h alf w ay between a pinion an d a rack tooth If mo re precise

-
.

me asurements are required a vernier as m ade by Me ssrs B rown

, ,

Sh a rp e mu st be set to e ach different ge ar

, The Tables on pp 30 . .

an d 3 1 are given by the fi rm for c alcul ating the chord al thickne sse s

of teeth by both fo r di ametral an d circular pitches

, .

To cal culate the chordal thickness K I of half the circularpitch

an d the len gth to addendum plus H D Fig 2 0 to set the ve rnier by
, .
, ,

Fig 2 2 let :
.
,

T= Cho rdal thickness of tooth K I in Fig 2 0 ,

. .

H= Height of arc or versed Sine H D in Fig 2 0 ,

. .
30 GEAR CUTTI NG
diameter
D = Pitch .

R = Pitch
radius .

A = A n gle = 9o divided by the nu mber of teeth in the ge a r

°
.

Then T= D x Sine of angle A

—
.

H= R x ( I cos of A) -
.

Fig .

CH R O DA L THI C KNESS O F TEETH FO R S UR G EA RS P .

ON A B ASI S or 1 D A MET A L P
I R I TC H .

To o bt i
a n d l thick
cho r a n ess of te eth an d co rre cte d d pth f P i t h Li
e o c ne fo r
an y di m t al pi t
e rach l e ss than 1, di id v e g
fi ures i t bl
n by th di m
a e e a etra l
pi t h q ui d
c re re .

The Gleason Works , R ochester, N . Y .

 CHA PTER IV

T OOTH P R OP ORTIO NS
TO O TH P R OP OR TIO NS the di ametral pitch is Simpler th an the
.
-
If
circular it also Simplifies the proportioning of the teeth The mill
, .

wrights an d p attem mak ers h ave long employed sc ales of propor

tions b as ed upon a div ision of the pitch into a cert ain number of
equal parts an d t ak ing cert ain numbers of these to represent len gth s
,

an d cle arances The old rules m ade the teeth longer th an present
.

practice recogn izes Short teeth are now in .

favour not only as being more in h armony with

,

the condition s of strength advoc ated by Mr

Lo ngri dge but also as being better ad apted to
,

the practice of cutting A lso the adoption of .

the Brown Sh arpe system of cutters an d

proportions has gre atly favou red the movement .

A ll these p roportion s both for circul ar an d ,

.

di am etral pitch are t abulated in columns to ,

facilit ate the Sizing of bl an ks setting up of ,

Fig 23 . .
Fig . 24 .

m achin es an d selecti n f cutt e r The propo rtion s on which these

,
o o s .

Tables are based are as follows illustrat ed by Figs 2 3 2 4 an d

, .
, ,

re fe rence letters .

In Fig 2 3 D is the pitch di ameter an d D the outside di amet er

.
1
.

In o rd in ary ge ars it must be st ated which di amete r is intended .

The pitch di amet er is the p roperon e to give The cent res C of a pai r .

of gears in conjunction with their di ameters give the ratio between

, ,

t he two both as di ameters an d numbe rs of teeth

,
In Fig 2 4 the . .

ci rcul ar pitch is p the tooth thickness t The dist ance between the
,
.

3 2
 T OOTH PRO PORTI ONS 33

SI Z I NG A ND CUTTI NG O F GEA RS .

Nuttall .

D A MET A L P
I R I TC H .

R ul e

Th e Diame Th e Circu ar l
Divide b y t h e Circu ar l
t ra i P it ch Pitch Pitch

T e
h3 p:
t ra
fi r
3 m
?
to
“N
h e r o f Teeth
m
Diame
u m- Div ide Numb er of Teeth b y
P itch Diame ter
.

.
P

Th e O utside Di
Th e Diame n t e n d No
Di v ide Numb e r o f Teeth p l us 2
t ra l P it ch ' ‘
i eg
gm b y O utside Diameter

Pn l
Th e NO ofTee t h Div ide Numbe r o rTeet h b t he
y
Di m a e te r
$ 3g
9
1 pé h
Dia me Diame t ral P itch

Th e No o f Tee t h Div ide th e p ro duct of O utside

.

a n d O uts ide Di Diameter a n d No o f Tee t h b y

ameter No o f Teeth p us 9
l
T h e O utside D i Strbt ract from t h e O utside Di
P i tch ame te r t h e q uot ie n t o f zdiv id
e mote r an d t h e D '
D
Diamet er Diametral P it ch ed b th Diame al
a

y e tr Pitch “

P it ch A dde n dum a n d Mu t ip l y A dden dum b y t h e l

D iamet er t h e No 0 1 Teet h Number 01
.

O ut s ide
Th e N°
° °f Tee t h Div ide Numb e r f Tee th l us 2
o p
D iameter by t h e Diametral
t ral
ii
Gu
a m “ ,
Th e P itch D iar e A dd to the P itch Dia me te r th e
t e r a n d t h e Di
amet ra l P itch
q uot ien t o f 2 div ided b y t h e
Diametral Pitch
" ”

Th e P itch D iame Div ide th e No o fTee th pl us 2 b y .

ter an dt h e Num t he uotien t of No o f Tee th .

ber of Teet h di vi ed b y Pitch

Mul t ip ly th e Number of Teet h
p l us 2 by A dde n dum .

Mul tip l y P itch Diameter by t he N a DP

’

Diametral P itch
D
"

Mul t ip l y O uts ide iameter b y

th e D iame tral Pitch an d sub

Th ick n ess Th e Div ide b y th e Diamet ral

O f Too t h P iwh o e s o 0 a t o oooooo
Div ide l by t h e Diamet ral P itch
Th e Diame t ral D 1
A dden dum
Pitch 01 8
’
ooooooooo d o

N
Th e Diamet ral Divide b y t h e Diamet ra l
Pitch P itch

Th e Di‘ me t‘ '
t iitch
‘vo r ‘
ep th
g Div ide 2 b y th e Diame tral P itch

Who l e Th e Diamet ral Div ide b y t h e Diame t ral D

I

De p t h Pitc h P itch . o o o o o o o o o o o o o o o o o o o o o o o e 6 0

Th e Diamet ral Divide . 157 b y t h e Diame tral

P itch

Cl e aran ce Thick n ess o f

Too t h
34 GEA R CUTTING

C I R C UL A R P ITC H .

Nut tal l .

To Get Havin g R ul e. Fo rmula .

Th e Circul ar 3 by t he D ia n e
The Diame tral P itch
P it ch
.
.

Th e P itch Diame ter D iv ide Pitch D iame te r

The Circular
t
an d t h e-Numb er o r M il ot o f 8 183 an d Num .

ccal
0

The O utside D iame Divide O utside Diame te r by the

Th e Ci rcula r te r a n d t he Numbe r roduct o f 3 183 an d Numb e r o f P
'

g
.

P itch o f Te eth eeth pl us 2

.

The Numb er ofTee th

P it ch
Dla meter
a n d t he Circul ar D '
=Nl "
. 3183
.
P itch

The Number ofTeeth

P itch
an d the O utside D i
Diamete r
a ms ter
.

The O utside Dis me Su btract fro m t he O utside D iame

t e r t he p roduct of th e Circula r D =D
P itch ter a n d the Circul ar
'

Diame te r .
P itch P itch an d 6866 .

P itch A dde n dum an d the Muit ipl t he Numbe r or Teet h by

Diame te r . Number o f Teeth . the A den duni

The Nii mb er o t Tee th The co n tin ued p roduct o f t he

O utd de
D iameter
an d t he Circular Numbe r o f Teet h p l us 2. t he
.
P it ch Circula r Pitch an d 8 183 .

The P itch D iame te r A dd to t he P itch Diamet er the

O utside
D ia mete r
an d t he Circul ar p ro duct o f t he Circul ar P itc h
P itch an d 6366
.
.

O utside The Numbe r o i Tee t h Maitl i A dden dum 1»I Numbe r

N M)
D iamete r an d t he A dde n du
. m oi e gth p l iis 2
D— N-

The P itch Diameter D iv ide the p roduct of P itch D iam

Number o f N
.

an d t he Ci rcul ar e t er a n d by the Circular

Tee th .
P itch P itch

Thick n e ss
oi Toot h .
Th e Circular P itch . O n e-hal f the Circular Pitch

Mul tiply the Circul ar P itch by

A dde ndum The Circular P itch =P
8 183 . o r s =
g
'
. .

.
- a . 3 183

M ‘ ‘ ‘Y “ w “ m m" ” m" by
T he Circular P itch .
gf
g g

Workin The Circular Pitch .

"
M ”W
O O
“m
O 0
u"
O O
P M"
O O
by
O
D '
=P ’

. 6366

“ 3" " w C mf ‘" =P

3 f
Wh ol e Depth P ‘fcl by
2 j D +f 6866
'

The Circula r Pitch

"
.
. .
. .

Cl earan ce . Th e Ci rcularP itch . Mul ti pl y the Circular P itch by . 05 i

‘
P 05 .

O ne te n th the Thick n ess of Tooth

Cl earan ce Tuck u "
.

at P itch Lin e
.
 TOOTH P RO P O RTIO NS 35

TO O TH P RO PO RTIO NS .

( D IA METR A L P i TC ii .
)
B row n 62 Slzaq ie
°
Man ufacturi ng Comp any .

A dd d um
en
Who l e D e p th
o fTo o th .
.
3 6 GEAR CUTTING

pitch di ameter D an d the out side of the tooth is the addendum 3 or ,

face Twice the addendum equals the wo rking depth d of tooth

.
,

an d the working depth in side or below the pitch ci rcle is the flank .

The Cle arance c at the bottom added to the wo rki n g depth equals , ,

t he whole depth d of the tooth which is the d e pth to which t he

‘
,

cutter is set to wo rk The addendum 3 is a ve ry useful number in

.

the diametral pitch system bei n g equ al to one diametral pitch so

-
, ,

th at to get the out side di ameter it is only necessary to add two to

the number of teeth an d divide the sum by the di ametral pitch ,

which is simpler th an consulting a t able of p ropo rtions of tooth

p art s Messrs B rown Sharpe c all the addendum a diameter pitch
. .

It is equ al to a circular pitch multiplied by The clearance

is proportion al to the pitch being { 6 o f the thicknes s 15 of the tooth
,

at the pitch line Having ratio given to find t he pitch di amete rs

.
,

D ivide the Centres by the sum of the t e rm s of the ratio Twice .

the quotient is multiplied by each term sep arately an d the two p ro ,

duct s will be the pitch di ameters of the two wheels .

The two t ables on pp 3 3 an d 34 give both in wo rds an d formul ae

.

the rel ation s of the st and ard (B S ) tooth p ropo rtion s fo r di amet ral . .

an d Ci rcul ar pitche s To save the l abou r of c alcul ation t ables are

.
,

provided by the gear cutti n g firm s fo r all the ordi n ary di amet ral an d
-

Circul ar pitches Th at on p 3 5 is for the first n am e d

. . .

The gi o up s of Figs 2 5 2 7 illu strat e to actu al size teeth of the

,
-
, ,
-

commonest di ametral pitches to the B rown Sh arpe proportion s .

Gear R ules To lessen the ch ance of erro r in sizing bl anks is

—

the object of these rules They are divided out like sc ales in.

several lines of divi sion s to corres pond with di am et ral pitches ,

Fig 2 5 showing on e line o r divi sion only for 5 pitch Thus

. .
,

a rule by the B rown Sh arpe Manufactu ring Co h as fou r li n es .

of gradu ations on e ach side n amely I8 20 2 2 2 4 2 6 2 8 30 —

, , , , , , , ,

an d 3 2 p a rt s of an inch runni n g along a len g th of min A s the .

addendum di am ete r of a whe el is equ al to two di am et ral pitche s ,

all th at is necessa ry is to me asu re o f f the number of teeth 2

on the line of divisions which corre sponds with the di amet ral
pitch Thus if a wheel is to h ave 2 0 teeth of 1 8 pitch 2 2 part s
.
, ,

will be me asu red o ff on the rule bei n g 2 0 for the pitch di amete r , ,

an d 2 for the addend a .

A nothe r rule of the same len gth includes a l arger numbe r of

divisions by gradu ating Iin only from e ach end the inte rmedi ate
,
.
,

Toin cont aining Iin divi sions ru

. led ri ght across These numbers
. .
GEA R CUTTING
4 0 GEA R CUTTING

include 6 7 8 9
, , , , 1 0 , 1 1 , 1 2 , 1 4 , 1 6 , 1 8 , 2 0 , 2 2 , 2 4 , 2 6, 2 8 , 3 ,
0 3 ,
2 34 ,
3 6 an,d 3 8 p t of an inch The large numbe rs are t ak en on the
a r s .

inte rmediate inches an d the sm all on es on the divided inches

, ,

simil arly to drau htsmen s sc ale s Thu 6 tooth wheel of pitch

’

g s a 2 1 0 -
.

would have 60 me asured on 6 plain inches an d the two p arts on ,

the divided inch on the line divided into tenths of an inch Other
, .

rules are also m ade with v arious other graduations .

Steel gear gauges (Fig 2 9) are m ade in which the trouble of

.
,

c alculating depth an d thickness of tooth is saved The gauge .

resembles a disc wire gauge the place of the notches being t ak en ,

by teeth cut around its edges in sets of two or three of each diametral
,

pitch so that there are several pitches in the circle of each separate
,

gauge It is a convenient arrangement bec ause the depth an d

.
,

width of tooth can be m arked on a bl ank ; an d a wheel when cut or ,

Fig 28
. .

partly cut can be t ried with the teeth on the gauge when an y
, ,

in accuracy will be apparent .

C han ges P rop osed The ordin ary or st and ard p roportions give
—

one module as the length of addendum an d one for the dedendum .

The st andard angle of pressure is Out of this to some extent

a rises the ques tion of len gt h of tooth The longer the addendum .

the more prolonged the cont act but the gre ater the influence of ,

the undercut in sm all pinion s ( Fig T0 lessen this is the object of .

the stub tooth proposed by Mr Fellows with a 20 pressu re angle ,

°
,

an d an addendum equ a l to three fourths of the module Mr Wilfred -

.

Lewis proposes a 2 2 3 pressure angle an d an addendum of seven

°
,

eighths the modulu s .

Wh at the present 1 4 5 of an gle en t ails in sm all pinions has bee n

°

shown in Ch apt e r II The shape of the teeth of every rack an d every

.

sm al l pinion involves a dep arture from strict theory a compromi se ,

m ade to get either a smooth gear or a stronger tooth th an the rigidly

generated form would yi eld R ack teeth are rounded slightly the .
,

addend a of pinio ns are len g t hened an d numbers of modi fic ation s ,

n an d dep artures from the theoretical forms arise A higher angle

,
.
 roo m PROP O R TIO NS 4 1

of pressure avoids these m akeshifts pe rmitting correctly generated

,

form s to be adopted without exception s It may be increased to .

18, 20 , o r 2 5 degrees B ut the highe r the angle the stronger

.

the roots of the sm all pinions become This fe ature is one of much
.

value in most feed an d Speed

Ch ange ge ars If there were no .

sm all pinion s no trouble would

occu r But as they are in .

regul ar dem and a sound re as on

e xi st s why the b as i s should be

such as to include them leg iti

m ately instead of ret aining an
u n satisfacto ry b ase an d mak
ing corrections for the sm al l
pinions .

A lteration s in P ressure
The 1 45 angle system
A n gle —
°

Fig 29
. .
can be ret ained without the
modific ations in construction
for ge ars below 30 teeth by incre as ing the di ameter of the blank .

This t akes advan t age of the fact st ated p 7 that the essenti al ,
.
,

basis in the involute curv e is not the pitch circle as it is in the ,

curves of the cycloid al gears but the b ase circle since on this the
, ,

curves are generated Hence the rel ative positions of the base an d
.

the pitch circles can be

v aried without affect
ing the accuracy of the
engagement A n dthus
.

by enlarging the blank

the lengt h of adden
dum is incre ased an d
th at of the dedendum
dimin ished In other
.

words the tooth faces

,
F ig 3 0 .

are len gt hened an d the

fl anks are shortened This is sometimes done of necessity but
.
,

it is another c as e of a compromise inseparable from a low

angle of pressu re rigidly fi xed Fig 3 1 shows for comp arison
. .

the undercut of a sm all gear A of pressure an gle the effect of

, ,

increasing the addendum on the sam e gear at C an d the resul t of ,

4 2 GEAR CUTTING

altering the pressure a ngle to 20

°
at B , without a ltering the
addendum .

Shorten in g of Teeth — If in addition to the alteration in angle

, ,

the teeth are shortened the diffi culties inseparable from the present
,

st and ard s s tem v ani sh The c e not perh p s trong for the
y as . 18 a s s o

short tooth as for the ch ange in angle but it has m any advoc ates ,

an d is adopted rather exten sively in speci al practice The differ .

e nce between the two is seen in Figs d 33 In Fig 3 2 the pr es

3 2 an . . .

su re angle is an d the teeth

are of ordin ary len g th The arc .

of cont act A is long extending ,

from a to b being nearly as long ,

as the arc of action B an d the .

sliding an d rubbing action which

occurs during appro ach is pro

longed In Fig 3 3 the pressure . .

angle is 2 0 an d the teeth

°
are

shortened The result s are th at .

the arc of cont act is reduced to A

extending from a to b only while ,

t he arc of action extends to B .

Ge ars cut on thi s system may still

utilize the t ables of st andard tooth
propo rtions but the pitch depth ,

Fig 3 1 . .
is selected from a di ametr al pitch
different from that of the pitch to
be cut Thus a Io pitch gear is tu rned as for a 1 2 pitch gear
.
- -
,

being one of two pitches sm alle r .

Hence
Di amet ral pitch 4 5 6 7 8 _9 _
IO 1 2

P itch dept h 5 7 8 9 1 0 I I 1 2 I4

Some abnorm al spur pinions cut on t he Fellows ge ar sh ap e r

illustrate in an instructive W ay the f act th at the le ngth of addendum

need not be const a nt in wheels with involute teeth ge aring together

correctly as it must be in cycloid al teeth Three bl anks were cut :
,
.

one of the correct di am eter for 2 4 teeth one for 2 6 an d o n e for 2 3 , ,

.

Each however w as cut in the gene rating ge ar cutter with the index
, ,

m ech a nis m set for 2 4 t eeth an d e ach therefore whe n in ge ar re

, , ,

volve d at the same speed an d each ge ared correctly with the other
,
.
 roo m P R O P O R TIO NS 43

The expl an ation is to be found in the difference between pitch sur

f ace a n d b ase line The le ngth of adde ndum w as differe nt in each
. .

I n the l argest wheel it w as gre atest the teeth being nearly all
,

face s in the sm allest it w as le ast the teeth being ne arly all

,

fl a nks .

Objection s to Chan ge Much discussion h as t aken place in recent

.
—

ye ars on the rel ative values of longer or sho rter teeth The adv an .

Fig
. 32 . Fig 3 3
. .

t ages on the whole seem to be in favour of adopting teeth shorter

, ,

th an those which are at present st andardized B ut the gre at ob .

je ct io n to ch ange in thi s respect as in pressu re angle s is the immen se

, ,

vested interests sunk in theenormous stocks of cutters c arried in the

s hops as well as the nece ssity for renew als of ge ars to engage with
,

those already existi n g in thousands of m achines .

The stock of single disc cutters c arried in a l arge est ablishment

is immen se .Every sep arate pitch must h ave its set of cut ters an d ,

for some pitches more than one set when the work done is extensive .
44 GEA R CUTTIN G
B esides these there are the numerous stocking or roughing cutters .

Mo reover the 1 45 pressure angle has been adopted for so long a

,
°

pe riod th at the substitution of anothe r angle would for a long whil e

ent ail the use of both the old an d the new New gears would often
.

be requi red to engage with existing ones an d until these were wo rn

.

out or scrapped the two system s would have to be run side by side .

The attempt therefore to substitute another st an dard for gears would

not only fail to comm and general approval from the m anufacturin g
point of View but it would cover a wide deb at able fi eld It is even
, .

open to discussion whether a univers al system is desirable The .

subject is not on a p arall el with th at of screw thre ads or rail s ection s

or of m an y other products which are st andardized St andardization

.

is desirable in some things but it m ay not be so in all

, . P erh aps th e
teeth of gears are an exception .
 CHA PT ER V

GEA R S RELA TED To THE SP U RS

GEA R S w hich are rel ated to the spurs include racks intern al ,

gears spirals helicals an d worms The teeth of e ach of these

, , , .

are derived directly from the strai ght rack tooth an d e ach has ,

teeth of parallel section throughout .

In tern al Gears These are designed as though the teet h were those
—

of an extern al wheel but the di fference is th at the met al is ju st

,

reversed Th at is (Fig . the teet h of the cycloidal Spur wheel A

.

would fil l the tooth Sp aces

in the intern al wheel B of ,

t h e same size an d vice ,

versa The only mo difica

.

tion is that t he point an d

ro ot cle arances are reversed .

The drawing is m ade as

for the wheel A For the .

Fig 3 4
intern al gear B the flanks
. .

o f B woul d be deepened an d the faces shortened in rel ation to the

pitch line .

The Tooth Forms In the c ase of an intern al involute wheel

.
-

( Fig . the point s of t he teeth c annot a ct beyond t he interference

l imit line of the p air an d they m ay therefore be either cut o ff eu
,

tirely as in the figure or well rounded o fi to cle ar an d the pinion

, , ,

teeth be deepened But as there can be no mesh bene ath the limit
.

line thi s altern ative is merely a m atter for t aste an d good appe ar
,

ance In practice the conc ave form is often dep arted from the
.
,

teeth being cut with the flattest cutter of the set (No I) used for .
,

wheels of 1 35 teeth to a rack .

These general principles are not of universal applic ation except

ing to gears in which there is a l arge v ari ation in the sizes of wheel
an d pinion as there is in the gre ater number of inst ances
,
Intern al .

cycloidal st and ard gears are m ade upon the same b asis as Spur
g e ars of t he same size only so long as the re is a di f ferenc e of 1 5
,

teeth o r more between the wheel an d pinion Thus a pinion of .

,

45
4 6 GEA R C UTTIN G
15 t eeth would engage with an annular ring of 3 0 teeth but ,

a p inion of 2 0 teeth would not on the st andard b as is of a 1 2

,

toothed pinion It is necessary therefo re to t ake a new b ase as

.
, , ,

sm all as the di fference between the whee l an d its pinion ; in the c ase ‘

of the 30 an d 2 0 teeth pair a b ase O f IO teeth or less The tooth

, .

cu rves would therefore be obt ained by a gene rating ci rcle of the same
di ameter as or less than the radius of a To toothed pinion This is a
, ,
-
.

general st atement of the prin ciple suit able fo r p ractic al work though ,

the subject itself would admit of wider treatment A ctu all y the inter .
,

feren ces which have to be gu arded again st in the c as e of l arge pinions

are sometime s got over ne atly an d f ai rly effi ciently by adopt ing the
knuckle gear which only gives t rue cont act on the pitch line
,
.

These intern al gears therefore st and alone an d the rules by

, , ,

which the construction of

Spur ge ars are gove rned

a re not regarded in these .

Out side the c as e of pin

ions an d wheels which are
l argely diSpro po rtio n ate
in dimensions every pair ,

of ge ars must be dealt

with individu ally on its
Fig 3 5
own merit s .

There is no re al difli
. .

culty in designing teeth for gears of low ratios ; but it is

usu ally better to st art ab in itio In double cu rved ge ars a basis
.
-

can be t aken by employing a gene rating circle h aving a definite

relation to the pinion as say one h aving a di ameter equ al to

, , ,

its radiu s o r l arger if Sp re ading fl anks are desirable

, , Then the .

tooth cu rves of both pinion an d ge ar can be obt ained directly an d

accurately In a pair of involutes the st andard pinion being t aken
.

as a b ase if the di f
, ference in the number of teeth of pin ion an d ge ar
equ als the number of teeth in the b ase pinion the gear teeth cu rves ,

can be tho se which correspond with the st and ard cutters Thus .

though a 1 5 toothed pinion would mesh with a 3o toothed intern al

- -

ge ar if the Sh ape of the teeth corresponded with the tooth Spaces of

,

a 3o toothed spur m ade to a st and a rd cutter f

-
o r th at n umbe r if the ,

pinion has a larger number of teet h then a construction must be ,

m ade Speci ally to suit it The pinion teeth as sh aped with st andard
.

cutt ers may b e t aken an d the teeth f the ge ar simil arly an d

,
o ,
4 8 GEA R CUTTIN G
This ge ar is used chiefly in c ases where motion has to be trans
mitted through Sh aft s which are not in the s ame pl ane an d for ,

which bevels would be unsuit able They may be regarded as .

Spur ge ars with Sh aft s at an angle the teeth be ing twi st e d to suit the
,

angle . Ge nerally the Shaft s are at right angles an d the numbers

.
,

of teeth are equ al But the numbers are also often unequ al an d
.
,

the shaft s may be v aried in position from They are preferred

to worm ge ars when the velocity ratios are alike or not very dis ,

simil ar being less diffi cult to construct th an worm gears of high

,

angles an d m any thre ads Since the Speci al ge ar cutting m achines -

h ave come into gene ral use the manufactu re of spiral gears has been
.

est abli shed on a better comme rci al b as i s th an hitherto an d l arge ,

numbers of these are the refore employed Man y are now hobbed
,
.

inste ad of being milled with single rot ary cutters .

Spiral ge ars can be m arked out an d dimen sions obt ained graphi
c ally or the various rel at ion s can be got by c alculations The first
,
.

is the older the second the alm ost general practice now
, The pro .

portions of the teeth are the same as those used in st andard Spur
gears the tooth propo rtions an d cutters being selected for the norm al
,

pitch .

The elements in a Spiral ge ar ( Fig 3 7) are the circul ar or real .

Fig . 37 .

pitch 0 1L which multiplied by the number of teeth gives the

, .
, , ,

pitch circumfe rence of the ge ar the an gle 0 of the teeth or screw

,

which screw in m aking one tu rn round the cylinder gives the

adv ance or le ad L the norm al circul ar pitch n p or shortest
, , . .
,

dist ance between adj acent teeth or th reads for the section of ,

which the cutter is selected an d the divided lead or axi al

,

pitch up The rel ations of the circular an d norm al pitches an d

,
.

the angle included between them are the mo st import ant elements .

Norm al pitches are c alcul ated on a b asis either of circul ar pitches or

of di amet ral pitches .

The A n gles ofSp irals In the m ajo rity of inst ances Spiral ge ars
—

are u se d t o tran smit e qu al rate s of rev oluti on at ri gh t angle s in ,

 GEA R S RELA TED TO THE SP URS 49

which case the angles are 45 (Fig 38) an d the numbers of teeth are
°
.

equal in both ge ars But ratios up to 2 an d 3 to 1 are frequent

. .

Then the diameters of the gears an d the leads of the screws w ill be
in the same ratios If the ratio is 2 to I ( Fig
. the di ameters an d .

the leads will be as 2 to 1 The norm al pitches are alike an d the

.
,

circular pitches are alike bec ause the t angent line T m akes equ al
,

Fig 3 8
. . Fig
. 89 .

a ngles with the axes of the gears In Fig 40 the elements of the . .

two gears are shown developed 0 is the circumfe rence of the wheel .

in Fig 3 9 c that of the pinion a j> the tot al axi al pitch or lead of
.
,
l
, . .

the wheel ca p th at of the pinion The angles are simil ar in e ach

,
}
.
,

as are the circul ar pitches an d al so the norm al pitches rap

, ,
.

Cutters will be selected to correspond with the numbers of teeth

in each .

Velocity R atios Such ge ars transmit unequ al velocity rati os ;

-

but the axes also of Spiral gears for imparting either equal or unequ al
velocity ratios may be either at right or at other angles The angle .

included between the axes whether of 90 or less must be bisected

,
°
,

in the ratio of the ge ars equ ally fo r equ al ratios unequally for other
, ,

ratios.

Unequ al velocity ratios are obt ain ed by varying th num ber s e

of teeth The di ameters may or m ay not be al tered correSpon din gly

. .

A condition of ge aring is th at the t angent p assing through the pitch

point common to the helices of both gears corresponds with the line
of bisection which corresponds with the ratios of the gears If this
,
.

is at an angle of or m akes an equal bisection in the cas e of an y

D
50 GEA R C UTTIN G
other angle th an th at of the di ameters will v ary exactly as the
numbers of teeth as in Figs 3 9 an d 40 But if the diameters are
,
. .

t he same but not the numbers of t eeth the t angent line an d line
, ,

of bisection of the an gle will be in the same ratio as the numbers of

teeth The pitches of the Spirals or thei r le ads will also be in pro por
.

tion to the numbers of teeth Thus ge ars of 2 to 1 would have the

.
,

angles of their axes bi sected in the p ropo rtion of 2 to 1 ( Fig an d .

Fig 4 1
. .

Fig . 40 .

the axial pitch or le ad of the fi rst would be twice the

,

lengt h of that of the second In Fig 42 the angles 0 of the

,
.

Spiral s corre spond with tho se in Fig 4 1 an d the ci rcumferences c c

.
, ,

of the two gears are alike The no rm al pitches n p are also alike
.
,
.
,

but the circular pitches c j> an d

, . .are in the ratio 2 to 1 In .

s uch c ases t he ge ar w hich h as the shorter l ead an d the co arse r

ci rcul ar pitch drives .

D iameters
. The angles of the Spirals are gove rned by the
—

di ameters as well as by the leads For given equ al lead the sm aller
.
, ,

the di ameter the less is the angle For equ al diamete rs the longer
.
 GEA R S RELA TED TO THE SP UR S SI

the le ad the less is the angle These are the rel ations which are .

use ful vari ables in obt aining velocity ratios while norm al pitches ,

an d their tooth proport ion s rem ain un af

fected .

The spiral gears are thus an example of ge ars where the velocity
ratios do not except in the c as e of those with 45 of angle depend o n
,
°
,

di ameter but on numbers of teeth only We have seen th at gears

, .

o f the same diameter can h ave velocity ratio s of 2 to 1 Foll owing .

the an al ogy a Spi ral gear may be regarded as a coarsely pitched

,

worm as the worm too may be con sidered a short Spiral of fin e lead
, , ,
.

A n d again the di ameter of a worm has no influence on the velocity

, ,

o f its worm wheel The number of its th re ads is the determining

.

element as is the number of teeth in a Spiral ge ar

, .

Fig 4 2 . .

R elation s with the Rack nother relation is that of the rack

.
— A
wh hic whether tr ght or kew is a Spur or spiral gear respectively
, s ai s ,

unrolled an d laid out in a plane Hence either form of rack will .

,

ge ar with a Spiral ( Fig In these c as es the common t angent

.

pas ses al ong the teeth of the rack an d of the tooth of the wheel in
cont act through the pitch point A rack an d a spiral gear both of
,
.
,

45
°
of a ngle will work at 90 with
,
norm al pitche s al ike an d circul
°
a r ,

pitches alike an d the rack is a 45 gear laid out flat When a

,
°
.

s qu are rack engages with a Spiral ge a r the common t angent mu st

m ake unequal angles with These ge ars then come under the
cl ass in which the circul ar pitches are unlike .

Grap hic Methods Graphic methods of obt aining t he rel ation s

.
—

of Spiral gears are adopted When c alculations are m ade it is safe r

.

to supplement them with a proportion al di agram in order to check

the figures In the foregoing developed di agrams the le ad or to tal
.
52 GEA R C UTTIN G
pitch of the Spiral is the base the circumfe rence of the cylinder
,

round which the Spiral is laid is the perpendicul ar an d the ,

h ypotenu se is the angle of the Spi ral .

The pe rpendicul ar divided by the number of teeth gives the

Circul ar pitch The b ase divided by the number of teet h gives the
.

pitch me asured along the ax is the divided le ad or axial pitch

, , .

The norm als to these divisions give the norm al pitch Hence from .

two elements the third can be obt ained thus ,

To fin d the angle of Spiral for a given axial pitch or lead an d

perpendicul ar (circumfe ren ce) : Draw the axial pitch as a hori
zo n t al an d the circumfe rence as a perpendicul ar an d connect with ,

a hypotenuse The angle which the l atter m akes with the hori
,

zon tal is the angle of Spiral If this angle is given an d the ci rcum
.
,

fe rence draw the perpendicul ar equ al to the Circumference an d the

, ,

hypotenuse to the an gle with the horizont al an d the lengt h where,

t he horizont al meet s the hypotenuse is the axi al pitch or le ad A lso .

the Ci rcumference or perpendicular divided by the b as e gives the

t an gent of the angle of Spiral The perpe ndicul ar divided by
.

the t angent of the angle gives the axi al pitch or le ad of the Spi ral .

A n d the t angent of t he an gle multiplied by the pitch or le ad of

the spi ral gives the circumfere nce or perpendicular .

Spiral ge ars h aving axes which are not at right an gles can h av e
equ al or unequ al ratios as seen in Figs 44 an d 45 respectively In
,
. .

Fig 4 3
. . Fig
. 44 . Fig . 45 .

rst the angle included between the axes is equ ally bi ected
th e fi s
,

forming a t angent line common to both gears Here the Ci rcul ar .

pitches are alike In the second the angle included between t he

.

axes is bisected in the unequ al ratio s desired Here the Spirals are.

of unequ al an gles an d the Circular pitches differ

, .
 GEA R S RELA TED TO THE SP URS 53

G en eral F mn lw
or For Circular P i h tc es — . Having the real Circ ul ar
pitch an d angle of Spiral given to obt ain the norm al circular pitch
,

Multiply the circul ar pitch by the cosine of angle of spi ral or : ,

c p x cos 0= n c
p .

Note .
— ngle of spiral with ax is is al ways understood
The a .

Ha ving the norm al pitch an d an gle of Spiral given to obt ain ,

the circular pitch : Divide the norm al pitch by the cosine of the
an gle o rz
,

To obt ain pitch di ameter

Number of teeth x Circul ar pitch
Pi tch di ameter

To obt ain the whole di ameter of bl ank

A lso when t ables are available for the addenda of teeth from ,

t hese the whole di ameter is obt ain ed thus ,

Whole di am eter P itch diameter 2 addendum .

For Diametral P itches Having the norm al di ametral pitch

.
—

an d co sine of angle of Spiral to obt ain the Ci rcul ar d

, iametral pitch :
Multiply the norm al di ametral pitch by the cosine of the angle orz ,

cd p = n (i
f x co s 0
.

Having circular di ametral pitch an d the angle of Spiral to

the ,

obtain the norm al diametral pitch : Divide the circular diam et ral
pitch by the cosine of the an gle of Spiral or : ,

0d
M _ ?5
” — ‘

a
‘

c s o

To obt ain pitch di ameter

Number of teeth
Number of teeth
n d p x cos 0
To obt ain the whole diameter of blank

Depth of tooth
54 GEA R C UTTING

The circular di ametral pitch as in Spurs is the number o f teeth

, ,

divided by the pitch di am eter A n d conversely the pitch diameter

.
,

multi plied by the Circular diametral pitch gives the number of teeth .

The no rm al diametr al pitch in 45 Spiral s is alw ays °

:

Circul ar di ametral pitch

n d P
being the cosine of the angle
The norm al diametral pitch for an y other angle with , the ax s e
at right angles which occurs in ge ars of e qu al si zes is
, ,

Number of tee th
P itch di am eter Co sine of angle
x

o rz

ircular di ametral pitch

C
Cosine of angle

In a angle Spiral the le ad is the sam e as the Circumference

°
45 .

Hence :
Lead= Pitch di ameter x

i
In gears ofan y other angle the axes being at r ght angles :
,

P itch di ameter x

T angent of angle
( In an ang le of 45 the
°
t angent of the an gle is

The relati ns may be summ arized

o

If N= uumber of teeth ; N c p =c1rcumferen ce of pitch Circle

x .

Nx n c p
x co s 0

N
x
co s o n dp n ap cos 0
A nother method of c al culating is to use a Table of Sec ants , as

below
Sec ant x
Ci rcul ar p“Ch
Norm al di ametral pit c
h

P itch di amete r
P itch di ameter
Norm al di am etral pitch
56 GEA R CUTTIN G

cos o
p= c p cos 0

n d ( pitch of cutter)
B — D
2

D + f= 2 s +

1
00 2 3
a
( cutters of regular B rown Sh arpe involute system )
_N Cp N qr _ N n CP
1
t an 0 t an 0
'
P
t an 0008 0
’

The cutters in the B rown Sh arpe system are given at p 80 . .

Helical Gears These are essenti ally Spiral gears of l arge di amete r
.
—

an d long le ad In the helic al pinions the spiral fo rm is very obv ious

. .

The relation is cle ar in Fig 4 6 in which the teeth of the double

.
,

io —A A

Fig 4 6
. .

helic al pinion of width A if prolonged are true Spiral s of lead L

, , .

In helic al ge ars the axes are p arallel an d the action of the teet h
wholly rolling ; in Spirals the axes are at an angle an d the action
wholly Sliding Comparing helic al ge ars with the spurs which they
.

suppl ant rollin g cont act of the teeth is sub stituted for the cont act
,

which is mainly of a Sliding ch aracter in common Spur gears In .

these the only roll i n g cont act which occu rs is at an d ne ar the pitch
line The intensity of the Sliding action incre ases in proportion to
.

the dist ance of the parts in cont act away from the pitch line .

A t the b asis of the helic al teeth is the old stepped ge ar in which

the length of a tooth is cut into steps in order to reduce the amount
of sliding action by dividing it between the steps Obliterating the .
 GEA RS RELA TED To THE SP UR S 57

angles of the steps gives the Spiral form of tooth which wil l engage ,

with a ge ar of the sam e angle of Spiral an d pitch but of O ppo sit e ,

han d Theoretically an y angle will be suit able but In practice high

.
,

angles are objection able for several re as ons Fig 47 shows a gea r . .

w ith teeth at angles of 4 5 with the axis Fig 4 8 one with 30 of

° °
.
,

angle an d Fig 4 9 one wit h 2 3 of angle e ach of which accords with

°
.
, ,

common practice In the high angled gears the .

-

diffi culties of ensu ring correct cont act are greater

th an in those h aving lower angles an d the lon gi ,

tudin al thrusts must be more n icely b al an ced A .

l arge angle weakens the norm al section of the teeth

an d produces a more wedge like action -
.

Essenti ally the gre at adv an t ages which the

helical teeth have over the straight teeth of Spur
gears are that the friction of Sliding cont act is

Fig 4 7
Fig 4 8 Fig 4 9
' °

. . . .

eliminated an d that the whole pressure due to the lo ad on the gears

,

never comes on one edge of the tooth but is distributed over other
portions .

The action being continuous pinions can be used much sm al l er

,

than for Spur gears The action being that of rollin g m ainl y in
.

ste ad o i Sliding combined with rolling the lo ad is trans ferred fro m ,

tooth to tooth without Shock Even if the teeth are not stronger
.

than those of similar pitches in Spu r gears the elimin ation of Shock ,

an d the fact th at a po rtion of the lo ad is alw ays being born e at

an d ne ar the pitch relieving the pressure on the point s averages the

, ,

pres sure on the teeth .

A result is th at teet h of the same pitch as Spurs can be more

seve rely lo aded an d ru n at highe r Speeds with less vibration an d ,

noise If accurately cut the f ullest use may be m ade of sm all

. ,

pinions of hard steel to en su re equ al we ar with the wheel This .

is impractic able with Spur ge ars in which sm all pinion s produce ,

shocks vibration s an d v ariat ion s in p ressure in the line cont act s

, ,

fro m poin ts to roots This is the re as on why raw hide gears are
.
-
58 GEA R CUTTING

freely used to reduce noise an d lessen Shock Well m ade double .

-

helic al ge ars will secure equally good or better results w ith smal ler
pinions .

Generall y when helic al ge ars are now mention ed the double

, ,

helical form is understood The single ge ars are used extensively

.
,

especi all y on some Continent al m achine tools B ut there is an .

endlong thrust on these which is objection able an d which is ,

absent from the double form w hen correctly m ade in which the ,

thrust in one di rection is neutral ized by that in the O pposite

w ay . But here the difli culties of m anufacture come in which ,

are discu ssed at p 8 5. .

The W st Gears
a D im ensions propo sed for an interch ange able
-

system for the Wiist e r re as follows :

g a s a

Tooth Shape l nvolut e .

P re ssure angle 2 0 deg .

Spiral angle 2 3 deg .

Numbe r o f t eeth
P itch di ameter 2 0 teeth an d over
( ) I) I
Number f t eeth L 6
Bl ank di ameter teeth an d over)
(20
BI
—
D

Nu teeth )
gg
x erO f
P itch diameter ( under 20

Nu ft th )
gg
x er O ee
B lank diam et er (under 20 teeth)

A ddendum D P. .

Dedendum
D P. .

Full dept h D P. .

Working depth D P
. .

t an dard face width fo r gears with pinions of not less than 2 5

S
teeth = 6 times c ircular pitch .

Face widths for high ratio gears w ith small pinion s = 6 to 1 2

times circul ar pitch .

When a pinion of less than 20 te eth is u sed with a st and ard gear ,

the cent re dist an ce must be slightly increased to suit the enl arge
ment of the pin ion If it is desired to keep the centre dist an ce to
.
 GEA R S R ELA TED To TIIE SP URS 59

the st and ard dimensions the ge ar di ameter may be reduced bv the

,

amount of the enl argement g iven to the pinion For example : .

If a pinion of 1 0 teeth 5 D R is to mesh with a ge ar of 90 tee th at

, ,

1 0in cent res

. .

1 0) 1 x
P itch di am eter of pinion 2 1 in — . .

5
Enl argement over st andard p in io n = o . 1 in .

P itch di ameter of st and ard ge ar 90 —

1 8 0in
. .
d

a
Reduced pitch di ameter of ge ar= 1 8 o .

Centre dist ance min .

Worm Gears The efficiency of these gears has been increase d

.
-

v as tly in recent ye ars Formerly unsatisfactory an d neglected they

.
,

hav e now displaced bevels an d Spurs in l arge numbe rs of c ases .

This is due to a better design an d improved systems of cutting an d ,

to t h eir enclo sure in gear c ases w ith oil b aths There is no h ard an d .
-

fas t division between Spiral an d worm ge ars A Spiral is a worm .

o f l o ng le ad an d some worm ge ars might be regarded as Spirals of

,

qui ck lead So me Spiral gears are cut with conc ave faces just as
'

wo rm ge ars are Multiple thre aded worms appro ach to the Spiral
.
-

fo rm The points in favour of wo rm ge ars are that two or three

.

teet h are in cont act between the wo rm an d wheel at one time while ,

in Spurs but two can be in cont act at once an d often only one when ,

pinions are smal l The lo ad is divided in the first but concentrated

.

in the second A lso while the wholly s liding cont act which t akes
.

place between the wo rm an d its ge ar is regarded as objection able ,

it h as an advant age The cont act is smoother an d the lo ad is t ak en

.

mo re e asily between successive cont act s than in the direct p ressu re

of Spur gear teeth When in addition suit able m ateri als are used
-
.
,

an d ample lubric ation af forded the worm gear is the most perfect ,

type for economical reduction an d transmission In the b est .

gears the worm is of forged steel of high tensile st rength an d the

wheel is of h ard phosphor bronze faste ned to a centre of cas t iron
-
.

En d thrusts are t aken on ball bearin gs Holl ow faced spiral gears .

-

are cut for g as an d o il engines including the D i esel type ,

.

Worm Gear Elemen ts The teeth of involute worm s an d worm .

-

wheels are proportioned simil arly to those of spu rs an d Spiral s The .

p resent st andard an gle of the Sides of the worm thre ads is 7 55 wit h °

the axi s of the wo rm an d 1 4 4 with the pe rpe ndicul ar to the a xis

°
, ,
60 GEA R CUTTING

Fig 50 The pitch is commonly c alled line ar pitch in worm s an d

. .

racks although it is the equival ent of circular pitch in other

,

ge ars The number of thre ads in one lin ear inch is the reciprocal of
.

the linear pitch If the number of threads to on e inch linear is

.

multiplied by the product is the di ametral pitch of the worm

wheel .

The lead of a worm as of a Spiral gear is the ax i al pitch or the ,

line ar adv ance which a th read m akes per revolution The pitch .

is the dist ance from the centre of one thread to th at of the one
adj acent In a Single threaded wo rm this is identic al with the lead
.
- .

But in a double threaded wo rm the lead is twice the pitch in a

-
,

treble threaded wo rm it is three times the pitch an d so on In

-
, .

worm gears the no rm al pitches of worm an d wheel must be al ike But .

the circul ar or line ar pitches are t aken as in Fig 50 The section . .

o f the hob thre ad b eing identic al

with that of the worm it develops ,

the teeth of the wheel in cutting .

The angle of a wo rm thread

is obt ained by drawing a di agon al
on the pitch circumference from
the pitch or le ad This may be .

embodied in a diagram for a l arge

range of le ads The angle is im .

port ant as affecting effi ciency an d

reversibility It must be large .

for high effi ciency but the ge ar ,

Fig 50 .
ce as
.
es to be self su st aining if -

the angle exceeds about 6 or °

The angle of thre ad is usu ally less th an or from 6 °

to 9 when Single thre aded It is re adily obt ained by l aying down

°
-
.

th e Circumference of the pitch circ le as a pe rpendicul ar the pitch ,

as a b as e an d drawing t he hypotenuse wh ich gives the require d

, ,

angl e .

In the section Fig 50 the pitch di amete rs are set out as for Spu rs
.
,

an d also t he addend a an d bottom cle arance From the ce ntre of .

the wo rm radii are struck ( Fig 5 1 ) for the bottom an d top of thread
,
.

both of the wo rm an d of its wheel an d for the rim thickness The , .

ends of the wheel t eeth are drawn to the worm centre The di amete r .

of a worm usu ally ranges from three to fiv e times the Circul ar pitch ,

but it is sometimes less or more , .

 GEA RS RELA TED To THE SP UR S 61

In the circul ar pitch system

P itch diamete r= Numbe r of teeth x Circul ar pitch 3 3
1 8 x .

Thro at di ameter ( Number of teeth 2 ) Circul ar pitch 3 1 8 3

: x x .

Ci rcu1ar p ItCh
’

D P . .

A T able in the A ppendix by Messrs Bardons Oliver gives , ,

propo rtions for the teeth of worm ge ars .

Un dercn t The unde rcut

.
—

ting wh ich occurs in the teeth

of Spur pinions having less
than 3 0 teeth when the flanks
of the generatin g rack teeth
are s tr aight occurs also in
,

worm whee ls which h ave a

less number of teeth th an 3 0 .

The corner of the wo rm thread

holl ow s out the flanks of the Fig 5 1 . ,

whe el an d bears only by its

,

corne r against the unde rcut flan ks This may be avoided by rounding .

of fthe addendum as in racks o

But as it is more usu al to m ake worm
.

t hre ad tools with straight sides another device is adopted that of,
—

enl arging the bl an k to bring ne arly the whole of the teeth out side the
pitch line ( Fig The Brown Sharp e rule is : Multiply the pitch
.

di am eter of the wheel by an d add to the product four time s

the addendum The sum will be the out side di ameter of the throat of
.

the blank The l argest part of the di ameter is obt ained by drawing
.

the curve from the cent re of the wo rm Messrs David Brown Sons .

incre ase in addition the pitch diameter by twice the addendum .

Thus :
P itch di am

diameter
eter
.
4 x = E nl arged out s
W
ide

Circul ar pitch
P itch d i ameter 0 9 37 2 x Enl arged pitch
diameter .

A nother w ay is to alter the angle of the wo rm thread section from -

2 9 to 40 for g e ars with wheels of less than 30 teeth

° °
.

Hollow faced Worm Gears With refe rence to the enveloping

-
.
—

cu rves of the usu al design of worm wheel ( Fig this design is .

62 GEA R C UTTING

a dopted bec ause it spre ads the cont act of the worm an d wheel
over larger surf aces an d therefore the gears wear very much longer
, .

They are now general ly used because the methods of cutting them ,

by means of hobs in speci al hobbing machines h ave been improved

an d de veloped In old practice the teeth were generally roughed
.

out with a rot ary cutt er an d finished by a hob of a crude fo rm not ,

backed o ff the hob driving the worm wheel in the absence of change
,

ge ars Unless wheel teeth are hobbed there is litt le or no advant age
.

in h aving them curved to envelop the worm Cast wo rm wheel s .

were often used in preference to cut

ones as they are now sometimes , ,

bec ause it is possible to obt ain more

accurate result s by c asting th an by

cutting an d correcting without hob

bing an d hobs are costly Worm ,
.

wheel patterns are cut an d corrected

Fig 5 2 by using the pattern worm o rt he cut
. .

wo rm as a hob is used by setting the ,

two up at temporary centres an d runni n g them around an d e asing ,

of f the t ee th with the chi sel until pe rfect cont act is obt ain ed .

The diffi culties of getting accurate wheel teeth were al so very

much greater under the old crude system whenev e r multiple threads
were in question th an they are under the present Their accurat e
,
.

cutting or c asting w as practic al ly impossible Now with a m achine .

,

in which hob an d ge ar are driven by independent mech anism s an d ,

t he hob is b acked o ff wheel s can be hobbed correctly for worms of,

two three four or even more th reads

, , ,
.

Worm Gears with Straight Teeth These are p roduced with single —

rot ary cutters ( Fig 53) on a gear cutting m achin e or on a milling

.
-
,

m achine the bl ank being turned like th at of a spur wheel They are
,
.

easily cut but the wo rm cont act is th at of poi n t s only alo n g the pl ane
,

of the worm axis an d therefo re such ge ars are not suited for he avy
,
’

service For light duties they are used extensively an d for dividing
. ,

mech anism s A nothe r design used fo r dividing is a modific ation of

.

each fo rm The blank is t urn ed flat but the teeth are gashed in
.
, ,

slightly conc ave only so th at point s of the wo rm thre ad alone are in

,

engagement The straight di agon al tooth form of worm wheel has

.

the advant age ove r the other that it can be used to gear with a
rack Simil arly to a s piral ge ar
,
.

A lthough usu ally the ax is of the worm lies at an angle of 90

°
64 GEA R C UTTING

precisely as the finished wo rm an d wheel would revolve The idea is .

to cut a worm with a cutter head each tool in which represent s a ,

tooth an d to convert the wo rm so cut into a hob for cuttin g the

,

actu al worm wheel The worm u sed is cut in the same way as the hob
.
.

Looking at Fig 54 it will be noted that the th re ad of the worm

.
,

in following round the curve corresponding to th at of its wheel leans

over as it appro aches the ends so th at the section al View shows,

radi al sections A lso th at the .

,

inner faces of the l as t turn of

the screw are parallel with each
other Further unlike the .
,

common worm the dist ance ,

from centre to centre of ad

j acent teeth is slightly less
at the p oint s th an at t he
root s These peculiarities .

produce interesting develop

ments during the early st ages
of the process of hobbing
Fig 5 4 . .
the wheel t aken in con un c
j ,

tion with the di fference in

pitch at the commencement an d termin ation of the hobbing of a
worm wheel .

It has been found impossible to c arry out the theoretic al method

of cutting by an exact inte rchange of wo rm an d wheel used as cutters ,

bec ause the conc avity of the worm wheel is not present in the he ad
or disc of flat cutters which is the equivalent of the worm wheel
,
.
"

The result is th at the worm an d wheel will not enter into perfect
cont act The c as e is similar to that of forming common conc ave
.

teeth with a milling cutter instead of with a hob The difficulty .

is got over by using two hob s to cut the worm th re ads by roughing ,

out with one h aving a di ameter equ al to th at of the worm wheel on

the centre plane followed by another a little larger but d riven by
, ,

the same gear at the same rate The centre of this is Set b ack so
.

th at it t akes nothing more out of the centre tooth space of the worm ,

but cut s away some portions of the inner face of the outer turns of
t he thre ad . The cont act of the wheel an d its wo rm in the centre
pl ane is see in Fig 54 The result of this double hobbing is that
n . .

there is cont act on both sides of one tooth only (the middle o e) ; n

But see n o te o n p . 66 .
 GEA RS RELA TED To THE SP UR S 65

on the othe rs there is cont act only on one side ; on the other side
there is Cle arance The d ri vi g action is therefore con fi ned t o about
. n

one h alf the wo rm th re ad but this is more than compensated for

-
,

by the l arge amou t of su rf ace in action There is no b ottom

n .

cle arance in this ge ar an d the length of tooth is m ade greate r th an

,

th at in the common wo rm an d wheel .

The recent rapid g rowth of this gear is a rem ark able fact an d ,

it is Cle arly due to t he perfection of modern hobbing m achines apart ,

from which the diffi culties inherent in this peculi ar const ructio n
would p rob ably still be as they h ave been fo r so m any years
, ,

in supe rable .

The object in adopti n g this gear is to incre ase the surf aces in
cont act an d so reduce the friction an d we ar per unit of surface .

The friction b eing p roportion ate to pressu re the l arge r the surf ace ,

ove r which it is spre ad the less the pressu re per squ are unit of
s urf ace
. This perh aps has been ove rrated bec ause the th re ad of
t he wo rm can only be in p arti al co t act with the wheel teeth aw ay n

from the cent ral portion bec au se the angle of thre ad Ch anges as
,

t he di amete r inc re ases so th at there is a di ffe rence between the

,

angle of thre ad at the c e nt re an d th at at the end due to the ,

di ffe rence in diam eters .

If the we ar is reduced by the substitution of this gear fo r the

ordin ary worm there are counteracting disadvant ages It is more .

di ffi cult to m ake an d set an d end thrust c annot be allowed for

, .

Neither app arently can the advan t ages of multiple th re aded worms -

be secu red in this type of ge ar .

The Globoid worm gearing as m ade by the Maschinenfabrik

P e k run of Dre sden is designed to dimini sh f rictio
, , an d incre ase n

e ffi ciency The wo rm is a hollow cut design following the curve of

.
-
,

the wheel but the teeth of the l atte r are conic al rollers which revolve
,

on steel pins hard ened an d ground a n d fixed in the rim In this

,
.

w ay rolling friction is substituted for t he sliding friction of the

o rdin ary worm ge ar In additi on the ge ars are enclosed in an oil
.

b ath with the worm underne ath En d cle arance is p rovided to the .

rollers on thei r pin s so th at they are thrown outw ards on their

,

pins by the rot ation of the worm le aving a sp ace into which oil enters
an d preve n t s risk of the rollers sticking on their studs The worm .

thrust is t aken by ball races an d th at of the wheel on steel discs

h ardened an d ground The effi ciency is from 90 to 95 per cent
. .

Variabl e or In termitten t Gears These though u sed to but a .

—
,

E
66 GEA R CUTTING

slight extent in engineers m achine tools are adopted in m any ’

,

other typ es of m achines for producing v ariable intermittent or re

versing motions The principal fo rms u sed are squ are st ar shaped
.
,
-
,

triangul ar elliptic al an d scroll ge ars in e ach of which variable

, , ,

motions are produced varying in number an d in m aximum an d

,

minimum rates with the sh apes an d the proportions or ratios of the

pitch lines In each of these the Shapes imparted to the teeth are
.

those which correspond with the curv atures of e ach particular

section In a squ are gear there will be fou r st raight Sides with rack
.

Sh aped teeth an d fou r curved corners corre sponding with a ge ar of

the same radius In t ri angul ar ge ars there will be three straight

.

an d thre e curved In elliptic al gears two curves of Short radii

.

correspond with the t ransverse diameter an d two of longer radii ,

suit the conjugate di ameter The mutil ated gears p rovide th . e

same kind of movement s v ari able but with a bre ak or pause in the
—

m otion an d often too with a revers al of direction There are m any

, .

forms of these with extern al an d intern al teeth to which the st ate

ment just m ade applies But in c ases where the teeth would be
.

liable to leave ge ar the teeth are gene rally lengthened beyond

st and ard or pin s an d c atches are in serted
, .

The Hindley Gear Co of P hiladelphia US A who m ake the .

, ,

gear as illustrated in Fig 54 has kindl y o ffe red the fo llowing .

,

obse rvation s on the rem arks m ade on p 6 4 : .

iy
The sta temen t tha t the co n ca v t o f the w o rm w he e is n o t re se n t in the
‘
l p
he ad di or i q i l
sc o f fla t cut te rs, w h ch is t he e u v a e n t o f t he w o rm w he e ,
’
is n ot l
i ly
st r ct accurate . di
The en d faces o f the scs f o rm n i g
the cut te rs a re ro un a g d
to gi i g dg
v e a cu tt n el big
e , t he at ter e n in a ra a an e di l pl
A c rc e ha v n the same i l i g
g
.

di pi
amete r as the l
o n ts o f t he w o rm w hee t ee th can , t he re f o re , be asse thro u h p d
t hepi o n ts o f the cu i k pl
t te rs , w h ch t a e t he ace o f th e w he e in cut t n t he w o rm , l i g
i ld pp
fro m w h ch it w o u a ea r t ha t t he co n ca v t o f the w o rm w heeiy does ex st in l i
the hea d .

l ill
The fact that the w o rm an d w he e w n o t fi t to e t he r w he n g
rst cut mu st be fi
due t o o ther reaso n s O n e o f the se rea so n s is ro a
. the p b bly
e cre ase in t he an e of d gl
l i d di
the he i x , due to the n cre ase ame t e r o ft he o u te r t urn s o f t he w o rm
p b bly d
.

A s t o t he too t h co n tact , t he ef fect o f t he c earan ce cut is ro a l to estro y

the co n t act a t the e n d o f t he o ute r turn s o f the w o rm t hre a on Near the d ly
b b
.

o t to m o f the threa d
t he co n tact is st e to be o n ill lik ly
o th s e s o f the w o rm id
l i d
w hee too th n stea o fo n o n e s e as state id d
.
 CHA P TER VI
B EV EL GEA RS

B E VE L These are more di fficult to cut by an y process

GE A R s .
—

th an the Spurs because the section al forms of the teeth Change con
,

stan tl y The principle on which they are designed has for its b asis
.

the c o ne ; but properly the cone should be considered as included

in a Sphere on the surfaces of which the tooth Shapes are formed .

A ctu a lly the tooth sh apes are alw ays m arked on pl anes t an genti al
to th e surfaces of the pitch cones The di fference between this .

syste m an d the Spheric al b asis is a m atter of no practic al import ance ,

bec ause the shapes of the teeth in one ge ar are always by the ,

metho ds which are adopted m ade conjugate to those of the other ,

gear Thus in Fig 55 where the relations of three bevel ge ars to

.
, .
,

the Sphere are Shown it can m ake no practic al difference whether

,

the teeth are m arked out on the curved surface or on the t angential
pl anes It is therefore only necessary to bear in min d the fact th at
.

an y bevel ge ar in axi al section is a fru stum of a cone ; the b re adth

of thc tooth face the portion of a cone which is termin ated by

the ends of the teeth lying at right angles with the pitch planes ;
an d th at all boun d in g lines or plan es in the teeth in fl anks an d point s , , ,

an d ro o t s term in ate in the ape x of the con e which is a vit al f act in

, ,

considerin g methods of m anufactu re It e xplains why rot ary cutte rs .

are the most in correct an d why pl aning processe s are the mo st

,

accu rate .

Relation to Sp a r Gears J From one point of View it is conveni ent

—

also to connect the spur ge ars with the b evels on the b asis of the r ack .

A crown bevel ge ar is im agined as b ei g th at of a bevel rack or a n ,

rack rolled into a circle with the teeth flanks roots an d points all , , ,

termin ating at a common centre in the axis of the pitch plane ( Fig .

It is an essenti al an d convenient b asis in studies relating to the

pl aning of teeth by a generating p rocess .

El emen ts Fig 57 illustrates the element s of a p air o f bevel

.
—
.

gears The sizing of blanks is done by such a diagram o r by cal

.
,

culation The accuracy obt ained by each depends on the degree

.

of c are exercised The rel ations of the element s of these ge ars will
.

67
68 GEA R CUTTING

be clear from the di agram without the necessity for insertin g

num erous reference letters .

The di ameters of a p air are as their angul ar velocity ratios as ,

in Spur gears The axes may be at right or other angles The pitch
. .

is reckoned on the m ajor or l arger di ameters of the wheel an d pinion .

The pitch surf aces of both are cones the common apex of which ,

int ersect s the cent res or axes of both the ge ars A ll the lines or .

co e surf aces of faces roots an d flanks of w heel an d pinion would

n , , ,

if prolonged meet in this common apex These rel ations are shown
, .

in the di agram .

Tooth P rop ortion s The tooth proportion s ( alw ays me asured

—

on the m ajor di amete r) are the

s ame as for Spurs th at is the —
,

le ngth of the addendum the ,

dedendum root cle arance an d , ,

tooth thickness are the same as ,

for Spurs ( see pp 35 an d Th e .

system s an d Sh ape s o f the teeth ,

Fig . 55 . Fig 5 6 . .

the pressure angles are as in Spurs The tooth curves are either of
,
.

cycloidal or involute form In the l atter the pressure angle may be

.

1 4 5 o r more an d the same int e rference s h ave to be avoided as in

°
,

Sm all Spur pinion s .

The pitch di ameters being t aken on the m ajor di ameter lines ,

are drawn thence to the common apex to which root an d point line s , ,

set o ff in the same proportion s as Spur ge ars are drawn The ends , .

of the teeth being on pl anes at right angles with the pitch surface s ,

these pl anes when project e d to the centre lines or axes of the

,

gears termed the b ack cone dist ance give the radii on which the
, ,
”

teeth are drawn That is the radiu s of the pitch circle for m arking
.
,

the teeth on is not h alf the di ameter of the gear but one of l arger ,

di ameter very much larger the more the gears appro ach to the
—

crown form as is the c ase in the wheel in Fig 57 It is on these

,
. .
 V
B E EL GEA R S 69

de v elo p edz
curv es that the tooth sh apes are obt ained as though they
w e re Spur gears of corresponding radiu s so th at the fl atter the gear
,

a n d the l a rger the radiu s the more ne arly the tooth form s ap p ro x i
,

m a te to tho se of rack teeth . The sm all ends of the teeth may be

m a rked with equ al accuracy on either of the radii indic ated directly
,

o n the in side or inner b ack cone dist ance from centre s a a n d b

, or

Fig 5 7
. .

by tran sference fro m the cent res A an d B from which the tooth
,

dimensions at the l arge ends are st ruck ( Fig Thi s can m ake
.

no difference whatever in the rel ative proportions at the l arger an d

s m a lle r ends
.

It is most usu al to h ave beve l ge ars with axes at right

a ngles,
but that is not an essential featu re They m ay be .

at acut e or obtuse an gles without affecting the principles of

7 0 GEA R CUTTING

construction The one fe ature which is essential is th at the axes

.

an d the v arious tooth element s mu st converge to a common

ce ntre or apex .

The element s of bevel gears if drawn out i the m anner shown n

in Fig 57 can be me asured from but the element s of cut gears are
.
,

usu ally c alculate d Ce rt ain n ames are given to the p art s as in the
.
,

di agram Fig 58 some of which are common to spurs some inherent

.
, ,

f l In :

O U TSID E

in the bevel form The out side di amet er is me asured at the l arge
.

end o f the gear as is also the di amet er at the root obt ained respec
, ,

t iv ely f rom t he addendu m a d dedendum which are t he s ame a s

n ,

in Spur gears The angle s which the pitch line point or face line
.
, ,

an d root lin es m ake with the axi s are termed respectively the

pitch angle the face angle an d the root angle

,
”
,
The”
.
”

dist ance from the l arge end of the t oo th to the apex of the cone is
termed the cone dist ance The dist ance from the pitch line on
.
”

the l arge di amete r to the axis t aken at right angles to the pitch cone
7 2 GEA R CUTTING

of tee th in the two are ignored the numbers which would correspond ,

with the projected pitch circles are t aken an d the bevel gear cutters ,
-

are selected for tho se app roxim at ely A n d here too the question .
, ,

of t he pro per length of face to give to bevel gears comes in .

Face Width This is dete rmin ed by the following considera

—

tio n s z It Should not be longer th an fi v e t im es t he thickness of

—

the t eeth at the m ajor diam eter A n d t his is too much when .

it exceeds one third of the pitch cone dist ance It is bett er to have
-
.

it rather less If it is mo re the rot ary cutters ordin arily supplied

.
,

for bevel ge ars are not thin enough to pass through the tooth Spaces
at the inner end When however a good width of face is essenti al
.
, , ,

it is better to extend the larger ends of the teeth m aking the pitch ,

there in excess of th at actually required The sizes of the teeth .

at the sm al l end a re in p ropo rtion to tho se at the l arge en d as the ,

inner cone dist ance is to the outer con e di st ance D ividing the fi rst .

by the second should give 3 or or rathe r less as just stated ,

.

This is a proportion adopted for convenience in using st andard

rot ary cutte rs see p 80 an d is not imperative when teeth are pl aned
, .
,

by formers or generated an d planed .

G EA R S WIT H A X ES A T O BTUSE A ND A C UTE A NG L ES .

R UL ES FO R FIG UR ING A NG UL A R G EA R S .

The Gl eason Works .

To F n i dT g an en t of Rue l
C A SE I .

Pi t
ch a n gl e of g e ar w he n an gl e

o f Sha fts ( S) is l es s than

Fig 59
. .

Sin e gl an e o fshafts .

No o ftee t h i pi i
n n on
.

No o ftee
. th i g n ear
+ \ C o s an gl e o f Sha fts ) .
 V
B E EL GEA R S 73

To Fin dT g an en t of R ue l .

Pi tch an gl e of pi i n on w hen
An gl e o fshafts pi t ch an gl g
e o f ea r.
an gl e o fs ha f
ts is l ess t han

CA SE II .

P it h gl
c an e of g ear w hen an gl e

o fshafts ( S) is g reater tha n

To d t mi e er ne w he ther a gi ve n

ex a m pl b l g
e e on s to Case II . or to

Case III .

Fig . 60 .

S ne i 1 80
°
an gl e o fsha f
ts.

N0 . o fte e t h in g ea r
cos 1 80 (
°
an gl e o fsha f
ts )

CA SE III .

If nu mbe r of te eth in g ea r x

i
s n e an( gl e o fshaft is s ma ll er

than n um e r o ftee th b in pi i n on , use

Case II .

If nu m b er o f tee th in g ear x

sin e gl
( an e o fsha f
ts i l g
s ar e r

t h an n umb er oftee th in pi i un on , se

Case III .

Fig 6 1
. .

i
S n e ( 1 80 °
an gl e o fshafts ) .

Pi tch an gl e of pi i n on w he n an gl e
An gl e o fshaf pi tch gl e o fg
i g
ts an ear.
o f shaf
ts s re a te r than

A bn ormal Gen efe rence has been previously m ade to

a— R t he
limit ations of the Sizes of the sm aller involut e wheels due to , t he
inte rferences in the roots an d to the fact th at the positions of , the
74 GEA R C UTTING

pitch lines have to be alte red in such c ases in order to produce satis
factory engagements These gears are abno rm al an d co rrespond
.
,

bro adly with wh at the millwright s te rm b ast ard gears That is .

,

they are gears in which exact proportions are departed from in ,

order to obt ain workable res ults which for v arious reasons are some
,

times desirable in practice The term b as t ard has reference

.
”

generally to pairs of abnorm al bevel wheels the pitch cones of ,

which do not meet in a common apex but w hic h are rende re d ,

necessary or desi rable when velocity ratios have to be transmitted

greater or less than those which would correspond strictly with the
correct pitch cones .

In bas t ard bevels the con ditions to work able gear are that
the teeth of the pinions the pitch cones of which do not meet
,

in the apex of the

pitch cone of the
wheel but above or ,

below it shall have the ,

addend a fo r m ed in re
l ation to the pitch cones
of the pinions That is .
,

the addenda will v ary

from gre ater to less
than the norm al from
Fg 2
i 6 . .
the middle pl ane of
the teeth tow ards e ach
end There is of cou rs e a limit to such m alform ation the ext reme
.
, , ,

bein g that at which the pitch cone falls out side the points an d roots
of the teeth But within such limits (Fig 62 ) working gears are
. .

practic able an d sin ce the pinions are generated di rectly from the
,

wheel the gear is correctly fo rmed

, .

The result of varying the position of the b ase lin es is most

curious when bevel wheels are designed with pitch cones meeting
at dif ferent apices Mr B ilgram once m ade three bevel wheels of
.

di fferent di amete rs gear with o n e crown wheel correctly though the ,

apices were e ach on a di f fe rent loc ation These wheels were gene .

rated with cutters origin ated from a crown wheel The result w as .

t hat the flan ks developed a Spiral form as the addendum incre ased ,

an d dimini shed on the p airs in cont act .

Skew B evels These are related to the Spiral ge ars when the
—

a xes of the l atter cro ss at an angle If these axes are continued an d

.
 B EV EL GEA R S 75

bevel gears are substitut ed meshing at a locality away from that

w here the Spiral gears would mesh skew bevels are produced The .

action is better th an t hat of Spiral s b ec ause for the s liding action

o f the l atter the com bined rolling an d Sliding action of b evel ge ar -

teeth is substituted But the gear is diffi cult to construct an d is

.

s eldom adopted . The pitch su rfaces of the skew bevels are fr ustra
o f a figure generated b y the revolution of a straight line ab out an

ax is to w hich it is not parallel a hyperboloid of revolution ”

.
,
 S EC T I O N II .
—
MET HO D S O F C U TT I NG

CHA P TER V II
FO RM C UTTER S

THE pri n ciples on which the t eeth of ge ars are formed are con ven i
e n tly regarded from the m ethods of cutting which are practic ab le .

They may be broadly divided into three by rot ary disc cutters —
,

the sections of which correspond with those of the tooth Sp aces ; by

form plani n g ; an d by generation Each h as give n birth to a large
.

group of m achin es The Chronologic al order of the three methods is

.

th at of the order in which they are given .

Curves which are conjugate to others are conveniently m ade o n

a principle of moulding such as would result from rolling a ge a r

h aving its teeth of a h ard subst ance in a soft blank A single gear .
,

a rack or a pinion is the b ase which imp art s the conjugate sh apes
, ,

to al l gears of th at pitch The actu al cutting is n Ot done thus It

. .

is pe rfo rmed in the following w ays :

By rot ary cutters the objection to which is th at they are liable
,

to error in outlines an d which being u sed in relatively sm all

, ,

set s out only as m any wheels accurately as there are cutters in

,

a se t the intermedi ate wheels being only approxim ately correct

, .

By a planing process using a tool Sh aped like a tooth Sp ace

, ,

the objecti ons to which are s imil ar to tho se m ade to rot ary
cutte rs .

By a plan ing process u sing a pointed too l or one h aving a knife

, ,

edge the movement s of which are controlle d by the edge of a form

,

representing the tooth curves e n larged Here accuracy depen d s .

on the truth of the form .

By a planing process u sing either a tooth or a cutte r sh aped

,

like a b ase gear which is reciproc ated an d rot ated the rot ations ,

synchroni zing with tho se of the ge ar being cut an d of the ge ar ,

represented by the cutter .

 FO RM CUTTERS 77

By a planing process in which synchronous movements are em

bodied in the design an d construction of the m achines themselves ,

an d in which the cutting portion of the tool is a point an e dge or a , , .

face milling cutter

-
.

Moulding by a generating process of simple rolling is not a

practic able one It must be combin ed with a planing action In
. .

this the cutting point or edge comes into operation on successive

portions of a tooth which is being rot at ed at a suit abl e speed
corresponding with that of the pitch line Thus the Sh ape is .
.

ge n erated .

Generating by a Circul ar cutter in the form of a worm hob is

utilized in Spur spiral an d wo rm gears It is the most recent
, , .

method an d h as developed in a rem ark able m anner

, .

The R otary D isc Cutters The cutters for st and ard ge ars are
—

s elect e d by a method of averaging since it would be impossible com ,

mercially to m ake a distinct cutter for e ach di fferent si ze of ge ar .

Even so an enormous stock is necessary bec ause a set is required

, ,

for e ach diffe rent pitch an d usu ally a sep arate set for different
.
,

m achines Since the l arger m achines h ave l arge arbors an d use

, ,

cutters of larger di ameter though the sectio n al sh apes of the teeth

,

for a given pitch must be the same A sm all light m achine is n ot .

s uit able for cutting the he avie rpitch es n e ither is it economic al to ,

put the finer ge ars on the heavier m achin es A m achine therefore .

, ,

of a cert ain c ap acity is properly nt ended to de al with some one range i

of gears not necessarily a sm all range but one which has its limits
, ,

at extreme s an d the m achine h as to be equipped with a full set of

,

gear cutters within th at range o r at least of as m any different p itches

,

as are i n cluded in a fi rm s requi rem ent s To these a number of

’
.

stocking cutt e rs h ave to be added for the he avier pitche s .

This ent ails a ve ry he avy item of expenditure an d is one of the ,

reason s why the hobbing an d other gen erating m achines are regarded
with so much favour A lso obj ection is t aken to the practice of
.
,

u sing gears which are produced by a sm all number of cutters eight ,

in involutes (Fig an d twe nty fo ur in cycloid al ones bec au se a

.
-
,

cutter can only be absolutely correct for one gear It was formerly .

said th at the di f ferences were no gre ater th an the differences in

errors of wo rkm anship a ple a which is seldom o ffered now Errors
, .

there are of course but these alw ays te nd to lessen as the design
, ,

an d con struction of m achi n es improve an d as the m anuf acture an d ,

the O pe ration of cutters is also improved Erro rs in workm an ship .

'
7 8 GEA R CUTTING

an d origin al errors do not necessarily nullify on e anot her ; they may

be cumulative an d they are more ob vious as ge ars incre as e in co arse
,

ne ss Bec ause of this some firm s use cutters of intermedi ate Si zes
. ,

often also cutters m ade exactly to the Sh apes required as when l arge ,

quantities of simil ar gears for motor c ars are wanted -

.

R an ge of Cn tters The b asis on which a system o f cutt ers

.
— -

is arranged is th at the same amount of di fference of form

Sh ould be present in each cutter in the whole range from
the b asis pinion of say 1 2 teeth to a rack the extreme s
, , ,

of which are seen in Fig 64 . .

Then the number of cutters to be

se lected w ill be dete rmined by the

amount of in accuracy w hich is

con sidered permissible In the .

Fig 63
. .
Fig 6 4
. .

Brown Sh arpe system which is generally adopted eight cutte rs

, ,

are embodied in all pitc hes though the dep arture from accuracy ,

w ill b e more in teeth of co arse pitch th an in tho se of fine pitch not ,

relatively but absolutely due to the larger dirn en sio n s Thus if

, , .
,

the difference between the teeth of the smallest pinion an d the

rack at the point of the teeth is iin in the teeth of a given .

pitch it will be double th at in a wheel an d rack of twice the

,

pitch , an d so on .

The selection of eight cutte rs is therefore an arbitrary one .

P rofessor Willis with whom the idea origin ated obt ained by c alcula
, ,

tion equidist ant v alues of twenty five cutters rangin g from gears of -

1 2 teeth to a r ack an d also prep ared a t ab le Showin g wh at cutte rs

,

Should be selected on the suppo sition t h at a sm aller or larger

number of cutters were to be selected If a si n gle cutter .

were thought suffi cient for an entire set of very sm all wheels ,

one for 2 5 teeth should be selected A n d so on for numbers .

of cutters ranging from two to twenty four as given in the -

,

t able on p 7 9 . .
80 GEA R CUTTING

In the Brown Sh arpe cutte rs a difference may be m ade in the

construction acco rding as the pitches are finer or co ars er For gears .

below 1 0 di ametral pitch the Simple uncorrected involute const ru o

tion can be t aken For ge ars of 1 0 diametral pitch an d coarser
.
,

cert ai n corrections are m ade to avoid inte rferences In the fi rst .

the cutter fo r 1 2 an d 1 3 teeth is m ade to a di agram for 1 4 teeth an d ,

t he oth ers as below

F 14 or 16 t h di g m f1 6 t t h
to ee t , a ra o ee .

17 20 18
21 25 22
26 34 28
35 54
55 13 4
13 5 ra c k
In the second the cutters are as follows m ade to co rrected
,

di agrams :
Fo r 12 an d 1 3 tee th , di g a ra m of 1 2 te e th .

14 to 16 14
17 20 17
21 25 2l
26 34 26

54
13 4
rac k
The cutters m ade by J E Rein ecke r t ake account of the gre ater
. .

interference of co arse pitched ge ars th an of those of the fi n er

-

p itched o ne s H .e m ake s a set of e ight cutters for 2 4 di ametral

pitches an d fine r an d anothe r se t of fourteen cutte rs for di ametral

,

pitche s up to 2 5 P A compariso n of these will Show th at for the

.

co arser pitches t he range of a single cutt er is more limited th an th at

for the finer pitches .

Half numbers of cutte rs are m ade giving in addition to the , ,

eight usu al ones seven more (fifteen in all) a concession to those

, ,

who require accurate an d Silent gears Brown Sh arpe an d othe rs .

, ,

h ave h alf numbers as follows :

No . of

C utte r .

15
2
3

This system is c arried still further as already st ated by the , ,

growing practice of m aking Speci al cutters to exact sh apes for

st and ard ge ars an d it has bee n developed by the dem ands of the
,
 FO RM CUTTER S 81

m oto r -
builders for Silent ch ange Speed ge ars Many ofthese are
car -
.

cut with single disc cutters in prefe rence to u sing a generating hob .

The eight cutters in the u su al set are also m ade in high Speed -

s teels
. P rices ran ge approxim ately double while the output is ,

a bout three time s as gre at .

Each cutt er in the ordin ary st and ard set s is u su ally m ade ex actly
for the lowest n umber of teeth for which it is to be u sed the excep ,

tions occurring in two or three of the low numbered gears The in -

.

a ccuracy in all oth e r ge ars is in the right direction for e asy working .

Thu s when a No 3 cutter m ade right for 3 5 teeth cuts 54 teeth

, .
, , ,

o r an y number betwee n 54 an d 3 5 the teeth w ill h ave more roun ding ,

of fth an the correct con struction would ent ail with a correspondingly ,

Slight decre ase in be aring su rf ace which however is much to be , , ,

preferred to inte rference .

Cutters f or Cycloidal Teeth Cutters for cycloid al or double—

curved teeth are m ade in l arger set s th an the involutes bec ause , ,

e xcept ing in the fi n er pitched ge ars the v a ri ation s in the tooth fo rm s

-
,

are gre ater th an in the Single cu rved involute s an d bec ause they
-
,

are generally re served for the co arser pitche s Twenty four cutters .
-

are m ade de sign ated by letters A to X in ste ad of by n um b e rs to

, ,

prevent confusion with the involute cutters

Cutte r A cuts 12 tee th C utte r M cuts 27 t o 29 teeth .

B 13 30 33
C 14 34 37
D 15 38 42
E 16 43 49
F 17 50 59
G 18 60 74
H 19 75 99
I 20 100 14 9
J 2 1 to 22 t ee th . 15 0 24 9
K 23 24 250 or m ore .

L 25 26 rac k .

A llthe sm allest numbered gears requi re a sep arate cutter an d ,

the cutters for medium ge ars are very limited in their range They .

are not m anuf actured in so l arge a range as the involute cutte rs ,

being stocked in a few pitches only They are however m ade for .
, ,

di ametral an d circ ular pitches while the involutes are more often,

m ade only for the first though some fi rms m anufacture both kinds
, .

The cycl oid al cutters h ave a shoulder which the in volutes h av e not
'
, ,

in order th at the depth of tooth sh all be controlled by the cont act

of the Shoulder with the rim This ensures th at the pitch lines Shall
.

be in cont act an d the double curves t ake up their exact mutual

,

r
82 GEA R CUTTING

rel ations , a point which is of much less import ance in Single curved -

ge ars.

Irrecon cil abl e Systems In ttempt to wo rk on an ex act

.
—
an y a

sy tem
s the , di metr l
a a an d r ci cul ar pitches cl ash Since neither can ,

be cut correctly with a set of cutt ers m ade for the other system .

Y et customers so metimes w ant one sometimes the other For the , .

best result s a l arger stock of cutters is re quired th an for average

,

results ; an d sometimes gears are wan ted to conform to the metri c

system for which again other set s of cutte rs are nec essary
, , , .

The commonest problem is th at of using the st andard cutters

m ade for di ametral pitch to cut wheels of circular pitch by The,
.

pro per w ay is to h ave set s of cutters for e ach cl ass of wheel But .

as the dem and for the l att e r is so sm all the occ asion al orde r is fi lled

by selecting a cutter which comes ne arest to the circular pitch re

quired Thus a 4 diame tral pitch is the Closest to a gin circul ar pitch
. .
,

with a vari ation of about gam a se rious differen ce A 3 diametral

l —
.

pitch comes very close to a fi n ci rcul ar pitch A 2 ; diam etral pitch is . .

very ne ar to a 1 1in Circul ar pitch The bl ank is then Size d for circul ar
. .

pitch an d the di ametral cutter u sed This is not recommended for

, .

adoption in re ul ar practice but it is ju stifi able at a pinch an d in

g , ,

the worst c ases it is preferable to a b adly c ast ge ar The devi ation -

.

from st rict accuracy however is not quite so serious as appears

, ,

from the di fference in the pitch of the cutters The tooth thicknesse s .

an d Sp aces come out above or below ex act dimen sion s ; but the in

volut e is so el astic a type th at the meshing of the teeth is practic ally

un affected On l arge wheels say of over 50 teeth the differen ce
.
, , ,

is much le ss app arent th an it is on sm aller wheels say below ,

2 0 teeth in which th e de vi ation s from accuracy are more obviou s

, .

But it is practic able to m ak e decent ge ars in most wheels by using

di ametral cutters an d this has been done with satisfactory result s
,
.

It is well to keep fu ll Sized section s of teeth b ased on the di amet ral

-

system for re ady re fe rence ; but a close approxim ation to the

circular pitches which correspond with diametral can always be
m ade me n t al ly by remembering th at the relation between the two
is alw ays th at of di ameter to circumference or as I is to or as ,

7 is to 2 2 or C irc ul ar pitch
, 3 3
1 8
,
= di amet ra l pitch an d x .
,

jl g
15
Ci rcul ar p i tch .

diamet i h
a tc
Thus t ake 1 in Circul ar pitch = 1 in
,
. . x which doe s
not co rrespond with an y e xact di ametral pitch , an d so on through
 FO RM CUTTER S 83

an y circul ar pitches . On the other ha nd t ake , a di ametral pitch ,

say 6 then ,

5 4
2 circul ar pitch ,

which again is not an even number .

SO th at a 4p ( four representing a fourth of an inch or module )

.

would give kin 3in gin . of kin gin full for the correspond
x . . . .

ing Circul ar pitch ; 2 p would give gin 3in 1 §in 4 of { in or a

. . x . f

trifle o ver 1 T 3 in for the circul ar pitch A n d to derive di ametral

9 -
. .

pitch from circular the operation would be reversed .

R elief of Cutters Cutters are relieved th at is the teeth are

.
— —
,

s truck from a centre which is set eccentric al ly in rel ation to the centre

of revolution The result is th at the cross section al sh apes of the

.
-

teeth remain unch anged by the repe ated grindings which are done
acro ss the faces So th at a cutter m ay be u sed down to a mere
.

Skeleton with out lo ss of accuracy or ef fi ciency cutting a few hundred ,

ge ars during its life It is highly essenti al to keep it Sh arp regri nd

.
,

in gat about every two or three hours between the cutting of ge ars .

Stockin g Cutters The foregoing relates to the cutters used for

.
—

finishing But gears of about 4 di ametral pitch an d over are better

.

roughed out with stocking cutters le aving only a sm all amount of

-
,

met al to be removed by the fin ishing cutter This tends to greater .

accuracy b ec au se le ss di sto rtion is likely to occur an d it prolongs

, ,

the life of the finishing cutters Stocking cutters are m ade for . .

pitches sm aller th an 4P but they are not employed so much for

.
,

these as for the co arse r pitches .

In thes e also improvemen ts h ave been m ade with a view to save ‘

time an d to lessen the work of the finishing cutters The Simplest .

fo rm rough s out p arallel as in Fig 65 These h ave been modified

-
. .

to t ake out more m ateri al from the Spaces above the pitch line
( Fig . A clo ser approxim ation to the fi ni shed sh a pe s h as

been m ade by Messrs Brown Sh arpe (Fig In this pl ain .

,

an d stepped te eth altern ate The first do the great er part of .

the cutting the second bre ak up the chips while the tooth is
, ,

roughed out more nearly to the finished Sh ape an d dimensions

-

than by the ordin ary kinds of stockin g cutters .

The r adi al ga ng cutt ers ( Fig 68 ) cut from two to te n teeth .

at one tr averse of the cutt e r slide They are u seful as a me a ns .

of incre asing output where qu antities of duplic ate ge ars h ave

to be cut an d where a fine degree of accuracy is not required
,
.
84 GEA R CUTTING

Each g ang will only cut one di ameter o f gear an d o n e cert ain
number of teeth The teeth are sharpe ned in the same w ay as
.

those of single cutt ers a n d whe n the g a ng is assembled on t he ,

arbo r t he t ee th are e t in s t aggered f ashion to hit a n d mi ss e ach

s

other in the axi al direction These cutt ers are m anufactured by .

Me ssrs Gould Eberh ardt .

Cutters f or Sp iral Gears Spi rals Single helic al an d double .

—
,
-

h elic al ge ars an d t angent worm wheels are all cut by me ans of the
,

disc cutters the rel ation ships of which h ave been est ablished in a
,

previou s chapter .

Sin gle helical Gears

-
These are usu ally cut in the universal
.
—

milling m achine with o n e of the st and ard disc gear cutters provided ,

Fig 6 5 . . Fig 66
. .

of course th at the ge ars are not of l arge dimensions In this m achine .

the dividing he ad an d the feed sc rew of the t able on which the head
,

is mounted t ak e Ch arge of all the movement s of the bl ank the t abl e

, ,

providi n g its angular setting while the cutte r is simply rot ated by ,

the m achine Spindle The t able screw an d the change gears in unison
imp art the helic al movem
.

ent to the blank an d the indexing is don e ,

by the index plate an d peg The t able of the m achin e is set to the .

angle of the Spiral on it s pitch lin e But if the angle exceeds 4 5 °

.

att achment s are provided f o r swivelling the cutter Seve ral firm s .

provide these att achm ent s for the m achines which they m anuf acture .

In the wide range of angles othe r th an 4 5 all c ases are met with
°

from 1 0 or
°
in which the tooth section v aries but little fro m th at
of a spu r gear to high angles of 7 0 o r
,
where the di fference is °

extreme In the fi rst the re would be only about on e tooth difference

.

in the selectio n of cutters an d the Spur ge ar cutte r of the same -

di ametral pitch In the second a rack cutt er would be used of a

.

ve ry fin e pitch In the fi rst c ase a single too l like th at used fo r

.
,

cutting worm thre ad s in a l athe would fre quently be u sed ,

.

Messrs B rown 8 : Sh arpe advoc at e fittin g a templet to the curve

 FO RM CUTTERS 85

of the fl ank alon gthe line of the no rm al pitch which will of course , , ,

be fl atter th an the curve alo n g the pl ane of the circul ar pitch The .

di a meter of a Circle is found to coi n cide with the cu rve of th at t em

ple t an d t ak en as the addendum circle of a gear for which a cutte r
,

h as to be selected With increase of angle of spiral there will be

.

g r e a ter fl attening of the cu rve an d t he l arger will

,
be the number of
S ur ge ar teeth from which the cutt e r will be selected
-
p .

D ouble helical Gears Spiral ge ars of l arge

-
.
—

di ameter are usu ally termed helic al gears

imply B ut the prefix single helic al should
s .

then be employed to disti n guish them from

the true or double helic al ge ars to which the -
,

term properly applies Y e t as we h ave seen .

, ,

these di ffe r from Spiral s only in the double

arrangement of teeth an d not in an y esse nti al ,
.

Hence w e must study them through the spiral

gears with which they must be cl assified The .

duplic ation of the teeth on opposite h and s

ent ails diffi culties in cutting which do not ,

ari se in the Si n gle helic al ge ars The success

-
.

ful cutting of l arge double helic al ge ars in the -

solid h as be en accompli shed only in recent

Fig 6 7
. .
Fig 68 . .

years This diffi culty here arises from the meeting of the t eeth at t he
.

a p e x hence
,
non e of t he cutt e rs w hich a re ordin a rily u se d for Spir a l
ge ars can be employed for double helic al t eeth bec ause the meet in g
-

of the right an d left hand teeth at the ape x arrest s the movement s
of the cutter s The s e c a
.n only be employ e d in the W u s t de s ign in ,

which the teeth hit an d miss thus bre ak ing their continuity
,
.

S ince rot ary di s c cutter s c annot be u se d wh e n r ight a n d left h and

teeth meet in an apex o n ly one practic able method is available then
, ,

th at of an end cutter having its axis set perpendicularly to the rim

86 GEA R C UTTING

of the gear which is b eing cut an d rot ating an d traversing along,

t he Spiral p ath .

In the e n d mil ling process the mill is sh aped to the section of

-

t he norm al toot h Sp ace or th at t ak e n at ,

right angles to the direction of the Spiral ;

It is the same as the section of a rot ary

cutt e r B ut unlike the l atter the cutting
.
, ,

teeth are so few in numbe r an d the tool is ,

so sm all th at it w e ars r apidly so th at the

, ,

method is ill suited to wheels of fine pitches -

,

an d h aving a l arge n umber of teeth A lso .

,

as a radiu s is left at the inner angle ofm eet

Fig 6 9 .

in g t eeth ( Fig either this must be cut

.

aw ay subseque n tly or which is e asier t he apex of t he outer angle

, , ,

of the m ating wheel mu st be re moved an d rounded by h and work -

.

In these resp ect s it comp ares unfavou rably even with the disc
rot ary cutters an d ve ry much mo re so with the hobbing cutters
, .

B ut it h as no rival bec au se no other Sh ape w i ll answer

, A n d t he .

cutters are e asily renewed Thei r t eeth are co arsely pitched to

.

prolong their lives Fig 70 shows a group of cutters used by Mess rs

. .

Fig 7 0 — En d M
. . ill Cutt e rs use df or b
D o u le he -
li l G
ca e ars .

Da vid B rown Sons Ltd of Huddersfield in cutting thei r solid

, ,

double helic al Spur ge ars

-
.

In using a rot ary ge ar cutte r for single helic al ge ars or for the ,

hit an d miss system of double helic al ge a rs the problem is rendered

- - -
,

difficult by re as on of the differenc e between the norm al an d circular

88 GEA R CUTTING

ment for e ach side of a tooth Space ( Figs 7 2 an d The effect is to

.

alter the proper sh ape of the tooth so th at a pinion of sm all con e

,

angle which would h ave to be rolled mo re th an a wheel of l a rge

,

cone an gle to get the co rrect tooth thickness at the pitch li n e ,

would have its faces thinned somewhat an d its root s thicke n ed at,

the large end Less however in th at c ase has to be filed o ff the

.
, ,

f aces at the sm all en d of the tooth .

A w ay to lessen these slight in accuracie s at the l arge en d in sm all

pinions is to select a cutter one or t wo numbers removed from tha t

Fig 7 2
. . Fig 73
. .

s uit able for l rger ge r as fo r inst ance a numbe r 6 or 7 inste ad

a a s— , ,

of 9 These cutt e rs b eing thinn er at the roots do not round o ffthe

.
, ,

f aces of the teeth quite so much In either c ase the cutt er selecte d
.

can only be an ave rage to cut to the ne arest approxim ation right

through the tooth an d thus lessen the amount of corrective filling

,

or subsequent corrective cutting .

The difficulty of produci n g bevel gear teeth with rot ary cutte rs
-

is e n h anced by t he approxim at e an d corrective ch aract e r o f the

settings which are necessary before the e x act amount of roll can be

ascert ained which is required to give the right thickn ess to t he t ee th

at the l arger an d the sm aller ends The following explains the n at ure
.

of the O perations
In al l but the sm allest gears three cuts are t aken through a tooth
sp ace a central p arallel stocking cut an d two fl ank cut s one on e ach
, , ,

Side In sm all ge ars the ce n tral cut may be omitted A bevel ge ar -

.
.
 FO RM CUTTER S 89

c utting m achine is illustrated at p 1 7 0‘ Showing in Fig 1 53 the pro

.
,
.
,

visions for setting the blan k to the cuftin g angle or Section al angle ,

corres ponding with the angle of cut which m ay be th at of the work

,

in g depth or the cone angle of the roots

,
In Fig 1 5 1 provision is
. .

Shown for setting the cutter out o f c e ntre for cutting the l arge ends
-

o f the tee th It includes vernier me asuremen t o n a gradu ated di al

.

fo r re ading to thou san dths of an inch The cutter being set away
.

f rom zero the bl ank is rolled up into co n t act fi rst with one side then
, ,

w ith the other In this rolling of the blan k the tooth flank is swivell ed
.

a bout t he ape x of the cone of the ge a r so bri n ging the large end of the
,

tooth radi ally into line with the sm all en d The cutter is set out of
.

cent re to bring the Side th at is cut centr ally with the bl ank Hence .
,

w hen these adju stment s are m ade con siderably more m ate ri al wi ll
,

be removed from the l arge end than from the sm all The exact .

a m ount necessa ry is in the first pl ace tested by t ri al cut s but when ,

qu antities of Similar gears are being out these tri als need not be
repe ated The amount of tri al dist ance may be on e sixth of the
.
-

tooth thickness at the l arge end in a 1 2 toothed pinion an d ranges

-
,

fro m that to one seventh in larger numbers of teeth A fter a tri al

-
.

out h as been t aken o f f e ach side a tooth gauge is use d one at the ,

l arge an d another at the sm all end A n y further corrections which

.

m ay be found n ecessarv are m ade before the rem ainder of the teeth
a re cut.
 CHA PTER V III

FO R M P LA NING , A ND GENERA TING METHO D S

F ORM PL A Bevel gear planers using forms or forme rs which

N/ Nt — -
, ,

are enl arged profiles of the teeth are popul ar They are m ade in
, .

several de sign s which di f fer in the methods of c arrying an d rolling

,

the blank in those adopted for operat ing the reciproc ating cutter
, ,

in the loc ation of the form an d in the practice of cutting one Side
only or bo th sides of a tooth simult aneously
, .

The Form The prin ciple of action of these m achines is Simple

.
—

enough A form which is a piece of steel h aving an edge out to an

.
,

enlarged profile of the teeth to be pl aned becomes a guide which con ,

trols the lateral movements of the tool between its reciproc ations .

The feed thus t akes pl ace along the curved edge of the form The .

gear blank is held st ation ary during the actual cutting an d is in dexed ,

or pitched when a tooth flank is finished Obviously the accuracy .

of the teeth th at are cut depends prim arily on th at of the form an d ,

therefore the l atter is m ade on the same principle as a dividing

wheel usu al ly is n amely l arger th an the to oth being cut for which
, , ,

it is the guide A s a rule t he curves of the form are from three to

.

four times the dimensions of the ge ar tooth at the m aj o r di ameter so

th at errors in the form are reduced in the ge ar which is cut Fig 74 . .

shows the form in rel ation to the ge ar A B is the cone dist anc e .

of the ge ar an d A C th at of the form not however set out to it s

,
—
, ,

re al dist ance in the di agram The line B D represent s the b ack

.

cone dist ance of the ge ar an d the line C E th at of the form With

, .

C E as radius desc ribe the are A in Fig 7 5

, On this are as a pitch . .

line const ruct the tooth curve a b c reme mbering that all the tooth
, ,

e leme nt s are enl arged in the ex act proportions which exi st between

B D an d C E in the previou s Fig 7 4 If C E is three times the

. .

length of B D all the tooth curves the pitch addendum dedendum

, , , , ,

an d root cle arance will be three time s l arger th an tho se in the actu al
,

ge ar The enlarged tooth curve a b c is now used as a centre line for

.

a series of circles shown the di ameter o f which is ex actly that of the

,

di ameter of the form roller used in the m achine The curves drawn .

90
92 GEA R CUTTING

fact in favour of planing is that the rot ary cutt e r

°

0b1ection s .
— A
must h ave a longer travel than a planer tool in order to Cle ar the teet h
at e ach end A n objection to pl aning is the l arge proportion whic h
.

the lost return strokes bear to the cutting ones an d th at fine fee ds ,

are necessa ry to l esse n t he e f

fects of Spring of the tool wh ich is m o r e ,

li able to occur bec ause the thickness of the chip is gre ate r at th e
larger di ameter than at the sm aller The cost of the fo rms is con .

side rable Since there should be at l e ast as m any of them as the re are
,

cutters to a pitch u su ally there are more To secure the full ad

,
.

vantage o f the planing methods the re Should be a form fo r ne arly

eve ry di ffe rent ge ar in the sm aller an d medium numbers of tee th ,

though not in the larger numbers These re ason s coupled with the .
,

growing de sire for absolute accuracy explain the rapid advances ,

which t he bevel ge ar generating m achines are now m akin g

-
.

P rin ciples of Gen eration No t so m any m achines are m ade for

—

generating Spur ge ars by planing as there are for bevels The re as on .

is th at spur ge ars can be out much more accurately th an bevel ge ars

can be with rot ary di sc cutters To underst and the action of the .

generating ge ar cutters it is advisable to appro ach the subject fro m

the point of view of the moulding generating process (see p 77 ) though .

th at is h ardl y yet a practic able method In this a h ard ge ar is

.
.

im agined to be rolled in a plastic bl ank such as w ax or clay ge ars , ,

an d bl ank being mounted on their axes an d rot ated at the velocitie s

corresponding with their diameters The teeth thus moulded an d .

generated woul d mesh correctly with those of the hard ge ar .

The Fellows Cutter Put into a practic able sh ape this is the b asi s
.
—

of the Fell ows Spur ge ar cutting m achine The h ard ge ar here is

-
.

actu al pl aning pinion sh aped cutter ( Fig which m akes a p art

-
.

rot ation between e ach cut t aken al ong a tooth the cutter being fed ,

round continuously with the ge ar bl ank between each reciproc ation , .

Though the rack tooth does n o t appe ar here it nevertheless lies at

the b as i s of the method bec au se the pi n ion cutter is ground by a
,

rack like generator ( Fig

-
an d an y ge ar th at is cut with a r ack
.

will mesh with an y othe r gear cut by the ge ar or by the same rack , ,

an d con sequently will g

,
enerate an y such gear
,
.

The gear shaped cutter is fin ished by grinding to the ex act for m

-
,

after roughing out an d hardening u sing a wheel h aving a flat f ace

—
,

set at the angle of the rack tooth which is selected as the b as is (see

Fig . This being rot ated the cutter is rot ated al so an d rolled
, ,

pas t it in the rel ations which subsist between a rack an d a ge ar .

 FORM P LA NING, A ND GENERA TING METHOD S 93

Th e motion of the cutter is produced by steel t apes which are

w r a pped upon a di sc th at repre sent s the pitch di ameter of the cutter .

O n e Side of e ach of the cutter t eeth is ground first an d afterw ards

a l l th e other Side s The cutter is resh arpened by grinding the ends
.

o n l y o fit s teeth .

Cl earan ce of Cutter The teeth are not backed o ff as are the

.
—

m ill ing or rot ary disc cutte rs but an equival ent of that is imp a rted
,

d uring the grinding To e ffect thi s the

.

fa ce of the grinding wheel is set at a

s light an gle with the axi s of the spindle

w hic h c arries the cutter with the result ,

t h at the tee th are sloped Slightly one ,

s ide of the teeth being portions of a

Fig 7 6 . . Fig 77 . .

i
r ght h and pir l ge r the other i e th at of a left hand spiral
-
S a a ,
s d -
.

The out side of the cutter is al so b acked o ff suffi ciently to

preserve the correct rel ation between the pitch thickness an d
the addendum A s the cutter is sh arpened on its f ace only it
.
,

is reduced in di ameter to a very minute extent A n d as the .

involute curves for the entire length of the cutter are generated
upon the same b ase Circle the t eeth generated by the cutter as
,

it wears are al ways alike This result s from the fact that the b ase
.

Circle is the generating su rface in involutes an d not the pitch circle ,

as in cycloid al teeth .

A ction of Cutter When p roducing int e rch ange able ge ars from
.
—

this pinion which st ands for one of the set the principle is as p re , ,

viousl y st ated th at which is termed moulding generating though

,
-
,

the cuttin g action is strictly that of pl aning or Sh aping Du ring the .

94 GEA R CUTTING

intervals of cutting the pinion cutter an d the bl ank rot ate or fee d
,

very slightly in unison A t the commencement the cutte r is fed

.
,

in to the p rO per depth of tooth after which the rot ation commences
, ,

the cutter finishing as it an d the work rot ate ( Fig A ll these .

movement s are autom atic The successive action is shown in Fig 7 9

. .
,

in which A is the cutter an d B the bl ank The lines drawn indic at e .

the Sh apes of the successive chips which run out to a thin edge at t h e
,

C UT T ER

B LA NK

finished surface but are thick an d co arse in the middl e of the tooth
,

Sp ace
. The bulk of the met al is thus removed there le aving only a ,

fin e Sh aving to be t aken o ff the sides of the tooth so combining a ,

roughing an d finishing cut in one A lso as indic ated at the upper .

,

left h and of Fig 7 9 the cut is a draw cut t aking place tow ards the
.
,
-
,

cutter slide which fact is favourable to rigid an d steady action

, .

The R ack shap ed Cutter

-
B ut for convenience the rack tooth
.
—

itself or its equivalent is almost invari ably incorporated in a gen erat

ing ge ar cutting m achine Such being the c ase it is obvious th at a
-
.
,

piece of rack may be formed into an actu al cutt er an d reciprocated

precisely as the pinion just mentioned is an d the rack an d wheel ,

bl ank m ay be fed in the interv als of reciproc ation This is the prin .

cip le of the de sign of the Sunderl and Spur ge ar generator ( m ade by -

Mess rs P arkin son Son ) in which an actu al length of rack comp ris
,

ing several teeth is used ( Fig h aving a sufficient number of

.

teeth (Six ) to m ake cont act with the m aximum numbe r of teeth
which can engage with it at one time The movements of the .

rack cutter an d the blan k are identic al with those which occur
in actu al engagement A ll ge ars of a given pitch th at are cut thus
.
96 GEA R CUTTING

duced during one series of cuts another Similar tool follow i n g ,

on the opposite Sides .

B ilgram s bevel ge ar sh ape r w as the fi rst pl aning generatin g

’
-

m achine m ade The system employs a tool which correspond s

.

with o n e t ooth of a rack for an interch angeable set of ge ars of a give n

pitch The rack tooth in the c a e of be vel gears must be th at of a
.
,
s
,

perfect crown wheel th at is a disc h aving teeth convergin g to t h e

—
,

disc cent re as an apex ( Fig This is Cle ar from a consideratio n

.

of the rel ation s of the b ase line an d the involute curve .

The curve is obt ained

by the roll ing of a point
in a straight line the line —

o f action upon the b ase — .

A s the b ase in a c rown

wheel is a plane the tooth ,

profile cannot be a cu rve ,

but must be a pl ane nor

mal to the angle of obli
q u it y of action of the ge a r .

Fig 8 1
. .
T h e ref o re t h e tooth pro
fil es of a crown wheel
must be like those of a rack From tho se pl ane profiles set at the
.
,

angle s determined on as st and ard the teeth of al l other ge ars are

,

generated ; with the result that an y wheel which ge ars with the rack
teet h will ge ar wit h an y other wheel ofthe set m ade on the same b asis .

A lso suppose such a rack tooth to be u sed as a reciproc ating cutter

, ,

an d a wheel bl ank to be rot ated against it at a suit able rate the ,

tooth it se lf will cut perfect teeth in the wheel blank (Fig .

Fig 8 2
. .

Fo r such yst em the cycloidal tooth is un avail able bec ause its
a s ,

sh ape c annot be developed by the rot ation of the wheel bl ank That .

system only can be utilized which generat es a singl e curve So t hat .

while in the planing system in which the use of a fo rm is embodied

, ,

t eet h of either kind are planed the gene rating m achines are limit ed
,

to the cutting of single cu rved teeth .

 FO R M P LA NING, A ND GENERA TING METHOD S 97

The D e Fries Cutter the Spur ge ar slotting m achine by De

.
— In -

F ries CO A k t Ges the wheel blank is fixed to the work t able

.
, .
-
,

with the t o ol set to the required depth of t ooth The action is seen .

in Fig 8 3 A Showing the tool out side the body of the blank an d it s
.
, ,

front edge t angential to the periphe ry The path of the wheel is .

then as indicat ed by the arrows combining a l ateral an d a rot ationa l,

movement on its own axis On e side of a tooth is thus gen erated

.
,

t he tool cutting down to the full dept h an d the oppo site side of the ,

tooth is then de alt with as the tool works up from the root to the
point until the t ool le ave s the finish ed tooth as at B in Fig 8 3
, . .

Fig 83 . .

The successive positions of the blank in rel ation to the tool

a re cle arly seen in Fig 8 4 A To save the work of slotting out the
.
,
.

m ass of met al in a tooth Sp ace when dealing with co arse pitches ,

t h e practice is to use a p arting tool m aking a n arrow groove as Shown

in B Fig 8 4 on oppo site Sides of the central are a of m et al le aving a
, .
, ,

t ri angle of nearly the Size of the tooth This piece fal l s out an d the .
,

t o oth curves are finished with fin e cut s .

Either Single or double cutting tools are u sed the first cutti n g ,

o n the downw ard stroke an d h av ing a reli ef motion for the return
, .

The tool can be turned over when the edge has become blunt an d
be u sed right up Two tools are employed in a rocking holder for
.

the double cutting system (Simil ar to double cutting planers) the

- -
,

holder being rocked autom atically at e ach reversal an d the tool ,

that is out of use being swung clear of the cut .

The P errot Gear Cutter In this design Spur ge ars are generated
.
—

of an y angle of obliquity an d an y desired thickness without employ

in g intermedi ate ch ange ge ars The principle is th at of a cam in
.

cont act with a rack bar an d the o bliquity of this can be varied so
, ,

that through ge ar an d screw connections the sliding movements of

G
98 GEA R C UTTING

the cutting tools can be controlled The arm of the cam rocks about
.

the axis of the blank to be cut the cam being located at the opposite
,

end to the pivot The inclined rack bar descends du ring cutting
.
,

an d is coupled by transmi ssion ge ar to the tool holder so th at the -

,

desc ent of the bar corresponds with the rot ation of the blank being
cut The cam corresponds with an enl arged m aster involute curve
.
,

an d the oblique bar is equiv alent to the fl ank of a rack tooth .

A ltering the angle of the l atter therefore al te rs th at of the rack

tooth an d consequently the pressure angle Two cutters are .

ground an d set in a holder at the angles of the tooth ( Fig

, .

an d provide d with screw ad

j ustment for v arying the

dist ance between them so ,

as to incre as e the thickness

of tooth on pinions an d the

sm alle r ge ars This m achine .

Fig 8 4
. . Fig 8 5
. .

is the invention of Henri Perrot of A rgylls Limited A lexand ri a

, , ,

( Dumb artonshire) .

B ut it is not necessary th at the cutter should be ar an y

resembl ance to the rack tooth It may be only a point
.
,

or an edge in which c ase another system of producing the

,

Sh ap e of the t eeth h as to be substituted for the mouldin g

generating method The tool reciproc ates an d the gear blank
.
,

is controlled by mech anism in such a w ay th at the involut e

cu rve is generated By means of various ingenious devices
.
,

the e quiv alent of the b ase circle from which the involute cu rve
is generated is embodied
, The tool being fixed an d recip ro
.
,

cating only Sh apes the tooth curves as the bl ank is fed roun d
,
IOO GEA R CUTTING

h ad hobbing m achine for cutting Spur worm an d spiral gears

a , , ,

of which l arge numbers h ave been built The ge ar bl anks are c arried .

on a horizo nt al m andrel But most m achines are now m ade wit h

.

the m andrel disposed vertic ally of which some dozens of design s ,

are now built We may consider the principle of action embodied in

.

the hobs .

Forms ofHobs The hobs employed are of two type s p arallel

.
—
,

F
( g i .8 6) an d t a pe re d ( Fig the fi rs t n
. a med being u s ed for S purs ,

Spiral s an d worm s an d the second for worm ,

wheels only an d those chiefly of high angled ,

-

spiral s The essenti al di fference in their actio n

.

is th at the p arallel hob is fed inw ards gradu

ally ( Fig until the depth of tooth is att ained
.
,

as there is no l ateral motion of the hob ; but

the t apered hob is set at the commencement

to the full depth an d is fed t angenti ally across
the bl ank as it rot ates (Fig in which the .

commencing an d finishing positions are shown at

Fig 8 7 . .
A an d B The t aper e d hob. is prefer able for
cutting wheels to mesh with worms of high
angles as the teeth are gene rated more correctly an d it cut s lightly
, ,

at entrance (lik e a t aper t ap ) gradu ally deepening , The teeth of .

hob s are fluted spirally in order to m ake the cutting angle equ al
on both Sides of the teeth .

A ction ofHob In this p rocess the b asi s is a rack tooth an d the

.
—
,

hob is merely a convenient device for the embodiment of the rack

tooth section in a practic al form This is illust rated in the di agram .

( Fig . in which the Spir al thre ad of the h o b is so se t as to c au se it

to t ake the place of a succession of rack teeth th at is the section —
,

of the hob thre ad t aken norm ally to its spiral is identic al with th at
of a st and ard rack an d the axis of its revolution has to be set at an
,

angl e with th at of the ge ar b eing cut to b ring the th re ad section s ,

into the same identic al positions which would be occupied by the

rack teeth The hob an d the blank are then rot ated at the ratio
.

which co rresponds with the number of threads in the hob an d of

teeth in the ge ar just as the im agin ary rack would Operate This
, .

is simple in principle an d app arently so in operation

, B ut the work .

ing out of the det ails an d the results are not uniformly satisfacto ry ,

for which there are several re asons .

In theory the action of a hob in generating the teeth of Spur gears

 FO RM P LA NING , A ND GENER A TING METHO D S 1 01

is perfect ; in practice it is not The worm sh aped ho b cont aining .

-

s everal thre ads rot ating continuou sly

, cut s the teeth of the spur ,

gear the blank of which also rot ates continuously as the hob is fed
,

inw ards in its rot ation Cutting therefore st art s from the top edge
.
, ,

of the blank ( Fig all the w a

.
y round to the full depth of tooth ,

a n d progresses downw ards with the f eed of the cutter slide from the

top to the bottom edge of the bl ank during which period both bl ank ,

a n d cutt e r will h ave m ade m any re volution s under the control ofthe

ch ange ge ars set up This method is in favourable contras t with

.

the employment of single disc involute gear cutters of which eight-

,

form a st andard set an d which are nearly doubled with h al f numbers

,

w here very good result s are dem anded for high rates of revolution .

A n d these mo reove r are e ach abso lutely accurat e for one Size o f
, ,

ge a r only being approxim ate for those immedi ately adj acent In
,
.

theory every ge ar cut with a hob is ab solutely accurate provided ,

the Section al Sh apes of the hob threads in the n ormal pitch conform
to the rack section which is the basis of the system of cutting an d
, ,

with tho se corrections which are embodied in Single cutte rs to avoid

inte rferences in low numbered pinion s as explained on p 1 7
-
, . . .

The hobbing m achine is perfect fo r pitching due to the regular ,

rot ation of the bl ank an d the correction al ch aracter of the hob The .

fi rs t n amed avoi ds loc al he ating ; t he second is a consequence of the

spiral fo rm of cutt e r which provides a l arge number of t eeth acting
,

in succe ss ion an d with ve ry little we ar t he te e th ret aining their

, ,

keenness of edge for a very long time The hobbingprocess is much .

more rapid than cutting with Single cutters

,

Supposing these conditions are all ful filled there sti ll rem ain ,

s om e po ssibl e source s of in accuracy not im agin ary but so re al —

,

th at whe n very accu rat e ge ars are required for moto r c ars an d other -

service som e firm s re serve t he hobbing m achine for roughing only

, ,

pe rfo rming the finishing correction al cut s with single disc cutte rs -
.

Objection s to the Hob The firs t obj ection to the hob is th at its
.
-

action is not quit e perfect The teeth produced by it are not so

.

entirely accurate as those which are m ade by the same hob when
cutting worm wheels The cause of this appears to lie fi Is t in the
.

slight di fference of the section t aken in the axis of the worm an d of

that in the axis at which it is set a m atter of from about 3 to 5 ,
° °

( Fig. But t he princip al one is due to the succe ssive n ature of

the action of the hob in slipping from tooth to tooth while the
blank is continuously revolving which produces extremely minute ,
1 02 GEA R C UTTING

facets on the teeth A ctually when a very high degree of accur cy

.
, a

is insisted on other m ethod s of cutting h ave preference over

,

hobbing but for ordin ary or average ge ars it is a sufficiently

,

accurat e method .

Tho ugh the di fferenc e of from 3 to 5 of angle is not much it is ° °

,

enough when the tooth section is imp arted to the hob parallel with
its axis to leave the teet h a little too thick on t he point s To avoid .

this som e hobs h ave the tooth flanks m ade Slightly hollow ; in othe rs
the point s are well rounded In some inst ances the tooth sh ape is .

t aken norm al to the direction of the thre ad If co rrections are m ade .

in this w ay the action of the hob Should be practic ally p erfect .

Machines however which use hobs must be built sti ffly Since t he
, , ,

stresse s to which they are subjected are of a seve re ch aracter an d ,

are detriment al to t he e ffi ci e ncy of t he hobs .

The irregular su rfaces c aused by the dist ance between the cutting ,

e dges of the hob operating on a wh eel bl ank while revolving con .

tin ually may be minimi ed as st ate d

, B ut when the be st po ssible
z .

result s are desired some me ans of co rrection seems desirable A .

re am er design of hob has been patented by Messrs David B rown

Son s Ltd
, It is a p arallel hob Corresponding with the worm of
.

the gear an d with continuous teeth of rack section but the sides ,

of the teeth (or threads) are formed with a number of fi n e cutting

teeth o r serrations arranged in different fashions Simil arly to the
,

teeth of Single or double cut files an d the hob is h ardened an d

,
-
,

ground to elimin ate distortion The amount of m et al removed

'

is ve ry sm all a me re fi lm co rrection whic h is all th at is required

— —
.

It may follow the ordinary t apered hob in correcting high angle d -

worm gears or it may be used for co rrecting spu rs

,
.

The Gra nt hob ( Fig 8 8) is designed to avoid o r to reduce the .

fo rm ation of flats on the t eeth ari sing from the combin ation of
the revolution of the bl a nk n d the succ e ssive cutting action of a

hob t eeth which are sp ced widely by the ordin ary mode of
,
a

flutin g. I n the hob Shown fi nely pitched t eeth are cut an d , ,

their section al Sh ape is as illu strat e d in the section al view ( Fig .

p roviding cleara nce whe n cutting an d al so cl eara nce fo r the ,

grinding wheel which is used to sh arp n them The R ich ards e .

Machine Tool CO of London is th repre se nt ative f the fi rm

.
, , e o

in this country .

Makin gthe Hobs Three methods of producing hobs are adopted

.
—
,

two of which are commonly followed There are turning an d mill .

1 04 GEA R C UTTING

angle of between 30 an d 50 to obt ain high effi ciency an d a pres

° °
,

sure angle of 2 2 which gives an included angle of thre ad of

The Humpage Hob Thi s (Fig 90) has inserted teeth the obj ect
.
— .
,

be ing to facilit ate hardening an d truing of the tooth p ro files an d ,

adv ant age is also t aken in the const ruction to embody an ingeniou s

w ay of producing the b acking o ff wit hout the trouble of doing it as

-

in solid hobs The grooves in the body are t apered with their
.
,

centre axes not radi al but t an genti al to a circle concentric with the
,

hob The bl ades cont aining the teeth are set in reve rs e fas hion to
.

th at in the section al view during turning an d cutting of the th re ads

, ,

so th at when they are reversed their po sition in the grooves imp art s
,

the necessary relief The teet h are ground accurately after being
.

h ardened an d are drawn down into their seatings by keys the nuts
, ,

at the end preventing l at e ral movement Messrs E G Wrigley . . .

CO Ltd are the m akers

.
,
.
,
.

The Wust P rocess The Wust helic al Spu r ge ars are hobb ed
.
—

the teeth being discontin uous an d st agge red Wiist ge ars cut with .

hobs are rem ark able for the very sm all size of the pinion s which
,

are p racti cabl e This is one of the advant ages which the helic al
.

design po ssesses ove r the o rdin ary Spurs .

The axes of the hobs used in cutting the Wust teeth are not in
clin ed but are set at right angl es to the axi s of the whe el bl ank
, .

The axi al sections of their teeth are tho se of a rack A pressure .

‘

angle of 2 0 is adopted an d t he t eet h are Short e r th an the B rown

°
,

Sh arpe st and ard the height of addend um b eing :

,

o8
_ _1
9.

77

The pract ice is adopted of enl arging the pitch di ameters of pinions
under 20 teeth to avoid undercutting the formula being : ,

P 1 Ch
d number of teeth) 1 } ; x
 FO R M P LA NING, A ND GENERA TING METHO D S 1 05

fo r 20
°
pressure angle an d addendum
, The teeth are cut at
.

a n a n gle of

A n o ther method embodied is th at of a milling cutter of which ,

o n e fa ce produc es the tooth cu rves on the bl ank the cutter bein gse t at
,

t h e a n gle corres po nding with th at of the r ack teeth ; the same result
is o b t a ined if a grinding wheel be sub stituted for the milling cutter .

T h e Ckambou Hob This is designed to cut bevel ge ars by m e an s

.
—

o f a h o b ( Fig which on first thought s seem s impractic able The

. .

a p p e a r ance of the h o b it self doe s not help one to

a n un derst anding of the method until the principle

o f t h e design is grasped It represent s the tooth

.

o f a crown ge ar B ut since the tooth t apers the

.
,

h o b combines the to oth section s at m ajor an d minor

di a m eters an d at all intermedi ate po sition s It is .

c o n ceiv able th at sep arate hobs should be u sed as ,

o n e to sh ap e t he t eeth on t he m ajor di amet e r an ,

o t h e r on the minor di amet e r an d an othe r on others

,

i n t e rmediate Ho w to combine th em in one hob

.

o f t he s ame di am eter is the di f fi cult problem si n c e ,

n ot only the dimensions but the angles of thre ad Fig 9 1 . .

v a ry with the di fferenc e in pitches .

To do thi s a bl ank is tu rned an d cut to the section of a thre ad

c o r responding with the section of the tooth of a crown gear on the
m a j or di ameter an d to the angle of th re ad correspon ding with the
pit ch on th at di ameter A second thre ad is cut on the same blank
.

corresponding with the section of a tooth of a crown ge ar on the

mi n or di amet er an d to the angle of thread which corresponds w ith
th e pitch o n t he di a met e r t ak en Si n ce the crown teeth h ave
.

s t raight sloping fl ank s t he angle of these will be alike in both thre ads .

B ut the angle corresponding with the pitch will be di fferent so th at ,

in cutting the second thread a po rtion of the fi rst thre ad will h ave
been cut away an d a po rtion of the second will be wanting The
,
.

s m aller thre ad is to h ave the s am e depth of tooth as the l a rger B ut .

th e met al th at is left h as at two point s a se ction common to both

thre ads an d if it is fluted at those point s these will form cutti g
, n

edges an d the one hob will t ake on it self the function s of the im agi
,

n ary hobs for the m ajor an d minor di ameters an d for all inte rmediate
position s The hob is flut ed at other positions all round The hob
. .

now t ak es the place of the crown gear in generating bevel gears of

the same pitch .
1 06 GEA R C UTTING

To hob bevel gears with this represen t ative of a crown ge ar three

movement s are necessary On e is th at of revolution in rel ation to
.

the bl an k similar to th at of the spur ge ar hobbing m achines the

,
-
,

hob m aking as m any revolution s to on e revolution of the gear blank

as the re are teeth in t h e l att e r The hob must al so t rave rs e acro ss
.

t he width of the teeth with a co st ant ch ange of angle suit able to n

the ch ange of angle correspondin g with the pitches A n d the hob .

must be rocked while being fed across the t eeth These movement s .

complic at e the con struction of t he m achine very much The .

t able for the wo rk is c arried on the ho rizon t al f ace of the m ain

f raming of the machine with ho rizont al adjustm ent for cone angle
an d h avi n g the dividing wheel actu ated f rom t he he ad of the m achine .

The cutte r is mou n ted on a Spi n dle di spo sed vertic ally in a swinging
c arri er slidi g on w ays on the face of the head the movement s being
n ,

d riven t h rough a telescopic sh aft The he ad o scill ates to ch ange .

the a gle of the cutt er which ch ange is regulated by a te mplet

n ,
.

Gen er tion by Millin g The Gr n t Machin e

a A curiou s m achin e a .
-

of the gene ratin g type w as d sig n ed by Mr G B Gran t of e . .

,

Le xington f r p r duci g the tooth ed p ro fi les of a p articul ar form

, o o n

of cycloidal teeth ( Fig 92 ) with a ci rcular milli g cutt er A S the

.
n .

tooth fl anks in this system must al

w ays be straight the t erm p lan o id ,

is applied to this epi cycloid pl ane -

fl ank syst em The fla ks are sh aped . n

with a thi n slitti g type of cutte r n

F
( g i t he bl a k b e ing se t at such
. n

an angle th at o n e f ac e of t he cutt e r

Fig 92 . fo rms one radi al fl ank correctly both

.
,

in rel atio n to the c entre of the wheel an d

to the ape x of the co ne A ft e rw ards the cutter is set Up in the c entre
.

of t he sl t an d revolved while the wheel blank is tu rned th rough an

o ,

arc of a c ircle c au s ing t he tooth point s to receive the epi cycloid al

,
-

curve ( Fig . This the refore di ffers from the ge ars which are pro
duce d by pl an o gene rating p roc esses
-
The su rfac e is fini sh ed in o n e .

rolli n g cut ; but mo re th an th at the actu al cont act of t eeth t akes

, ,

p l ac e only at an d clo se to the pitch li n e bec a u se t he h p o cycloid l

y ,
-
a

cu rve s which would be struck by rolli g circles i cont act are

,
n n ,

oblit erated by the necessity of u sing a flat cutter O e adv ant age . n

of this is th at there is no oblique pressure as in involute t eeth an d as ,

in a lesser degree in cycloidal teeth Mo reover it is a syst em which .

,
1 08 GEA R C UTTING

Though one cutter c annot be m ade to out both Sides of a tooth

Sp ace at once yet two cutters in thi s m achine e f
, fect the same economy
Iy being m ade to act on oppo site sides o fadj acent teeth at one time
( Fig . This is e ffected by the arrangement of the slides the ,

a ngle s of which in rel ation to e ach other correspond with the angles

of the tooth slides so th at each cutter runs on an ,

axi s pe rpendicul ar to the su rface being cut an d ,

their faces if prolonged would cut the apex of

the pitch cones .

The cutters are fed along the teeth by the

slide s which as the m achine is m ade to turn
, ,

out o n e Size of ge ar only are c arri ed o n fixed ,

bases The cutt e r s are rot ate d at the same

.

Fig 9 5 . time that they are fe d forward lengthwise to

.

the tooth an d t he ge ar bl ank is al so o scill at ed

,

through a dist nce equ al to the length of the arc of cont act o f the
a

teeth The machine too i s entirely autom atic from st art to finish
.
, ,
.

The cutt ers h ave quick return an d when a gear is finished the ,

m achine rings a bell an d stops .

The B eale Machin e In this shown by Figs 307 3 1 0 p 3 01 tw o

.
—
, .
-
,
.
,

cutt ers A A are milling cutte rs h aving in serted radi al teeth of which
, , , ,

a Fig 3 1 1
,
is the ope rating fac e
.
, The Sp ace s between the teeth le ave
.

room for t he t ee th of the other cutt e r to int e rlock so th at the f aces ,

of the teeth cut are those which lie opposit e to the cutt er body The
'

angl es of the cutt e rs in pl an vi ew ( Fig 309 ) can be v aried to suit .

diffe rent pressure angles of the teeth There is al so another .

adju stme n t th at in an angle from the vertic al to correspond

— —

with the bevels of the teeth in section or to the apex of t he pitch

cone The cutters represent the rack or crown gear of the involute
.

syst e m of bevel ge a rs In the ro lling of the bl an ks p as t the cutt e rs

.

t he tooth cu rves are gen e rated The bottoms of the teeth are left
.

ve ry Slightly conc ave .

 S EC T I O N [ IL —
MA C HI NES

CHA P ER T IX
MA C HINES USING FO R M CUTTER S

A U T O MA TIC MA cri m e s
Figs 96 to 1 03 illustrate a Spur gear cutting
— .
-

m achine of autom atic type by the B rown Sh arpe Manufacturing

Comp any of P rovidence R I US A in which rot ary disc cutters ,

a re used an d of th at design in which the cutter is travers ed in a

,

horizo nt al Slide bene ath the wheel blank c arried on a ho rizont al ,

arbor . Fig 96 is a side elevation of the machine ; Fig 97 is a pl an

. .

v iew ; Fig 98 is a front elev ation or right h and as the attend ant
. ,

s t ands ; an d Fig 99 is a re ar end or left h and elev ation

. The - -
.

general design has b een embodied in m achines by di fferent makers .

Gen eral Design The principal parts of the m achine are as

.
—

follows The bed A supporting the cutter slide B an d at one end the
—
,

upright C On the f ace of C the wo rk Spindle slide D is c arried The

. .

overhang of the Spindle is t aken by the supporting be aring E which

is c arried in the up right bracket F an d this is adjust able along the ,

edge of the bed A in tee grooves The work spindl e is actu ated from
-
.

the pulley G belted from the countersh aft which latter makes ,

2 3 0 revs per minute an d the fe ed an d Speed motion s of the cutter

.
,

ca rri age an d cutter spindle are derived from the same pulley The .

Sh aft Hconveys the motion to t he work Spindle through the group of

indexing gears at J an d the locking disc an dits adjunct s in the box K

,
“

The movement s are transmitted through the vertic al Sh aft L through ,

equ al Spur wheels to the worm which drives the indexing worm wheel
M The Spur wheels aa which have 3 0 teeth e ach are indic ated
.
, , ,

in dotted outline in Fig 96 above the wo rm also dotted in front of

.
, ,

the wheel c asing M The pulley G drives to the worm wheel N o

. n

the fee d screw 0 an d also to the wo rm P on the end of the cutt er

,

Sp in dl e Here it will be noted th at the driven member is the wo rm

.

an d not the worm wheel an interes ting an d u n usu al mech ani sm , .

The rates of both these movement s are varied by the feed an d speed
ch ange ge ars cont ained at Q (Fig R is the pulley by wh ich .

1 09
TIZ GEA R CUTTING

the movement of the cutter Slide is reversed These are the arrange
.

ments in outline We will next trace out the det ails

. .

Detail s. Beginning with the bed A of the m achine its section

—
,

is seen in Fig 1 00 which shows the Sloping opening down which the
.
,

Fig . 98 .

cuttin gs an d w aste lub ri c ant fall the l atter to be removed from the
,

trays at the sides seen in the general views an d retu rned by the
, ,

pum p The cutter c arri age B i s gibbed to one She ar only of the bed
.

— the right h and one in Fig 1 00 an d it h as a slight clearance next

-
.
—

the Squ are edge on the side opposite The overhang of the right hand
.
-

side of the c arri age is cou n ter acted by a be aring an d gib on the under
 MA CHINES USING FO R M CUTTER S 1 13

Side of the n arrower She ar at the left h and The upright C which
.
,

is c ast in one with the bed h as sp ace s for tools an d index ch ange
,

ge ars an d a portion of the bed is recessed for feed ch ange ge ars

, .

The pulley G drives both to the cutter c arri age an d to the cutter

Fig 99
. .

spindle It is keyed on the driving shaft the be arings of which are

.
,

bu shed (Fig an d c arried in a bracke t a which is bolted to the

Side of the bed . The driving Sh aft b passes through the bed This
.

Sh aft is the first in operating the tr ain s of ch ange ge ars at Q

. These
transm it t he motion for feeding the cutter slide as indic ated in the
,

H
1 14 GEA R CUTTING

ch ange ge ar di agram to the right of Fig 96 termin ating in the wo rm .

,

c ( Fig 1 0 1 ) which drives the worm wheel Non the feed screw sh aft 0
. .

The speed worm sh aft d is dri ven by pai rs of ge ars only one on b , ,

an d one on d ( Fig the l atter c arryin g the wheel which d rives

.

the worm ge ar P ( Fig 1 00) on the end of the cutter Spindle In

. .

thi s particular m achine there are twelve rates of slide feed an d six ,

rates of revolution of the spindle The slide travels at gi { gin . n ”

I gin
—-
l
l
1 4m 1 }g in 2 §in 3 iin
, 41 m 53
. m , 7 in
gin . an d m in
, , ,
.
,
.

per minute The spindle m akes 2 0

.
35 60 an d 8 0 rev s , , ,
.

per minute The gears for these ch anges are given in t ables sent by
.

the firm .

Wh atever the rat e of revolution of the cutter Spindle the return ,

Fig . 100 .

is const ant Speed driven from the pulley R m aking 498 revs
at a , , .

per minut e The mech anism is shown in enl arged det ail in Fig 1 0 1
. .

( comp a re with Fig The pulley

. R d rives the bevel ge ars S ,

the l arger gear running loosely o n a slee ve which is keyed on the feed
screw When the feed is on the feed screw 0 is driven by the worm
. ,

wheel by the clutch T fe at her keyed on the extension of the feed

,
-

screw an d move d to the left th e worm c becoming operative

, The .

l arge bevel gear S then runs loosely with its Sleeve driven by its ,

pulley R When the clutch is moved to the right it engages with an

.

intermedi ate clutch pl ate at the b ack of the bevel ge ar an d m akes ,

connection without Shock through the medium of the friction washers ,

which are fitt ed in annular rece sses in the ge ar The clutch is oper .

ated by the lev e r U sect ioned in Fi d een in pl n in Fi

g ,1 0 1 an s a g 97 .
, . .
1 16 GEA R CUTTING

which is seen in Fig 1 00 with an oil cover at one Side The entire
.
, .

box is covered in with a top which is removable for in spection an d

,

when end play of the cutter Spin dle has to be t aken Up This is done .

by adjusting the nut 1 an d lo ok in git by the screw k

°

Settin gthe Cutter P rovi sion is m ade for setting the cutter cen
.
—

t rally as follows
, A nut t ( Fig 97 ) is loosened an d the dirt gu ard m
—
.
,

( Fig 9 ) removed
8.
Then the in dic ator ( Fig 1 02 ) is clamped holding
. .
,

between the dotted po rtion an d the screw n an d the screw 0 is ad ,

j ust ed against the pitch line of the cutter first on one side an d then
,

on the other until the ze ro lin e on the arm is equidist ant from ze ro
,

on the plate 01 the screw 0 can be adjusted so th at the ze ro lines

.

on the arm an d plate will

coincide The wo rm p ( Fig . .

9 7 ) is u sed to adju st the

cutter Spindl e an d when set ,

the nut l is again clamped .

In dexin g The drive to .

—

the in dexing ge ar J st art s

from the pulley G an d is ,

tran smitted through the

s h aft H It is commenced .

by the Spur ge ars 9 (Fig .

the first of the ge ars being

Fig 102 . ,
driven by mitre gears from
the Sh aft of the pulley G an d ,

the Speed is reduced from 2 30 to 2 02 revs per minute The motion . .

is tran smitted to another Sh aft in the same pl ane H an d reversed ,

1
,

by gears r The sh aft H c arries the indexin g mechanism K for the

.
1

ch ange gears J This is shown enlarged in Fig 1 03 s is the locking

. . .

disc notched at the edge to be turned one two or four times with
, , ,

different arrangements of ch an ge ge ars particul ars of which are ,

Supplied in t ables To set these the knob t (Fig 1 03) is lifted an d

.
, .
,

the sliding block u is set at the recess which corresponds with th at

g iven in the t ables supplied by the firm The indexing. is effected
autom atic ally by the movement s of the cutter Slide from the dogs

1 an d w ( Fig
) v is cl amped on the slide in cont act with the
.

reversing dog x when the cutter Slide is moved forward su ffi ciently

,

far to le ave Sp ace between the cutter an d the work for indexi n g .

w is cl amped at the termin ation of the out while restin g again st the
reversing dog x B y the movement of the stop rod which c arries
.
 MA CHINES USING FO R M C UTTER S 1 17

x , trip at y moves a clutch at z an d renders the indexing

a

m e ch anism O perative .

The Ch ange ge ars at J transmit motion to the vertic al splined

Sh a ft L Fi g 6 d which d rives through equ al spur ge ars aa
( s
9 an .

t h e worm which operates the dividing worm wheel M The sh aft L .

b e ing splined permit s of the vertic al adju stment s of the wo rk Spindle .

Work Spin dle The work Spindle slide D is adjusted vertic all y
—

e ither by h and or power The fi rst is e ffected at the crank h an dl e

.

X ( Figs 97 an d. operating the bevel ge ars bb on a Shaft Y The .

Fig 103
. .

se cond is controlled by the lever Z (Fig Operating the be vel .

e a rs cc ( Fig 99) on the sh aft Y

g . .

The section through the work spindle an d its slide is outlined in

the plan ( Fig The slide is gibbed an d six bolt s clamp it to the
.
,

U prigh t C The bl ank is fi tted by its bore ov er the split bu shing

.

a t the end of the arbor in the Spindle con fi ned by t he nut dd On ,

.

the removal of this nut the bushing is forced o ffthe arbor by the nut
ee The arbo r is released by screwing the nut cc against the en d of
.

the Spindle t aking hold of the h and whee l A A an d then drawing

,

the arbo r back through the Spindle The bushing is then inserted .

in the bore of the blank an d being h eld in position the arbor is

, ,

pushed through it an d the n ut dd is screwed again st it expandin g it ,

in the bore of the bl ank The nut cc is then loosened a little an d the
.
,

arbor can be drawn into the t apere d hole in t he Spin dl e by the h and
1 18 GEA R CUTTING

wheel The arbor can be t aken out to be ch anged for one of another
.

size by removing t he h and wh ee l A A an d the screw The rbor

II a .

is then d rawn out at the front .

Settin gthe Work Work is set as follows The clamping bolt s on

.
— —

the work Spindle Slide are loosened an d also those on the outer ,

suppo rt E The crank or h and wheel at X is used to lower t he Slide

.

un til the cutter ju st touche s the bl ank The cutter slide is then .

moved b ack until the cutter cle ars the bl ank There is a di al at .

X which is now set to zero The work Spindle slide is lowere d a

,
.

little more th an is required for settin g to the depth of tooth an d the n ,

raised to the exact depth This is done in order to let the weight .

of the parts rest on the screw The work Spindle slide an d the outer .

support are then cl amped The rim rest B B is set in position . .

The Loewe Machin es The autom atic Spur gear cutting .

m achines ( Figs 1 04 to constructed by Messrs Ludw Loewe

. .

Co A kt Ges of Berlin are of the horizont al work s pindle

. .
, ,

type The l argest machine de als with a m aximum di ameter of

.

8
7 § in .

The speed ch anges are produced th rough a steppe d con e in e ach

c ase The feeds are obt ained throu gh a feed box with eight ch anges
.
, ,

these being driven on the smalle st type from a sep arate belt fro m
the countersh aft ; but a safety dev ice is included to connect to the
cutt er spindle which prevent s the feed from continuing if the cutter
,

Spin dle should stop or it s re volution s f all below a cert ain minimum
,

through belt slip The cutter Spindle is then driven by the feed
.

belt until the m ain belt works properly or until the feed is arrested , .

A s soon howeve r as the m ain belt pulls e ffectively the device is

,

autom at i c al ly disconnected The two larger type s derive the fee d .

from the m ain drive The quick return of the cutter slide t akes .

pl ace at about 4in per second . .

The indexing is d riven independently of the cutter spin dle an d

of the cutt er slide feed an d provision is inco rporat ed fo r preventing
,

the slide from adv ancing until the i n dexing is completed This is .

done by the use of an index wheel which must m ake one two or , , ,

four complete revolution s before the slide can advance Thi s .

wheel has a divided rim for adjustment for wear an d is bolt ed to ,

the work Spindle by me ans of a fl ange conn ection The adjustment .

of the work Slide upon the Upright is e ffected by me ans of a h and

wheel an d screw with b all thrust coll ars an d a ve rnier permits of
,
-
,

re ading to 002 in A t ailstock rest is provided for supporting the

. .
1 20 GEA R CUTTING

vertic al movement The objection th at in this design the dividing

.

wheel is more liable to receive cuttings on it is met by completely

enc as ing the wheel These m achines are m ade in variou s Sizes up
.

to 6ft 6in c apacity A 48 in by 1 2 in m achine is selecte d for illu s

. . . . .

t ratio n with general views an d det ail s

, .

Fig 1 08 gives a side an d Fig 1 09 an end elevation The work

.
, . .

arbor A is set in the spin dle B which p asse s down through t he ,

saddle C fi tting the bed by s qu are edge s an d c arrying at the

, ,

bottom the divided casing th at encircles the worm wheel E is .

Fig 105 . .
—
Loew e A uto mat i c Sp u g r- ear Cutt i g M hi
n ac ne ( R ear V i e w ) .

t he cutter slide b al anced which moves downwards for feed an d

, ,

U pw ards for quick re tu rn .

D rivin g The drive is t aken fi rs t f rom the pulley F belt ed from

—
,

the countershaft F d rives through Spiral gears a ve rtic al Splined

.

sh aft G which p asses through a bracke t on the cutt e r slide E

,
This .

bracket is Shown enl arged in Fig 1 1 0 Here G tu rns a ge ar a fitting . .

,

by two long keys an d a en gages const antly with anoth er gear b

,
.

O n the U pper end of th e sh aft b is a stud with a spring plu n ger ,

e n abling di fferent ch an ge gears to be put on to en gage with a gear o n

the top end of the shaft c arrying the spiral pin ion c with 9 teeth ,
.
 MA CHINES USING FO RM C UTTERS 1 21

By altering these ch ange gears six different speeds can be imparted

,

to the cutte r spindle c engages with the 36 toothed spiral wheel d

.
-

on the end of the cutter Spindle an d the boss of d fits in a gl and like
,
-

bearing e in which it may Slide endwise This is to allow of the

,
.

Slight l ateral adju stment of the Spindle an d it s be aring which is ,

provided for adjusting the cutter exactly central with the work .

Iis a cover for the hand hole in the c asing surrounding d an d gis ,

a hinged u rd covering the ch n ge ge ars ju st mentioned In st e ad

g a a .

of putting the cutt e r direct on the Spindle Sep arat e arbors are em ,

Fig 106
. .
-
L o e we Machi n e ll
I ustrat i gU
n se o fStea dy .

ployed so th at an y size of cutter can be put on without regard to the

,

Size of its hole The arbo r is lettered H in Fig 1 09 an d its outward

. .
,

be aring J The l atte r is adjust able longitudin ally an d is secu red

, .
,

by bolts fitting in tee Slot s on the side A pointer K is pivoted above

-
.

the arbor an d is brought down when required for setting the cu t t e r

,

t rue by its centre line the en d of the poin ter bein g central with the
,

axis of the Spindle B .

The Cutter Slide Squ are lips with a n arrow guiding ledge are
—
, ,

employed for mounti n g the Slide E It is fed by a spi ral rack an d

.

pin ion driven prim arily from the pulley E which operates spur gears ,

(n ot Shown ) an d thenc e a wheel 7 d rivi g a pinion h (Fig

°

, The n .
1 22 GEA R C UTTING

l atte r o perat es ch ange ge ars in the box L which has a hinged doo r ,

so th at di f ferent ge ars m ay be put on a range of nine Speeds being

,

obt ain able From the box L a wo rm gear just above it tra smit s
. n

the motion at right angles an d it is again ch ange d by anothe r set

,

of worm gear to the rack pi ion on Sh aft M A han d wheel N the

n .
,

rim of which is seen dott ed in end elev ation actu ates worm ge ar ,

fo r tu rni n g M when adju st ing the cutte r Slide

,
A trip l ever N pe r .

mit s the h an d feed to be disen gaged whe n o t requi red The t ri p n .

ping o f the autom atic down feed is effected by the dog 0 bolted on ,

Fig 107
.
—
Cut ter S lid M difi d f
e o e or Ho bb in g .

to a st epped surface at the Side of the Sli de to preven t risk of the dog
slipping adju stme nt s b eing fi n ally m ade by the screw locked with
,

a nut . This screw strik es the l ever P which t rips a clutch so , ,

throwing out the drive to sh aft M Q is a l ever coupled to P for

.

throwin g out the clutch by han d When the feed h as bee n t ripped
.

the slide E is f ree t o rise an d it d oe s so rapidly u n de r th e pull of t h e

,

count erweight att ach ed to the ch ain which is seen p assing around
t he pull ey at t he top of the f ram e In the bu ffer b racket at the to p
.

of the st an d ard is a spring which t akes the shock on the return of

the cutte r slide On the stop screw R is an adju st able n ut which
.
1 24 GEA R CUTTING

friction w ashe rs commence to drive l is in mesh with a ge ar 0 an d

.
,

m with a l arger o n e p o an d p run loo sely on a bu sh but a Sliding

.
,

key moved by the coll ar q ope rat ed by the h andle W ( Fig

,
.

c auses eithe r of them to turn the bush on the end of which there is,

a pinion eng aging with a wheel 5 ( Fig driving t on the top sh aft
. .

A s previou sly mentioned the l atter passes through the frame an d

, ,

then transmit s by mitre ge ars to a box X ( Fig 1 09) in which suit able .

ch an ge gears are arranged for the indexing required From X a .

sh aft Y p asse s alongs ide the m achine to actu ate the worm of the

dividing wheel in the c ase D A .

Splined ge ar uencircling Y engages

with a gear 1) (see Fig 1 1 3) held .

on the Sh aft of the worm w by a

Split bo ss A longside v is a h and .

wheel for tu rning the worm by

h and for adjusting pu rposes an d ,

on the other Side of v a micrometer

di al with 2 00 divisions is keyed .

The worm may be withdrawn

rapidly from mesh with the wheel
by me ans of a lever Z fixed o n ,

a spindle fi tted with eccentric

bu shes The Spindle p as ses .

through slotted lugs in the c asing

which form s the bearing for the
Sh aft of w an d the e ffect of moving ,

Z is t o draw the c asing an d worm

b ackwards thus le aving the worm ,

Fig
. 109 ,
wheel free for s pinning the bl ank .

It will be seen from Fig 1 1 3 .

th at the worm wheel has a divided rim bolted together SO th at ,

adju stment can be m ade for we ar In this fi gure is also shown

.

the provi sion for ste adying the wheel by a set screw above an d ,

a Sliding block it below y y a.re fi bre Shield s which

, go on the
ends of the worm bracket an d m aint ain a dust proof joint -
.

Min or D etails Referring again to the general view (Fig

.
—
.

three point s may be noted The saddle is moved along the bed by
.

a screw turned by a s qu ared end which is seen projecting with a

, ,

micrometer di al att ached A ste ady bracket supports the top of

.

t he arbor an d is applic abl e for pinion s an d wheels of moderate

,
 MA CHINES USING FO RM CUTTER S 1 25

diameter A nother st ay is p rovided for wheel s of larger di ameter

. .

This steady is seen in the Side elev atio n as is also a rim support (on
,

the bed close u n der the cutter slide) adjust able to be ar under the
rim of a wh eel close to the teeth to counter act the downw ard pre s
, ,

sure when cutting P rovision is m ade for lu b ric ation by a pump

.

(not see n ) the m achine st anding in a tray Ch ange ge ars are stored
,
.

in the pigeon holes in the top of the cupbo ard at the back of the
-

column .

The m achine will cut up to 2 di ametral pitch an d Ia in circul ar .

Fig. 110 .

p itch. The re are

4 2 ch a nge whe el s which will divide
, al l number s

up to 1 00 an d all excepting prime numbers from 1 00 to 2 40

, . .

Op eration In O perating the m achine the following point s h ave to

—
,

be observed the sequence in setting U p for cutting being as follows :

,

First the worm is withdrawn from the dividing wheel by moving

,

the lever Z so th at no strain may be brought on the teeth of the

,

dividing wheel when tighten in g the wo rk arbor Then the socket .

B c arrying the work arbor A is locked by a plunger pin seen in the ,

end elevation (Fig Care must be t aken to see th at the arbor

.

an d its hole are both perfectly cle an an d the arbor is th en in se rt ed

,

an d the nut unde rn e ath t ightened su f fi ciently to hold it from turni n g .

1 26 GEA R C UTTING

The gear blank is n o w placed in po sition noting th at the coll ar an d

,

packings for the arbor are free from burrs an d the top nut of the
,

arbor is tightened down .

The cutter is set centrall y by the pointer similar prec aution s,

regarding the packings being observed so th at it shall run perfectly

,

t rue on the arbo r .

When the bl ank has been properly secured on its arbor the rim

Fig .

rest is brought up into cont act lightly u sing the fi nge rs only for
,

adju sting it s nut an d it is then l ocke d

, R evolve the bl ank by h and
.

to test its truth both edgewise by bearin g on the rest all round
, , ,

an d over th e periphe ry . If it runs out the c ause may be burrs

, ,

dirt defective bushings an d coll ars bent or untrue arbors etc The
, , , .

worm is now re engaged with the dividing wheel c are being t aken
-
,
 MA CHINES USING FO R M C UTTERS 1 29

Chan ge Gears The change wheels for the dividing motion are
.
—

selected from the blu epri n t which is supplie d with t he m achine ,

an d are pl aced on their respective studs c are being t ak en not to ,

engage them too deeply The spindle d rive change wheel s are also .
-

obt ained from a t able which gives t he number of spindle revolutions

,

er minute for e ach combin ation of wheels The f eed drive ch ange
p
-
.

wheels are given with their respective rates in te rms of re volutions

of the spindle per inch on a brass pl ate att ached to the cover of the
,

feed gear box

-
.

When cutting l arge ge ars it is advisable to arrange a f ace pl ate

d rive for the work rather than rely solely upon the friction of the
collars an d work arbor nut besides which the face pl ate ste adies
-
,

the ri m of the wheel A f ace pl at e of the u su al l athe type mounted

.

on an d secured to the coll ar of the arbor socket is all th at is

necessary fi tted with loose dogs or othe r drivers of the form best
,

suited to the work A n O peni n g is left in the bo ss of the f ace

.

pl ate to pe rmit the locking plunger on the top of the saddle to

engage with t he socket .

Until the operator has become thoroughly conversant with the

working it is advisable after all adjustment s have bee n m ade to , ,

allow the m achine to through it s operation s for two or three

go

tee th without touching the work in o rder to m ake sure th at the ,

stroke cle arances etc

, h ave been p roperly allowed for A lso in
,
.
, .
,

cases where the bl ank to be operated upon is of a costly n atu re it ,

is as well to guard ag ain st mist akes in mounting the ch ange wheels

by letting the cutt er just m ark the rim of the blank through a com
l et e revolut ion if it is to h ave a few te eth or for a suf fi cient number
p ,

of teeth to determine the accuracy of the pitch in the c ase of l arger

wheels For this operation the h and motion to the cutter slide will
.

be u sed fi rst bri n ging down th e slide until the cutt er m ark s the
,

rim an d then returning it to t he top fo r the t appet to strike the

,

plunger for the spacing motion .

The object of the two speed dividing motion (Fig 1 1 1 ) is to save -

.

time in dividing a d reduce the st rain on the change wheels The

,
n .

handle by which the change is effected is set to readings 40 or

under or to 4 1 or over acco rdin g to the number of teeth to
,
” “
,

be cut .

The f ri ction drive for the sp acing motion is so adjusted that

ve ry little or anything should be require d in the w ay of adjustment
fo r some time ; but if on st arting it appe ars to slip at all fi rst
, , ,
1 30 GEA R C UTTING

e xamine the sh aft beari ngs an d meshing of dividing wheels to see

that al l is pe rfectly easy n d free to revolve ; an d then if still in
a ,

clin ed to slip tighten very slightly the two check nut s pro v ided
,

an d oil the friction f ace s through the hole provided for the purpose .

The friction plate should feel w arm to the touch aft er running for a
Short time .

The micrometer adjustment on the sh aft of the worm w

( Fig .1 1 3 ) is only u se d for a Speci al purpo se th at of touching —

round the teeth of a wheel on on e Side only This is rarely called .

for ; but if it should be the set screw which cl amps the partly
,

Split Spur ge ar 7) th reby di connecting it from the p indl e ) d

( e s s an

the worm is rot ated by the h and wheel al ongside until the
work is found to be o ffset su ffi ciently Then re tighten the set .
-

s crew an d proceed with the sp acing as u su al On no accoun t .

must the mech ani sm be rest arted before the cl amping screw has
been tightened properly .

The m achine as stated is intended to cut ge ars up to 1 3m c ircul ar 1 .

pitch or 2 diametral pitch For 2 3 diametral pitch an d co arser in

.

cast iron an d 4 di ametral pitch an d co arser in steel a stocking cutte r

, ,

should be used to remove the bulk of the m aterial He avier pitches .

th an those fi rst n amed can of course be dealt with by t aking a

, ,

Series of cut s .

The Gould G Eberhardt Ma chin e A 7 zin by 1 8 in autom atic

.
—
. .

spur ge ar cutting
-
m achine ( Fig 1 1 4) is the latest rep resen
.

t ativ e o f a typ e which h as been built for m any ye ars p ast It .

is seen in re ar view to illustr ate the motor driv e It will be .

noticed that the central type of construction is followed the work ,

Spindl e p assing through the hollow upright instead of lying t o ,

o n e sid e of it i an overh an gi n g po sition

n The cutt er Slide feed
.
-

screw is also lo c ated directly behind the cutter in a central

position The drive is furnished by the const ant speed motor or
.
-
,

alt e rn atively by a con st ant Speed pulley -

an d connect s through
,

gears to the cutte r spindle fin ally driving by worm an d bronze

,

wo rm wheel The range of speeds proceeds in geometric al pro

.

g ress io n . The cutter Slide h as al so a geom etric al range of feeds ,

an d a uniform rat e of quick return indep endent of th es e The .

various autom atic movements are conn ected so that nothing can
st rt wo rking to the detrim en t of t he m achin e cutter o r work until
a , ,

the prescrib ed motion h as b een completed ; thu s t he cutter Slide

c annot commenc e its travel until the div idi g is fully accomplished n ,
1 32 GEA R CUTTING

rim clamp which holds the rims of l arge gear bl anks as in a vice to ,

prevent them from creeping under the cut .

The outer arbor support is held upon a tee Slotted bracket b y -

bolt s an d is adjusted re adi ly for different lengths of m andrels or

,

for temporary shifting to remove or repl ace work Verniers are .

provided to accurately adjust the bearing head in align ment with the
main spindl e .

Q uill Gears A ll ordin a

. ry s pur
-
ge ars or pinion s can be re ad ily

Fig 1 15
. .
—
Q uill G
ear big
e n cut o n a B ro w n Shar p M hi
e ac ne .

cut upon the regul ar m achines without t rouble but in the c ase of ,

quill ge ars where there is a wheel an d a pinion in one with a sleeve

, ,

it is not always practic able to cut the pinion teeth on account of ,

the wheel fouling t he slide when brought down su f fi cie tly low for n

the cutter to re ach the pin ion A n att achment is consequently.

u sed with a supplement ary cutter spindle rai sed above the m ain one
on the Brown Sh arpe m achin es ( Fig an d drive n by a trai n.

of gears .

Cuttin gon Millin gMachin e The employmen t of a large att ach

.
—

ment on a B rown 8: Sh arpe universal milling m achine is seen in

 MA CHINES USING FORM CUTTER S 1 33

Fig 1 1 6 rep resenting a m agnified type of index centres with a Slotted

.
,

e xten sion above t he h e adstock be aring c arrying a screw with adju st

in g nut s to t ake the p ressu re of the rim du ring cutting The Spur .

ge ar being cut is a f ai rly l a rge one for the size of m achine it is done

Fig . MIL — Cutt i g

n a g
L ar e Ge a r o n E B ro w n p Milli g M hi
Sha r e n ac ne .

upon . ltern ative method sometimes adopted when l arge

An a

gears have to be cut o n a milling m achine is to let the cutter work

underneath an d raise the index cent res Up on blockings so that the
,

cutter spindle passes ac ross just above the t able an d the gear st ands
above the c ap acity depending Upon the range of exten sion af
, forded
by the raising blocks .
1 34 GEA R CUTTING

R ack cuttin g Machin es

-
These include some of l arge an d com .
—

plic ated types R acks are frequently cut on milling m achines an d

.

on universal ge ar cutt e rs R ot ary disc cutt ers Single or multiple .

, ,

are u sed But such m achines are not fully autom atic nor are they
.
,

designed for heavy duty or suit able for de aling with qu antities ,
.

For these re ason s speci al m achines are built fully autom atic an d ,

of heavy design in two bro ad types O n e may be te rmed of the

,
.

pillar an d knee milling m achine type the other the planer type
- - -
,
.

The fi rst deals with the shorte r lighte r racks ; the second with the ,

he avier ones O n e of e ach cl ass by the Wal cott Wood Machine

.
,

Tool Co mp any of J ackson Mich US A is shown by the aecom

, , ,

panying d rawings .

Figs 1 1 7 an d 1 1 8 Show the fi rst type of m achine in side an d front

.

elevations respectively The framing comprises a column an d to p .

hou sing The knee A is c arried on the front of the fi rst an d the
.
,

bearings for the cutter arbor B in the second .

Cutter A rbor The cutter arbor is driven from both ends as

.
—
,

see n in Fig 1 18 A th ree stepped b ack ge ared cone C b elted

. .
- -
,

from the cone D on the countersh aft d rives the arbo r th rough ,

ge ars at both ends on e set a being of double helic al form the ,

-
,

othe r set b comprisi n g common Spur ge ars the obj ect being ,

to elimin at e torsion an d vibration The three cutter Speeds .

a re ch anged at the counte rs h aft to suit work don e in o rdi n ary ,

or in high Speed steels In the NO 2 m achine shown they are

-
. .
,

for o rdin ary steel 1 4 2 0 an d 30 revs per min an d for high , , , .

Speed 1
9
, 2 8 an d
4 1 revs
,
.

The Work The rack to be cut is bolted o n the t able E the range
.
-
,

of movement of which in this p art icul ar m achine su ffices for racks

up to 3 6in long an d 8 in width of face This of course pe rmits of
. . .
, ,

cutting n arrower racks l aid side by side up to th at tot al width .

The t able E has a trave rse motion (for pitching) on the cross slide F ,

an d the l atter h as a tran sverse mov eme nt on the kn ee A for feed of

out both being autom atic ally produced

,
The knee has the usu al .

elev ating screw operated by a h andle pl ac ed at c The indexing for

, .

pitch is indep e ndent of the speed of the cutt er arbor the d rive being ,

obt ained directly from a sm al l pulley on the count ersh aft to the l arge
pulley ( G Fig ,
To accommodat e the ten sion of the belt to the
.

varyin g height of the apron the idler pulleys d d are provided The , ,
.

indexing drive from G to the t able E t akes pl ace through Spur

gears ch ange gears bevels an d Spurs to the end of the le ad or index
, , ,
1 36 GEA R CUTTING

screw at H on which the l ast change gear is seen The collar of

, .

the screw is indexed to re ad to Tfi m in P ositive clutches take l

.

ch arge of the indexing The t rip dog for indexing is seen at e .

-
.

Multiple indexing can be done through change gears Only .

the outlines of these features are indic ated in the drawings .

The feed for cutting is actu ated from cone pulleys K an d L ,

an d ge ars at the left h and of the m achine eight feeds being ,

provided for each Speed of the cone which drives the cutte r
arbor They range in this m achine from
. to o 4 3in per rev . . .

of cutter For racks of I di ametral pitch which is the limit on

.
,

this machine a roughing an d a finishing cutte r are u sed For finer

,
.

pitches gang cutters are u sed

,
.

Feed Drive The d rive to the stepped feed cones t akes pl ace
—

from the sh aft of the cones C through Spur ge ars J to the , ,

upper feed cone K belted to the lower cone L A s the centres .

of these cones v ary with the movement s of the kn ee a belt ,

tightener f accommodate s K thereto which swings on a link ,

connection The drive is continued th rough pai rs of Spur gears

.

M which are put in an d out of action by means of a slidin g

,

key the knob of which is seen at g The shaft which they

,
.

drive at eight distinct speeds as st ated c arries the feed worm

, , ,

h whence through ge ars not shown the fee d Screw 7 is drive n

'

, , , ,

imparting the t ransverse moveme nt to the cross slide F The .

feed is tripped by the dog k There is a quick retu rn the lever .

,

of which is seen at l .

When a rack h as been cut there is a provision m ade for

autom atic ally st o pping the m achine A dog m is cl amped in .

a suit able po sition at the edge of the t abl e When it strik e s .

the lever n this trips the dog 0 which pulls the chain 1 comin g , )

from the belt shipper bar q on the countersh aft so pulling the
-
,

belt on to the loose pulley N is the lever for ope rating the .

shipper bar by h and Machines of this type are m ade in five

.

sep arate c ap acities .

The P l an er Typ e of Machin e This is illustrated by Figs 1 1 9 .

—
.

to 1 2 3 The det ails are not fully Shown but enough are given to
.
,

permit the design an d method of operation to be understood The .

cutt e r arbor is driven from the cone pulley A at the b ase of the
m achine but the indexing is done di rectly f rom the countersh aft
,

to the pulley B at a const ant speed which is independent of the

Speed of the cutt e r arbor It is also wholly autom atic There are . .
1 38 GEA R CUTTING

eight rates of feed e ach of which is avail able for e ach Speed of the
,

cutter arbor .

Cutter D ri e Tak ing the cutter d rive first it is transmitted

v — —

from the cone pulley A ( Fig th rough the sh aft C th rough bevel .
,

gears to the m ain d riving shaft D ; thence through mit res E to the
,

cross sh aft F Sh aft F carries a Splined bevel ge ar a ( Fig 1 2 1 ) which

. .

drives the larger gear b on the shaft of which is a Sm all Spur ge ar ,

driving through a train to t he cut ter arbor G (comp are Figs 1 2 0 an d .

The arbor is c arried in the bracket seen att ached to the saddle
H It is rot at e d at the three Speeds corresponding with t he steps
.

of the cone A an d countersh aft drive For ordin ary steel they
,
.

are 1 3 1 9 an d 30 revs per min

,
For high speed steel they are
. .
-

2 7 an d 4 1 revs The eight different feeds to the saddle H c arrying

.

the cutter arbor are imp art ed to the screw J from a p air of cone
pulleys an d a rather formidable looking nest of gears on the upper
,
-

cone feed Shaft thu s :

-
,

Feed D rive On the other end of sh aft F which is d riven by

—

the mitres E is a four stepped cone pulley K which drive s to the

,
-

pulley L above The four feed changes thu s obt ained are doubled
.
,

an d reve rsed with a quick re tu rn by the nest s of ge a rs seen in Figs

, .

1 1 9 1 2 0 an d 1 2 1 which need not all be se p arately lettered as thei r

, , ,

functions can be studied in the views They drive down to the feed .

screw J thro ugh s purs an d mitres The four Speeds are doubled at .

the gears c ( Fig 1 2 1 ) by means of a Sliding k nob The nest of trans

. .

mission an d quick return gears comprising Spurs an d mit res are

-
, ,

actu ated from t he Sh aft M The clutches are seen at d e an d the .

, ,

quick return Shaft at N h aving the bevel ge rs C at its opposit e

-
,
a
’

e nds d riving b ack to the sh aft C The clutches are operated by a .

t rip arrangement the Sh aft of wh ich is seen at 0 ( Fig

, an d t he .

l atches studs dogs pin an d yoke are indicated in outlines at fan d

, , ,

g, fo r producing the rot ation of t he f e ed screw J( Fig .

The indexing is commenced from the pulley B The method of .

it s tran smission to the sh aft P is seen in Figs 1 1 9 an d 1 2 2 being t aken .

,

through ge ars From P motion is c arried to the feed screw Q

.
,

t hrough th e ne st of ch ange ge ars se en to the left of Fig 1 2 3 The . .

feed screw has an acme thread The feed is tripped by the sh aft .

R which is actu ated by the t rip of sh aft 0 just now notice d

, , .

It is thrown out of actio n by the clutch l The amount of .

the indexing is indic ated on the ring S which is provided With a

O

friction Sleeve .
1 40 GEA R CUTTING

When rack is completed the m achine is stopped automatic ally

a

by a dog g( Fig 1 2 0) striking a leve r which actu ate s a ro d h ( Figs 1 1 9

. .

an d 1 2 0) the movement of this tripping the ch ain which pulls ove r

the belt shipper rod on the counter so pulling the belt on to the
-
,

loose pull ey .

The elevation of the knee or Slide T which c arries the cross rail
along which the saddle H is fed is e f fect ed by gears U an d a screw ,

V . These are h and actu ated from the h andle k .

P rovision is m ade for forced lubric ation A pump W is d ri ven .

by the pulley X from the countershaft an d a flexible pipe Y ,

conveys the lub ric ant to the cutter whence it returns to a t ank in ,

the b ase .

The c apacity of the m achine shown is for racks up to g6in .

l ong an d m in width of f ac e an d to 1 di ametral pitch

,
. The ,
.

t able is 1 o 8in long by z4in wide an d the m achin e weighs about

. .
,

5}
1 ton s It
. is t h e re fo re r ath e r a m assive e x ample of a sp eci alized

machine .

Rack cuttin g A tta chmen ts

-
Short racks may be cut in qu antity.
—

by mounting a series of cutters upon an arbor in the milling m achine ,

an d hol ding a umber of racks upon the t able the t raverse being
n
-

then in the long direction of the t able For the ordin ary cutting .
,

however it is necessary to have a Speci al att achment to drive the

,

cutte r upon an arbo r at right angles to the m ain spindle There is .

then an op po rtunity to get in a much longer rack an d it is only a ,

question of indexing the t able along between each cut Either a .

Single cutt e r is u sed or two or t hree are mounted s ide by Side or a

, ,

roughing cutter precede s a finishing one so th at a Space is roughed ,

out alongside o n e th at is being finished This is seen in the vie w .

of the att achment by J P arkin son Son ( Fig . There is Spac e .

on the spindle to permit of seve ral cutte rs being clamped together ,

to a tot al width of 3 in an d as seen the arbor has an oute r .

, ,

bearing a con struction much prefe rable to the method of allowing

,

t he end to ove rh ang A p ai r of spiral ge ars tran smit s the d rive from
.

the m ain spindle an d the ge ars are hardened with ball thrust coll ars
, ,
-

p rovided for e ach The oute r e d of the att achment is suppo rted
. n

by the b racket of the overhan ging arm A Speci al long vice is em .

ployed to hold the blanks an d another Speci al provi sion is the in ,

de ing device (Fig

x which saves time a d ensu res accurate
.
,
n

pitchings obvi ating the bother of setti g by the use of the

, n

micrometer dial of the t able screw The device con sists of .

 MA CHINES USING FO R M CUTTER S 1 41

Fig l 24
. .
— P ar ki n so n Ra c k utt
-c i g A tt
n ach me n t fo r M illi g M hi
n ac n e.

Fig . 1 25 -
In d i gD i
ex n e v ce ki
fo r P ar n so n A ttach m en t .
1 42 GEA R CUTTING

an index plate with a plunger an d sixteen change gears The

, .

div isions are obt ained by combin ation s of these gears an d the ,

inde x plate is given a h alf tu rn or a complete turn before , ,

the lock ing plunge r is allowed to Slip into the notch If a com .

p l et e revolution of the pl ate is required t h e notch which is not ,

Fig
. 1 26
.
— R ack cutti g A tt
-
n ach men t to Bro wn p Milli g M hi
Shar e n ac ne .

in use is closed to prevent possibility of error resulti g in

,
n

false pitching In a pl ain milling m achine with rack feed the

.

device is mounted at the front an d is connect ed to the shaft ,

which t raverses the t able .

Fig 1 2 6 represents a B rown Sh arpe milli g m achine with th e

.
n

setting up of att ac h me t s a n d vic e for r ack cutting

n The bracket .
1 44 GEA R C UTTING

N by means of a screw an d p ad O the screw fittin g in a block P

,

which is inse rted an d look ed aft er the in se rtion of the bl an ks .

Downw ard fe ed for

t he depth of t eeth is
obt ained throu gh the
ratchet Q which feeds
,

the vertic al screw The .

ratchet is rocked at
e ach complete rev olu
tion of the wheel J by
a pin st andin gout from

its f ace thi s pin pu sh

,

ing a vertic al pin R

outw ards an d so mov
ing the ratchet p awl .

A stop screw S ( Fig .

1 2 9) cont rols the

highest setting of the
Slide L , an d anothe r ,

T the lowest setting

,
.

The l atter Serves to

stop the m achine wh e n

t he full depth of cut

h as been reached be ,

c ause the ratchet wheel

at
Q is fi tted b e tween
fi bre friction w ash e rs ,

an d when the Slide L

abut s again st the screw

T these w ashers slip ,

an d the m achin e ce ases

to O perat e The c ap a
.

city oi the m achine ,

which weighs 1 901b .

,

is for di ameters up
to fi in .

The inte rn al att ach

ment for the Loewe gear cutting m achin es is seen in Fig 1 3 1
-
.
,

comprising mean s for c arryi g the cutter at the end of a right

n

angled bracket which is bolted down on the cutt er slide A .

 MA CHINES USING FO R M C UTTER S 1 45

t rain of ge ars connect s up within the b racket from the m ain cutter
S p indle to t he Spindle of th e cutte r on the no se of the bracket In .

o t her re spect s the re is no di fferenc e in the mode of O peration If .

Fig. l 31 .
— l i g A tt
In te rn a Cut t n a ch me n t to a Lo e w e Machi n e .

th e intern al ge ar is not of such a form that the in side shoulder o f

th e ring of teeth st ands aw ay su f fi ciently from the f ace pl ate fo r
th e no se of the att achm ent to h ave a cle ar run it is nece ssa ry to ,

p ack out the gear .

 CHA P T ER X

MA CHINES USING FO R M CUTTER S ( con tin ued )

?

MIL L ING WOR M THR EA D s employment of a milling cutt er in

.
— The
place of a lathe tool for producing the threads of worms has ex
tended with great rapidity during recent years an d m any firm s mil l ,

al l their worm s now The ch ief advant age is of course the increa ed
.
s

rate of cutting possessed by the multiple tooth mill while another -

,

feature is th at the wh ole depth can u su al ly be cut at one p ass while ,

a l athe tool requires a numbe r of traverses .

Fig 1 32 shows a simple m ethod of l aying out the a ngle of the

.

side s of a tool for pl a ning out sp ac e s b twee n rack t eeth Upon e .

a lin e A B dr aw a ci rcle a n d f rom B l ay o f , f B C a n d B D e ach ,

e qu al to o n e qu art e r of the di am e ter of the circle

-
The n lines A C .

a n d A D drawn as shown are co rrect for the inclin ation of t he

, ,

side s of the r ack tool The e n d of the tool is m ade 3 1 of

.

.
,

Ci rcul ar pitch a n d then the cor n ers are rounde d to leave fi llet s
,

at the bottom of t he t ee th Thus if the circul ar pitch of a r ack

.
,

is 1 §in a n d w e multiply by 3 1 the p roduct 46 5in will be the

.
,
.
, , . .
,

width of the tool at the end for a rack of this pitch before the
corners are t ake n o ff This width is shown at x y Th fore
. . e

going rule is al so correct fo r a worm thre ad tool but sometimes -

,

t he tool is not rounde d for fi ll et In cutting wo rm s the widt h of .

,

top of thr ad Should be left 335 of the ci rcul ar pitch which will
e .
,

bring the depth of thre ad right .

Wo rm milling is done eithe r in a pl ain or a universal milling

m achine in a l athe with a rigup on the Slide rest or in a regul ar
wormmi ller the l atter being the most economic al an d suit able
-
, ,

, ,

particularly for l arge work A n att achment fo r a Garvin milling .

m achine is seen in Fig 1 3 3 from which the essenti als for wo rm mill
.
,

ing may be gathered The cutter is nece ssarily c arried by a swivel

.

ling head so t hat it m ay be an gled to the inclin ation of the thre ads
, .

Suit abl e ch ange ge rs are s t U p to con ect the t able scre w to the
a e n

e n d of the w ork Spindl e so th at the wo rm is rot ated at a corre ct

,

rate as the t abl e c arries it along p as t the cutter The reason for .

the sep aration of the wo rk Spindle into two sections e ach carried ,

1 46
1 48 GEA R CUTTING

ducin g these employed ( a) B y pl aning employing a t oo l

are .
,

h aving the same section as the tooth space ; ( b) by u sing the sam e
Single rot ary cutte rs th at a re emp loye d fo r spur ge ars which in th e ,

sm alle st spi ral ge ars is not an ab solutely correct method ; ( c by

)
employing a hob like th at u sed fo r generating spur ge ars al so n o t ,

wholly accu rate though much better than ( b) In these l ast tw o .

,

in accuracy is due to the int e rference of the cutter with the Side s of
the teeth resulting from the twi st ed fo rm of the helix Thi s e rror
,
.

Fig l 33
. .
— Wo rm Thread Mi lli n g A ttachmen t to a Garv i n

Milli n g Machi n e .

can be minimized by reducing t he diam et er f the cutte r or the hob o , ,

which however lessen s it s wearing q u alitie s A S howe ver the

, ,
.
, ,

int e rfe rence cut s away more fthe face s tow ard s the po int s thi s may
o ,

be accepted as rat he r an adv ant age tendi g t o easier running being

,
n ,

simil ar to the slight co rrective roun ding wh ich is given to r te th

ge a e

in general with the same object in View .

The diffe rence betwee a formi g method d a gen erati g

n n an n

me thod is : in the fi r t t h cut t r mu st be of the sam e section s

s e e a

the too th sp ace whic h it fo rm s ; in the Se cond it has the rack

se ction a d the move m ent s of the tool an d the rot ation of the
,
n
 MA CHINES USING FO R M C UTTER S 1 49

blank mu st synch ronize in orde r to produce the development of

the tooth sh apes .

Methods A dop ted The di fference s in the m ethods of cutti ng

—

Single helic al ge ars which are op en to selection ent ail the employ
-

ment of m achines of di fferent kinds When planing tools are em

.

ployed the sh aping class of m achine is the mo st convenient to use ,

or a l athe geared to drive directly to the le ad screw R ot ary di sc .

Fig
. 13 4 .
-
Ho l royd Wo rm Thread Milli n g Machi n e .

cutters are adopt ed on universal milling m achines an d on m any ,

gear cutting m achines of suit able de sign an d al so on the thre ad

-
,

milling m achine s Hob s are utilized on an y of the nume rou s spur

.

gear hobbing m achin es which are fitt ed al so with ge ar an d mech ani sm

,

for producing the spiral movem ent s an d also on the speci al Wiist
,

m achines En d axi al cutters like tho se in Fig 70 p 86 are occ asion

.
,
.
,
.
,

ally u sed for sm all ge ars on unive rs l milling m achin e s

a B ut t hey .

are employe d almo st e xclu sively on the sp e ci al m achine s which are

built by the firm who m ake a Speciality of this wo rk The se design s

s .

are con structed bro adly on the p attern of the l athe or on th at of ,

1 50 GEA R CUTTING

h orizont al drilling an d boring m achine s the re se mblance to the se ,

b eing of course b arely supe rf ici al .

Tool s Used A s in worm ge ars which are al so a p articu la r

.
- —

form of true spiral ge ars so in spiral s the rack might be Suppo sed
—
,

t o be of a h ard sub st ance which would mould correctly the t eeth of

,

all whee ls in a soft e r sub st ance to ge ar with it t he rack being moved ,

over the cylind ric al surface f the wheel blank In practice the
o .

m ethod of pl aning with a fixed cutter or of milling with a rot ary ,

Fig 13 5
. .
— P ra tt Whi tn ey Wo rm Thread Milli n g Machi n e .

cutter is adopt ed Planing in thi s case is the equivalent of tu rning

, .

a worm in t he l ath e with a tool Shaped to the section of the tooth

sp ace an d milling is done with a rot ary cutte r in a milling m ach ine
, .

The tool u sed for sh aping the teeth by the planing operation
mu st be of the section t aken i the line of the no rm al pitch an d mu st
n ,

be set at the angle corresponding with the norm al In st rict e ss . n ,

the tool u sed fo r cutting a common Single th readed worm m ade by -

,

the di agr am in Fig 1 32 should be so sh aped a d pre sented but

.
,
n ,

the di ffe re ce i the norm al an d actual pitch is o slight th at it is

'

n n s

a m atter of little import an ce in the c ase of the worm In the .

1 52 GEA R C UTTING

bec au se spirals of long le ad are much better done el sewhere

than in the l athe although the principle s are identic al The y
, .

can ,however be cut in tho se lathes which are provided with

,

a direct drive to the le ad screw of which there are a goodly ,

number built The difference is th at of drivi g b ack from th e

. n

le ad screw to the spindle being a c ase of speeding down in ste ad ,

-

of Speeding up These principles of operation appe ar in an y typ e

-
.

of m achine tool u sed for cutting spi ral s so me in a rather m akeshift ,

fashion in ot he rs in a legiti mate an d quite sati sfacto ry m anner

, .

The setting up fo r cuttin g a spi ral ge ar on a B rown Sh arpe

-

universal mill ing m achine is illu strated by Fig 1 37 Showing the .

,

swivel of the t able to suit the a ngle of helix a n d the settin

g ,

Up of the Ch ange ge ars to connect to the t able screw A s e ach .

tooth sp ace is milled th rough the next one is pitche d by the index ,

pl ate an d so on .

The use of a Speci al att achme nt on a Cinci n ati m achine is see n n

in Fig 1 3 8 the cutte r he ad bei g arra nged with a swivel fi tting

.
, n .

Ge ars of a y a ngle from a spu r ge ar to a r ack m ay be d e alt with

n , ,

thus I n the illust ratio n a 3 pitch steel ge ar 3 3m diamete r is

.
-
,
.
,

being cut at a r ate of feed p as t the cutter of Iin p er min ute . .

P l an in g Sp iral Gears These may be pl aned in a sh aper In .

— .

a Gould Eberhardt de sign addition al mech ani sm is fi tted con ,

si sting of a long t able bolted to the knee an d c arrying the bl ank ,

between cen tre s driven by a he adstock bolted to the t able th at

, ,

cont ain s the mechan ism th rough whic h the movement s of the bl ank
are controlled re spon sive to the reciproc ati g movement s of the ram
, n

which holds the cuttin g tool The se movement s are those of a helix .

corresponding with that of the gear to be cut They are derived .

from a long rack att ached to the shape r ram which being recip ro , ,

cat ed by it cont rol s the movement s of a spi ral ge ar an d ch ange

,

wheel s o n the he ad The spi ral ge ar is the fi rst o r le ading element

.
,

the v ari ation s in le ad are p roduc ed by the ch ange ge ars On the .

return stroke of the tool the rack re turn s the bl ank to it s origin al
po sition The down feed of the tool is e ffected by h and The pitch
.
-
.

in gis don e by a notched i n de x pl ate into which in succ e ssion a l ocking

bolt on the head is d ropped Thi s is a perfectly m ech anic al method .

of cutting although done by the aid of a rigU p to a m achine not

,
-

prim arily intended for it It is much bette r th an the l athe method . .

D ouble helical Gears -

The patent m achine of S St iick gold fo r
.
—
.
,

c utting double helic al sp ur gears is de sig n ed to set the ax i s of the

-
,
 MA CHINES USING FO R M CUTTER S 1 53

blank horizont ally The increasing dem and for ouble helic al
. d -

ge ars with continuou s teeth has given ri se to several patented de

vices for e ffecting the nece ssary reversal of the ge ar at the apex of
the teeth for right an d left hand cutting The on e illu strated will .

give an id e a of the kind of mech ani sm which c an be empl oyed .

Fig 1 3 7
.
— Cutt i g
n a S pi l G
ra B
ear o n a ro w n p
Shar e Un i ve rsa l
Milli g M hi
n ac n e.

Fig 1 39 is a side view Fig 1 4 0 a section at right angles to Fig

.
, . .

1 39 . The motion s are al l derived f rom the stepped cone s A on the

sh aft B from which the cutter c arri age C is travelled along the bed

D c arrying the cutte r a which is rot ated by the sp i ral ge ars b c

, , , .

The Work head The movement s of the work head Fig 1 39

-
.
— -
, .
,

are actu ated from the Sh aft B ( Fig 1 4 0 through v ariou s gears an d
) .

me chani sm s which provide fo r the rot ary movement of the blan k ,

1 54 GEA R CUTTING

in fo rward an d b ackward direction s correspondin g with the cutting

,

of each h alf of the width of the teeth The se movement s are tran s .

m itted from the worm ge ars d an d e seen at the right h and end of —

both figures to the wo rm ge ars f g at the left h and of Fig 1 39 The

, ,
. .

Fig l
.
-
l
Ct1tt in g a Spira Ge ar o n a C i i
n c n n at iU i n v ers a l Mil li g M
n a ch in e .

vari ou s degrees of an gle o fthe di ffe re t wheel t be cut re o bt ained

n s o a

by the Ch ange gears n at the left of Fig 1 4 0 an d the reve rsing

, ,
.
,

me ch ani sm is comp ri sed in the rack an d pinion etc arrangement s ,

.
,

seen in Fig . 13
9 an d in se cti o n in Fig 1 4
, Th e det ail s are as
. 0 .

follows :
Method ofD ri in g In Fig 1 40 the sh aft E is rot at ed from the
v —
.

worm gears d an d e through a reve rsin gclutch for the cutt e r he ad

, .
1 56 GEA R C UTTING

o bj ect of the latter is on ly to en sure regul ar an d con t ant moveme nt s s

of the ge ars z The rack Q with R is guided by the dovet ails se e

.
, ,
n

in Fig 1 40 an d in it movem e t s actu ates the gear r a n d thenc e the

.
,
s n ,

trai to the wo rk head as alre ady st ated

n -
.

The recip roc atio n s are p roduced by the rel atio s of the pi ion q n n

to the p i rack H The pin ion q is loc ated above the rack Huntil t he
n .

l atte r has co mpleted the ran ge of its t ravel The Since the connec . n ,

tion of the rack Hto the rack bar Q is p roduced through the toothe d
c rank di sc 2 the radiu s of which is equ al to the radiu s of the pinio n
,

q the
, se c rank s are tu rned ve rtic ally U p w ard s o r downw ard s ac co rd

Fig 1 40
. .

ing to the direction of motion of the two rack s H an d Q The rack .

H as soo n as it is pu shed alo g by the pinion q will in con sequence

,
n , ,

of the t enden cy of the crank di sc z to rot at e be pre ssed fi rmly down ,

into the wheel q an d thereby an y furthe r rot ation of the c rank di sc

,

z will be p revented Thi s continue s until the pinion q falls out of

.

engagement with the rack H at the end of its travel an d for so long ,

the rack Q will actu ate the pinion r an d it s t rain B ut when the .

pinion q get s out of mesh with the pin rack H the latt er lo se s its ‘

Suppo rt in the pinion Then following the p re ssu re exert ed by the

.
,

pinion q on its last tooth it move s from one po sition i to the other
,
n ,

a lowe r to a high e r o r high e r to lowe r being unde r th e coe rcion of

, ,

th e crank d isc s z which no longe r rot ate Then the pinion engage s .
 MA CHINES USING FO RM CUTTERS 1 57

in the othe r Side of the rack reversing it s di rection an d th at of the ,

train of ge ars which it operate s .

The L oren z Machin e A n exten sive p ractic e is do e on t he

.
—
n

m achines built by the Maschinenfabrik Lo renz of Ettlingen B aden , , ,

for whom Me ssrs C W B u rton Griffi th s CO of London are the

. .
,
.
, ,

B riti sh agent s These m achine s are built in two type s on e on the

.
,

l athe model the othe r o n the horizont al bo ri ng an d drilling m achin e

°

type The fi rst is m ade in two sizes fo r the sm aller di ameters of

.

ge ars the second in three size s for l arge gears ranging up to six
,

metre s di amet er In the lathe de sign the blank s are held b etween
.

c ent re s the axi s lyin g ho ri zont ally ; in the other the axi s is ve rtic al
,
.

The L athe D e ign In the l athe design ( Fig s 1 4 1 to 1 4 3) the

s — .

Fig l 4 l
. .
—
Cutt i n ga Dou bl e -he li l Pi i
ca n on on a Lo re n z M hi
ac n e.

bl ank s are held betwee a dividing he ad at the headstock en d an d

n ,

the loo se poppet at the other an d are fu rthe r supported by ste adies , .

The drive t ake s pl ace from the Single pulley seen at the left h and end -

F i 1 4 2 ) di rectly f rom the line sh aft Th pull y i th rown in a d

( g . e e s . n

out of action by a friction clutch F rom thi s the dividing head is .

driven through worm gear of the globoid type enclosed behind the
fac e plate the wh eel being of steel a n d the wo rm of b ronze with b all
, ,

be arings for end th rust The drive to the dividing he ad t akes pl ace
.

th rough ch an ge gears to impart the a gle o r le ad to the ge ar The n .

cutter Slide is of the f ront o r face design bei g c arri ed on ve rtic al ,

n

w ays to leave the enti re sp ace above the bed available fo r gear
blanks .

Method ofA ction The action of the machine is as follow s z The

— —

cutt er is set to wo rk to the depth of the tooth A fter re aching this .

1 58 GEA R CUTTING

depth the longitudin al fee d

,

comes autom at ic ally into pl ay ,

c arrying the saddle an d cutter

along the bed while the ch ange
,

ge ars imp art the nece ssary

ci rcul ar motion through the
dividing he ad to the bl ank the ,

two combining to produce the

tooth angle The too th space
.

is fi ni shed out at one trave rse .

When thi s is complete the ,

cutter m ake s a quick with

draw al an d the saddle retu rn s
,

to it s o ri gin al po sition the ,

blank at the same time being

tu rned th r ugh a di st ance
o

e qu al to the pitch completing ,

a cycle A ll the se movement s

.

are autom atic The with .

draw al of the cutter an d the

quick return of the saddle
occur independen tly of the
depthing an d feed motion s .

The B orin gMachin e Type .

Fig s 1 44 to 1 4 6 Show a heavy

.

Lorenz m achine w hich com ,

bine s the function s of hob

bin g on the right h and he ad -
,

an d cutting helic al ge ars on

t he l eft h and h e ad with en d
-
,

mill s Fo r the autom atic cut

.

ting o i Spur an d wo rm wheels

by the hobbing p rocess the ,

ordin ary hob s are employed ,

with straight rack teeth Di sc .

cutte rs removing a tooth space

at a time can al so be utilized

in the c ase of l arge wheels

which would require very ex
p n ive hob s
e s . n on -
cu t ting move ment s are e f fected in
1 60 GEA R CUTTING

po sition The auxiliary

.

mo tor supplie s the powe r

for dividing the wheel
fo r the next tooth an d ,

is then autom atic ally

th rown out of action .

The self acting t ravel of

-

the cutter slide is locked

until the pitching is done ,

an d then t he cutter Slide -

feed comme ces again n .

D rivin g The m achin e —

is driven by a v ari able

speed moto r The cutte r .

spindl e run s in long

cylindric al bearings an d ,

its he ad is
arr anged to
swivel through ,

a worm an d
worm qu ad rant by a ,

vern ier Set t ing The st a . n

d rd with its b al a ced

a n

cutt er slide can be t ra

v elle d rapidly in e ithe r

di rection by powe r an d ,

there is a fi n e h and ad
ju stment The st andard .

is a rran ged to Slide with

long guide s over the
low lying div iding whee l
-
,

so th at sm all wheels ca n

be cut The di v iding

.

gear in the bed is of

t he globoid wo rm ge ar -

type the worm be ing

,

adju st able an d h aving a

l arge numbe r of teeth in

mesh Siemen s Martin
.

steel is employe d for the

 MA C HINES U SING FO R M CUTTER S 1 61

ring of the dividing wheel an d the worm is of pho sphor bronze

,
.

A b all thrust r eceive s the axi al pressure of the worm an d the ,

whole drive run s in oil .

Feeds The feeds for all the cutting operation s are obt ained
.
—

through ch ange ge ars within ve ry wide limit s an d e ach self acting ,

-

movement is adj ust able through stops which autom atic ally trip , .

Fixed stop s a rrest the further travel in a po sitive m anner .

The left h and side of the m achine is arranged for helic al wheels
-

a n d pinion s either with sol id te eth or st aggered if nece ssary

, , En d .

m ill s are u sed for the solidly cut te eth Thi s side of
-
m achine .

is driven by a motor
with con st ant speed an d ,

the cutter spindle revo

-

l ution s are v aried by

n e st s of ge aring produc
,

in g eight ch ange s .

O p era ti o n Th e —

m ethod of working whe n

cutting double helic al
t e eth is as follo w s z The —

cutter is S et first of all

into the intended depth ,

a n d is then st a rted auto

m at icall y in it s lo n gitu
din al movement The .

motion of the dividing

Fig 1 4 6
w heel is synchronized
. .

t h rough change ge ars suit ably to p roduce the angle of helix During .

the travel of the cutte r over the whole tooth widt h the wheel is tu rned ,

by a reversing arrangement so that the double angle is imparted to

,

t h e teeth in one p assage When the tooth sp ace h as been cut through
.
,

t he cutte r is quickly withdrawn an d the cutter sli de return s to the

,

commencing po sition Duri ng thi s quick return the wheel is pitched

.

fo r the next tooth sp ac e an d t he operation goe s on until the whee l

,

is fi ni shed being e nti rely auto matic

, The feeds for depth an d .

l on gitudin al travel are v ari able in a l arge r ange through ch ange

wheels The quick return of the cutter out of the sp ace al so the
.
,

rapid retu rn of the cutter slide are e ffected at a con st ant speed
, ,

indepen dently of the r ate s of cutting .

Spiral ge ars can al so be cut wit h the help of an att achm ent
 CHA PTER XI
MA CHINES USING FO R M CUTTER S ( con tin ued
)
THE Brown Sh arpe combined
pur an d bevel gear cutting machine s

( Fig s 1
.
49 to 1 53) illu str ate the spur ge ar cutting m a chine de scribed -

on pp 1 09 to 1 1 8 with a bevel gear cutte r slide sub stituted for th at

.
-

which is u sed for spur gears alone The capacity which this has for .

setting to an y angle Up to 0 ent ail s ce rt ain alteration s in the method

°
9
of driving which are shown in the accompanying drawings Where
, .

the part s of th is m achine are identical with tho se of the spur gear -

cutter the same reference letters are employed but the part s spe ci al ,

to thi s machine are indicated by other lettering Fig 1 49 is a right . .

hand elevation Fig 1 50 a left hand ditto an d Fig 1 51 a plan View

, .
-
,
. .

Movemen ts The driving pulley G is ret ained an d the pulley R

.
—
,

an d the feed reversing m ech ani sm in Fig 1 0 1 on p 1 1 5 are identic al

-
.
,
.
,

in both m achines The letter A indicates the bed C is the upright

.
, ,

an d a is the bracket bolted to the side of the bed which c arrie s the

bearings for the driving Shaft as previou sly explained But the , .

etho d of drivin gfrom the pull ey G to the slide is di f ferent Bevel .

ge ars at CC Fig 1 51 driven by the pulley G drive the shaft DD

,
.
, ,

to the bevels EE to the cutter spindle FF in the cutter slide GG

( comp a re with Fig T he bo x w h ich
. c arrie s the ge ar s CC
sw ivel s on it s sh aft to be accommod ated to the setting of the sh aft

DD to angle which h as to vary with the angul ar po sition of the p art s

,

HH Fig 1 5 1 det ail s of which are shown in Fig 1 53 The motion

,
.
, . .

to the cutte r Slide is given by the screw splined sh aft KK t aking the -
,

place of the Screw in the previou s m achine an d O perated from the ,

same fee d an d reversing mech ani sm as in Fig1 01 p 1 1 5 But the .

,
. .

hand wheel adju stment in th at figu re is not u sed a rack an d pinion

-
,

being employed in stead (ggan d hh Figs 1 52 an d , .

Cutter Slide The m ain body HH on which the cutter slide GG

—

travels is hin ged at if Fig 1 53 an d adju sted for angl e round a

, .
,

quadrant slot kk with a locking nut ll adju stment being m ade w ith ,

a p inion mm an d a qu ad rant r ack seen in Fig s 1 52 an d 1 5 3 The . .

rack is gradu at ed an d a vernier is fitted ju st above the pinion The

, .

body an d qu adrant locking bolt an d pinion are c arried in the bed

, ,

1 65
1 66 GEA R C UTTING

sl ide JJ which is moved along by the pinion hh an d rack gg In

,
.

thi s m achine a horizont al movement of 1 2 3m is provided for The . .

cutter Slide GG has a trav el of 5}in The operation of the c utter .

slide is Shown in Fig 1 53 t aking place from the splined sh aft

. ,

KK driven as before st ated , , ,

from the feed an d reversing

mechani sm at the end of the
bed A sliding bevel gear .

on the sh aft K K drives

another n u both being con , ,

fined in be arings secured in

t he bed Slide Thence gears .

00 in the pivot tra n smit

motion to spur gears pp ,

which operate a screw qq of

quick pitch in the cutter slide
GG so imp arting a traverse , .

A S th e splined sh aft K K is
driven an d reve rsed by th e
same mech ani sm as the feed

screw in the spur ge ar cut -

ting m achine the return ,

'

non cutting stroke of the -

slide GG is e f fected at a
rapid an d con st ant speed .

In o rder to t ak e Up
an y b ackl ash pre sent in t h e

train of gears an d to pre ,

Fig 1 4 9 .
vent shock in the movemen t s

of the cutter slide the weight ,

is t aken up by a cord p assing round a pulley LI Fig 1 52 thence .

,

going over guide pulleys above an d held in ten sion by weights, .

O n t he spindle of thi s pu lley is a pinion rr which eng ages with a rack

SS under the Slide GG The movement between the pinion an d
.

rack m aint ain s the cord vertic ally in all po sition s of the cutter slide .

The Carriage To adju st the bed c arri age JJ swing the hinged
.
—
,

s top tt Fig 1 53 out of the w ay loo sen the gib s M

, .
, Mof the c arri age
, ,

Fig 1 52 an d move the c arri age out of the w ay by mean s of the rack
.
,

a n d pinion d hh Fig 1 53 S t the wo rk an d h aving thu s

gg an ,
e . .
,

determined the po sition of the c arri age cl amp the bl ock uu Fig 1 53
, , .
,
1 68 GEA R C UTTING

the cutter held in the slide re st In m any m achine s the dividing .

is done by hand but the ex ample t ake n is fully autom atic an d is

, ,

m ade in several Sizes up to 8ft diameter c ap acity The drawings

, . .

show a 2 ft m achine in det ail

. Some de sign s are m ade for cutting
.

Spur gears onl y but the pre sent ex ample is c ap able of cutting in
, ,

addition bevel s an d wo rm ge ars

, It is possible to produce worm .

Fig . 15 1 .

gears with a straight out across the face to suit t he teeth of the worm ,

owing to the swivelling movement of the cutter head .

This is a type of lesse ning interest bec ause t he prese nt ,

te ndency is al mo st wholly in favour of more specialized machines ,

but it Shoul d be ill ustrated bec ause m any of t hese m achines rem ai n
,

in use an d in the ge neral class of shops where only a moderate

,

amount of ge ar cutting is don e they fi ll a use ful pl ace

-
.
,

The Headstock Fig 1 54 illu strate s the con struction of the wo rk

.
— .

headstock It slides on the bed A fitting by a n arrow guide the

.
, ,

g ib portion embr acing only t he right h and she ar thu s se curing t he -

,

same assumed adv ant age s as in l athe s fi tted with n arrow gu iding
ledges The gib strip is pulled U p by a couple of bolt s tightened
.
,
 MA CHINES USING FOR M C UTTER S 1 69

fro m above There is a clearance at the edge of the other Shear

.
,

an d a pl ain gib below Simply se rve s to prevent lifting The he ad

.

is adju sted alo n g the b ed by a screw B h aving a micrometer fitting

,
.

C is the wo rk spin dl e turning in split bearings in the h ead ; it h as a

,

Slotted face pl ate D bolted on at th e front to c arry l arge ge ars

,
. The
a rbor E interch ange able for di f
, ferent bore s in blanks is driven by a
,

short key an d held in by a long bolt . The out er end of E is turn ed

to run in a steady be aring bolted to a slot on the under side of A
,
.
1 70 GEA R C UTTING

the end of C is keyed the worm wheel F z6in out side di ameter
On , .

with 1 80 teeth of 7 pitch an d 1 5m face The worm box G is arranged

. .

to dro s light ly, on releasing the set screw below so th at the wheel
,

m ayzbe s pun freely fo r testing the running of bl ank s previou s to

,

cutting .

The Cutter H cad — The det ails of the cutter he ad are giv en in
 MA CHINES USING FO R M C UTTER S 1 73

m itre ge ar S engaging with a companion which tran smit s the drive

,

t hrough a long be aring in the b ase H thence by bevel ge ars T an d U ,

( there being three of the l atte r) to a ho rizont al sh aft V Keyed on .

thi s is a spur ge ar W engaging const antly with another gear X on

, ,

a short sh aft th at c arrie s a ge ar Y me shing with one Z The l atter ,

.

a re re adily remov able so th at other wheel s m ay be sub stituted

, ,

t h e re bei n g Six gears in all giving with the two speed countershaft ,
-

t welve rates of speed to the cutter spindl e v arying from 2 0 rev s ,

.

t o 2 00 revs per minute

. The Shaft on which Z is mounted p asse s
.

t hrough a be aring on the slide M an d d rive s a st eel spiral pinion ,

m e shing with a pho sphor bronze wheel A A giving a ratio o f 4 to 1 -

,
.

A smooth drive without ch attering under he avy cut s is obt ained

i n thi s m anne r En d th rust of the pinion is t aken by a b all thru st
.
-

w a sher seen in pl an Fig 1 55

, ,
. .

Feed ofSpin dle The feed of the cutter Slide M is derived al so

—

from the Sh aft V through ch ange ge ars B B of w hich a set is pro

, ,

v ided to give ten ch ange s v arying from

kin to 5 m per minut e . .

t raverse ; thence by mitre s at CC an d worm ge ar DD Quick ,

.

return at a con st ant speed is e f fected through the ge ars EE Either .

DD or EE may be m ade to drive the screw N in reverse direction s , ,

b y th rowing the cl aw Clutch between them to me sh w ith one or the

o ther a lever c performing thi s movement
, A utom atic reversal is .

o bt a ined through the m edium of the stop rod d which h as a p air of ,

a dju st able coll ars upon it st ruck by the moving slide M so throwing , ,

the rod along an d moving the lever c

, .

O n looking at Fig 1 56 a lever e will be ob served keyed on the

.
, ,

s ame spindle as c thu s p art aking of it s moveme nt

,
The object of e .

is to rele ase the dividing m ech ani sm at the app rop ri ate time
n amely when rever sal t ake s pl ace
, A ch ain or cord is att ached to .

t he hook of e an d p asse s around a Couple of guide pulley s ff do wn

, ,

t o a lever g on the sh aft FF ( see al so Fig

,
Looking at thi s .

drawi n g it will be noticed th at the sh aft R previou sly mentioned

, , ,

is c ontinu e d into the dividing motion box an d drive s a spur ge ar ,

G G through two intermedi ate s seen in the pl an view to the left ,

.

G G run s loo se on it s sh aft an d only drive s it when a claw Clutch ,

HH is in mesh From the Sh aft a tr ain of ge ars JJ connect s to a

.

S h aft on which a dividing pl ate K K is keyed an d mitre ge ars LL ,

c onnect through the swing pl ate M M an d suit able change gears to

the sh aft NN which p asses alongside the m achine through the
,

w orm box G ( Fig The ge aring J " is so arranged that the first
.
 MA CHINES USING FO R M CUTTER S 1 77

an d more e speci ally for giving a cert ain amount of set to the blank
w hen cutting bevel ge ars where the cutter is m ade n arrower th an
the width of Sp ace at the sm all end of teeth an d the bl ank is tu rned ,

Slightly t o cut the ext ra width at the l arge end The di sc s a re .

gradu ated to Show the amount of set over so th at it can be recorded -

,

fo r duplic ate work With the ch ange ge ars provided all numbers
.
,

Fig 15 8
. .
—
A Go u ld E b d
e rhar t Un i v e rsa lg
- e ar Cutti n g M hi ac ne .

of teeth from 6 to 1 00 an d all numbers fro m 1 00 to 600 excepting

, ,

the prime numbers an d their multiples can be cut , .

The Gould <5 Eberhardt Machin e

»
Fig 1 58 Show s one of the
.
—
.

l ate st m achine s by Gould 81 Eb erh ardt of New ark N J for cutting , , . .

,

spur bevel an d f ace ge ar s an d p a rticul arly for roughing out auto

, ,
-

mobile b evel gears prep arato ryto being fi ni shed on a bevel ge ar pl aner -

( s ee al so p 3
. 2 6 ) It h as a c ap acity of cutting 3 6in di ameter an d m in . .

face spur gear s an d 24in di ameter an d 8in face bevel gears both
, . .
,

U p to 3 di ametral pitch in c ast i ron an d 4 di ametral pitch in steel

, .

M
1 78 GEA R C UTTING

Cutter Slide The cutte r slide move s in a vertic al plane an d the

—

work lies in a horizont al po sition on a t able arranged on the anvil ,

p rinciple In the pre sent de sign the reciproc ating p art s are mount ed
.
,

upon the vertic al upright po rtion of the m ain frame an d the feeding
arrangement is of the draw cut p rin ciple there being a Sep ar ate an d
-
,

di rect drive to the feed screw mech ani sm Thi s ve rtic al cutting
-
.

feature elimin ate s the disadvant age when cutting bevel gears of , ,

tilting the cutt er slide with all its m any moving part s The latt e r .

method is unde sirable bec au se it lack s rigidity for he avy cutting ,

p articularly since the advent of high speed steel The old m ethod -
.

al so n ece ssit ate s the mounting of the reciproc ating p art s U pon an

ang ul arly adju st able slide to which motion is tran smitted th rough
a circuitou s route from the p rime move r to t h e cut t e r spin dl e an d
'

feed screws .

Work table The work t able is adju st able to an y angle an d is

-
.
— -

s o mounted th at all the strain s imp arted by t h e cutter are tran s

m itted to an d t aken by the m ain b a se of the m achine Thi s arrange .

ment of the cutter an d wo rk slides elimin ate s one sliding surface an d

only require s two Sliding surf ace s When the t able is in this angul ar
.

po sition it is supported by a segment arranged cent rally an d pro

v ided with a worm wheel secto r whe reby the t able is adju sted
-
, .

In addition to these forming a lock the Secto r has a st rap in the seg ,

ment th at m ake s a rigid lock for the t able when prope rly adju sted .

A crank h andle on the f ront end of the m achine en ables t he operator

to adju st the work t able by degree s an d minutes one turn of t he
-
,

crank h andle corre sponding to one degree an d a sector vernier gradu ,

ated in degree s show s the amount of the an g le given to the t able .

This t able is cont rolled by an indexin gmechanism which is po sitive ,

si mple in con st ruction an d is pr actic ally the sam e as is u su ally found

,

in some of the l ate st spur ge ar cutting m achine s

-
Th e l ast mover of .

the indexing train is a worm wheel of l arge di am et er arranged to be ,

clo se to an d rigi dly secured with the wo rk t able upon which the ge ar -

bl ank that is to be cut is fast ened Upon thi s t able is al so mount e d

.

a t ri angul ar sh aped wo rk m and rel oute r suppo rt which su st ain s t he

‘
-

gear bl ank at it s outer en d in an y angul ar po sition .

Fcod The feed to the cutte r Slide is controlled by a v ari able

—

feed ge ar bo x w ith direct re ading permitting of a rapid ch anging

-
,

of the feeds It provide s fo r Sixteen di ffe rent feed s ranging in

‘

geomet ric progre ssion from fi n to 1 53m an d each of the di fferen t

.
,

feed s is obt ained by the operatio n of tw o hand wheels The cutte r .

1 80 GEA R CUTTING

Fig 1 61 show s the work he ad in thi s c ase fitted with two work
. ,

s pindle s for l
,
arger a n d sm all er ge a r s either of which c
,
an be brought
roun dlby the circul ar movement of the he ad o n it s b ase F provided ,

for setting the ge ar bl ank s at their correct bevel s The entire .

Fig . 15 9 —
Cutt i g
n a l
B e v e Gea r o n a B ro w n p
Shar e Un i v e rsa l
illi g
M n Mach i ne .

m ovement s of the head are actu ated from the Shaft B thence ,

through ge ars to the shaft G an d back through Ch an ge ge ars H to

the screw sh aft J The screw Sh aft J is u sed to feed the b as e F
.

o f the he ad along the bed an d bevel ge ars tran smit the rot ation s
,

to the cutter spindles through the vertic al Sh aft K The tran s .

mi ssion t ake s place through two spur gears one of which is seen ,

at c thence to the spin dle s th rough one worm an d wheel f

, an d ,
 MA CHINES USING FO R M CUTTERS 1 81

a nother p air g On the ge ar a a division plate L with index peg

.
,

pro v ides for indexing the ge ars th at are being cut .

Cutter Hcad The movement s of the cutter head D inclu ding

—
,

it s reversal are provided for thu s : a spur ge ar H Fig 1 6 1 one on

, ,
.
,

the end of the Shaft B drive s a train of gears the l ast of which
, , ,

a ctu ate s the screw spin d l e M wh ich travel s the he ad B Its re .

versal is e ffected by three swinging ge ars (not shown) which transmit

the forward or the b ackward travel as de sired The bed E which .

Fig 1 60
. .

c arrie s the cutter head D is moved tran sversely on a short length of

bed N towards or from the work he ad by mean s of a screw spin dle O .

Op eration . In operation the ge ar bl ank is swivelled by the move

—
,

m en t of the he ad on the b ase F until the axi s of the cutter st and s

pe rpendicul arly to the pitch cone of the gear The cutter revolves .
,

a n d move s in a straight line The blank receive s an arc movement

.

which is m ade to corre spond with the angle de si red suit ably to the ,

pitch by the change gears H When a tooth space h as been com

,
.

p let ed ,the bl an k is indexed by the pl ate L an d it s peg .

P rovision f or D ouble helical Cuttin g

-
Thu s far the m achine is
—

suit able for cutting single helic al bevel wheel s

-
For cutting double .

helic al teeth the addition al mechanism comp rises provision for

,

ch anging the direction of rot ation of the bl ank The latter is given .

a forward rot ation until the cutter re ache s the middle of the tooth ,
 1 82 GEA R CUTTING

an d then a return movement while the second half of the tooth is

being cut the cutter travelling st raightforward th roughout The
, .

addition al arrangement s involve the use of a st ar wheel an d p i n

teeth with e ndle ss groove s by which the blank is moved fo rw ards

an d retu rned Thi s is illu st rated in Fig 1 61
. . .

Commencing with the sh aft P which through bevel ge ars

, , ,

communic ate s motion to the sh aft Q an d thence through fix ed

ge ar s an d ch ange ge ars to t he wo rk he ad the bevel
-
ge ars,0 e ffe ct

Fig 1 6 1
. .

re versal (comp are with Fig . The ge ar p is mounted on a

S leeve with a se cond g e ar q, which can be sl id together al o n g t h e

Sh aft Q by
,
which they a re rot ated so th at eith e r one can me sh with
the crown ge ar 0 Though therefore the Sh aft Q alw ay s rot at e s
.

in one direction the bevel ge ars provide me an s fo r reversing the

,

direction of rot ation of the blank s as follow s

Th e rot a tion of the s h aft Q i s tr a n s mitted through spur ge a r s r
,

s, t . O n the sh aft of t a st ar w heel R is keyed the teeth of wh ich ,

e ng age with the teeth of a pin wheel S on the s h aft T to which it is

,

fe ather keyed The object of thi s is to pe rm it the pin wheel to

- .

s lide on it s sh aft in,

orde r th at t h e st a r w heel rot ating in one d ir e c

tion con st antly sh all imp art a reverse motion to the pin wheel .

This is accomplished by fl anking the zone of pin teeth with annula r

g roo v e s u u meeting an d retu rning into on e another at the en ds
, ,
1 84 GEA R CUTTING

A is Carried in the saddle B wh ich is traversed along the bed C It

, .

is rot ated by the bevel ge ars D from t he sh aft a d riven by the stepped
,

cones E The longitudin al feed o f the cutter is imparted by the

.

screw b driven from the sh aft a through ch ange speed ge ars cone s -
, ,

o r ot her equiv al ent method s throw n in by a Sliding clutch 0

.
, Motion .

is t ransmitted from the feed screw b to the bl ank F through Ch ange ,

ge ars reversing bevel s H dividing ch ange gears J to the worm an d

, , ,

wheel K an d to the work spin dl e L

, .

Du ring the rot ation of the mill from one side to the centre the ,

bl ank is rot ated through the angle of the spiral until the centre is

Fig 1 64
.

re ached The movement of the saddle then actu ates a stop which
.

in turn actu ates the reversing mech anism H so c au sing the blank ,

to turn in the oppo site direction at the angle of spiral when the ,

cutter completes the tooth space The cutter saddle is returned

.

quick ly by mech ani sm ( not indic ated) an d the dividing at J is

done by h and .

In a nother design of end milling m achine the helic al move ,

ment is not imp arted to the bl ank but to the cutter the bl ank , ,

being indexed only The method is applied to both spur an d

.

bevel double helic al ge ars

-
Fig 1 64 show s in outline di agram the
. .

e ssential mech ani sm of the helic al spur gear cutting m achine -

.

D g
esi n The —m ain bed A of the m achine c arrie s the work
 MA CHINES USING FOR M C UTTER S 1 85

t able B at one end extended at the other to receive an auxil iary bed
,

C on which t he cutter head D is c arried the whole being mov able

, ,

round the axi s a a of the work t able The cutter E is supported

- -
.

on a saddl e F wh ich is travelled up an d down the he ad D by a screw

b. D al so has a lon gitudin al adju stme nt on it s bed C to suit wheels G
of different diameters The radi al motion s of the bed an d cutter
.

round the centre a a is produced by worm ge aring J K This circul ar

-
,
.

motion is connected with the vertic al motion of the cutter slide F

by mean s of Change gears L so producing the result ant spiral p ath
,

Fig . 1 65 .

of the cutter The direction of motion is Ch anged by reversing

.

mech anism M c d is the h and dividing mech anism

.
,
-
.

Fig 1 65 show s the modi fic ation necessary for producing bevel

.

helic al teeth The circul ar plate N provide s the mean s for angling
.

the cutter until it s ax is st and s at right angle s with the pitch cone of
t he bl ank In other re spect s the movement s by ch ange gears an d
.

the reversal are the same as before the same reference letters being ,

ret a ined .Fig 1 66 shows a p air of bevel ge ars cut by the P ower
.

P l ant CO Ltd .
, .

The Citroen Gears These are cut at the work s of t he Citro n

— e

Ge ar CO L td P ari s with end mill s including the spur ( see pp 1 63

.
,
.
, , , .
,

an d bevel helic al kind s The teeth of the Citro n gears are

. e

sho rter an d h ave a h igher pre ssure angle th an the st and ard the ,
1 86 GEA R C UTTING

a ngle being Fig 1 67 illust rates a gear being cut in the

.

s hop .

In cutting helical bevel s with end mill s one mu st modify preco n ,

ceiv ed ide as g athe red in cutting straight bevel s with rot a ry cutte rs ,

in which the gears are rolled or the cutter is set over The incre ase d
,
.

width of Section in the helic al bevels is produced in the deepening

of the cut by the enl arged section of the cutter ente ring deeper
into the met al in trave rsi n g ac ro ss fro m the smalle r to the l arger

Fig
. l 66 — Do u
. bl li l B
e -h e ca ev e lG e ars C ut by the P o w er
Pl t C
an O. , L td .

dai meter Me ssrs Cit ro n h ave explained the method which the y
. e

adopt thu s :,

We h ave two pitche s the circular or app arent pitch in the pl ane
,

of the pitch Circle an d the re al or norm al pitch t aken in a section

,

pe rpendicul ar to the helix The no rm al pitch can be obt ained from

.

the Ci rcul ar by multiplying the latter by the co sine of the angle (A )

o f the two pl ane s which gi v e the two section s of the tooth above
,

refe rred to .

In the teeth of our bevel w heels the m ain point is to h ave a re al

( norm al ) pitch of equ al dimen sion s all along the su rf ace of the t eeth .

The apparent (circular) pitch will v ary but the real one mu st not , .

Thi s is obt ained by the peculi arity of the cu rve of our bevel tooth .
 CHA P T ER XII
FO R M P LA NING

T HO UGH the form pl aning methods appe ar to have been men ace d
-

by the advance of the generating bevel ge ar pl aners t hey n everthe -

,

less Occupy a very strong po sition The theory of a generatin g .

m achine suggest s the ide al but the actu al work done with a form
,

t hree or four time s larger th an t he l arge end of the tooth of a bevel

leaves but an infinitesimal degree of error We therefore fin d that .

fo rm plan ers are made in very l arge numbe rs for bevel ge ars an d ,

in larger numbers an d in more diverse de sign s on the Continent an d

in the United St ate s th an they are here Many sh ape both sides .

of a tooth at the same time or rather in al tern ating double stroke s ;

, , ,

m any are of horizont al type that is the arbor moves round in a

—
,

ho rizont al plane in ste ad of in a vertic al angle .

A Newton Machin e A n i llu stration is given in Fig 1 68 of a

.
—
.

very heavy spur ge ar being cut by the aid of fo rmers Here there .

is an undoubt ed advant age in adopting thi s method bec au se the ,

gears are much too m assive to be put on an y of the ordin ary m achines
of an y type It is really a port able slotting m achine att ached to a
.

bed which c arrie s a dividing t able on which the gear is mounted ,

an d which h as in thi s c ase a c ap acity for ge ars U p to 40 fee t in dia

meter The templet s are fitted on e ach Side of the tool slide When
. .

the he ad receives an outward feed at the top of the stroke it is al so

Simult aneou sly fed l at erally This last movement is imparted to a
.

st ar wheel which pull s the he ad to one side again st the templet A

'

friction device al low s the feed to slip to follow the curved fo rm of

the temple t Thi s m achine w as built by the Newton Machine Tool
.

Works Inc of P hil adelphi a an d is shown in use at the Vulc a n Iron

, ,

works Wilkes B arre P ennsylva ni a US A

,
-
, , .

Fig 1 69 shows a tool which is sometimes used on the Gleason

.

machines for teeth of 2 pitch an d sm aller for cle aning out the
-
,

whole tooth sh ape without employing sep arate tools for sides an d
fi lle ts. A simil ar e xpe dient h as often been adopted with ordi n ary
c as t gears on the slotting m achin e using a notched dividing pl ate
,

for pitching the gear around .

 FO R M P LA NING 18
9

The Gleason B evel gear Form P lan ers -

The se m achine s are of .
—

t he horizont al type — th at is the axi s of rot ation of the blank is

,

horizont al Thi s is preferable to the design in which the bl ank

.

is adju sted for angle again st the ve rtic al f ace of the m ain framing
o f the m achine In the Gleason the whole of the bl ank c arrying
.
,
-

Fig 1 68.
— Ne w to n Fo rm P l i g M hi
an n ac ne p
fo r S ur Gears .

an d indexing mechani m ell as th at of the tool holder is sup

s , as w -
,

p orted on a bed which is ste ady under the he avie st cut s The se .

machine s are m ade in several de sign s including tho se for the ,

cutting of spurs as well as bevel s The example illu strated is a 24in

. .

m achine shown in f ront an d re ar view s by Figs 1 70 an d 1 7 1 m ade

, .
,

at the Gle ason Work s R oche ster N Y , U SA Machine s of 1 8 in

, . . . . .
,

3 6 in .
4 8
, in 54
. in,an d 77in .c ap a city are al.so built .
1 90 GEA R C UTTING

The gear is as seen mounted on a horizont al spindle an d is ad

, , ,

ju sted for cone di st ance ( see p 7 0) by moving the he ad which c arries

.

the spin dle along the bed until the apex of the ge ar coincides with
the centre of the m achine The arm on which the tool holder travel s
.
-

is rot ated around thi s centre in a turre t in a ho rizont al plane .

The arm is al so h inged on the rot ating he ad in a vertic al pl ane over

the centre of the m achine to impart the vertical movement as it is
fed over the fo rm in order to give the correct travel to the tool an d
,

impart the correct cone angle s to

the flank s .

The Forms Three fo rm s are .

—

u sed On e se t is for roughing one

.
,

for finishing the upper side of the

teeth an d one for the lower side of,

the teeth They are c arried in a .

revolving holder so th at they can

e ach be b rought into po sition with
out re settin g The y are shaped for .

involut e ge ars but cycloid al form s ,

are supplied whe n d e sired Thi s is .

an obviou s adv ant age of the fo rm

planing m achine s which the gen er

ating m achine s do not po sse ss .

Settin g up the B l an k The —

Fig 169 . .
a ction of the m achine can be
unde rstood if we de scribe the
different p art s in connection with the setting up for O pe ration .

The angle s of the ge ar mu st all be obt ained fi rst There are the .

pitch an gle the angle of the f ace or point an d the root angle of
, ,

the teeth ( see p . The Circle of the full depth of the teeth
should h ave been struck round on t he l arge diam eter or b ack angle

of the bl ank before puttin g it in the m achine .

A Fig 1 7 1 is a centring fo rmer or pitch l ine pl ate

,
.
, This has a -
.

notch or t ape red slot in the cent re of it s U pper edge in w hich the ,

fo rm roller is seen re sting touching both sides of the slot Thi s plate
, .

is att ached to the fo rm h older B in pl ace of t he p arallel roughing

-
,

fo rm required l ate r .

The Turret The angul ar th ro wof the turret which carrie s the
—

tool holder is next Set Thi s th row is equ al to the di fference between
-
.

t he root angle an d the f ace angle of t he ge r to be cut to which 1 4m a , .

1 92 GEA R CUTTING

behind the cutting point e ach time the tool is ground Then when .
,

t he tool is put into it s holder the n ece ssary adju stment is provided ,

by the stop without an y further trouble to the operator The slide .

which c arrie s the holder is driven through t riple gears .

In selecting the tools the thickne ss of the roughing or stocking

,

tool at A Fig 1 73 mu st be such th at it w ill Clear the tooth space

,
.
,

at the minor di ameter The depth at B mu st cle ar the depth

.

Fig 1 7 1
. .
—
G l e aso n Fo rm P l i g M hi
an n ac ne l
fo r B e ve G ears ( R ea r V i ew ) .

of the teeth at the m ajor di ameter The fini shing t ools mu st be of .

th e p rOper thickne ss at the point to p ass through the sm all end of

the teeth without touching the oppo site side .

The stocking tool is first pl aced in the clapper block N Fig 1 70 ,

.
,

an d set by g auge so th at the edge of the g auge is even with the centre

of the tool an d the end of the tool is even with the end of the gauge
, .

The box tool holder is so con structed th at the tool can be readily
-

a dju sted into po sition by me an s of a wedge fo r height an d the st 0

p ,

nut c Fig 1 7 0 for length

, .
, .

A ft er the roughing round of the bl ank is done the stocking tool ,

is removed from the cl apper block an d repl ac ed w ith the lower fin ish
 FO RM PLA NING 1
93

in g tool Thi s is set so th at the cutting point of the tool is even

.

with the gauge an d the round on the tool if an y project s beyond the
, , ,

e n d of the g auge The U pper finishing tool is set at the same time
.

an d in the same m anner an d left in the m achine re ady for m aking ,

the next adju stment .

Gaugin g The gear bl ank may now b e mounted on an arbo r

—

suit able for it an d f ast ened securely in the Spindle of the m achine .

Then the he ad binder bolt s d d d Fig 1 70 are loo sened an d the ,

.
, ,

vernier slide in the cone dist ance gauge Fig 1 74 is set to re ad the ,
.
,

Fig . 1 72 .

depth to the pitch or to the addendum of the tooth to be out Then

, .

the cone dist ance gauge is pl aced on the tool slide arm M Fig 1 70 -
, . .

The gauge an d head are moved by me an s of the crank h andle N ,

Fig 1 7 1 until the pointer C Fig 1 74 on the vernier slide come s in

.
, , .
,

cont act with an d is even with the out side

edge or crown of the gear the vernier ,

Slide A h aving been set to re ad the sam e

a s the pitch depth or th e addendum of ,

the ge ar to be out When the indic ator .

B point s to zero the ge ar blank is in ,

it s proper po sition th at is the cone —

,

centre of the gear coincides with the

centre of the m achin e The h ead is Fig 1 73
.

now bolted Securely to the m achine

. .

f rame an d the cone di st ance gauge t ried again Then the pitch
,
.

line pl ate A Fig 1 7 1 is removed an d replaced by the straight

,
.
,

form or p arallel
,
.

Fcod The turret is n ext swun g in tow ard s the ge ar bl ank as

—

far as it w ill go by me an s of the feed cam lever 0 Figs 1 70 an d 1 7 1

, ,
. .

If the end of the tool when brought again st the gear blank is out side
o f the full depth circle the bolt s F Fig 1 7 1
-
in the turret mu st be
, , .
,

loo sened an d the cam turned with the feed cam lever 0 until the
,

roller is engaged at P in Fig 1 70 which swings the tu rret to it s inner .

,

mo st po sition Then the bolt s E Fig 1 7 1 are tightened an d the

.
, .
, ,

N
1
94 GEA R CUTTING

feed motion is Set But if the turret is swung inward s an d the too l
.

reaches the full depth circle before the turret has finished its feed
-

motion then the turret mu st be stopped leaving the point of the

, ,

tool on the full depth Circle an d the bolt s F Fig 1 7 1 be loo sened
-
, , .
,
.

Then the feed cam is turned until the roller is engaged at P Fig 1 70 ,
.
,

an d the bolt s F are tightened Next the Upper cut fini shing tool .
-

is t aken out an d the roughing to ol put in its pl ace an d set so th at

, ,

the end of the tool reache s the full depth circle The stop nut c -
.
,

Fig 1 70 on the box holder can be adju st ed for thi s purpo se A ll

.
,
-
.

three tools Should now be tried to see that the end of e ach
st and s at th e full depth circle the roughing tool being -
,

left in place an d the set screws c Fig 1 70 tightened

, ,
.
,
.

Now the turret is swung out

cle ar of the blank by me an s of
the feed cam lever O The .

crank pin bolt f Fig 1 70 is ,

.
,

loo sened an d the stroke of the ,

tool is set by the

adju sting Screw g ,

which st roke should

be about 3m longer .

th an the face of the

gear to be cut This .

allow s iin for clear .

ance at the b ack of

the teeth an d kin , .

Fig 1 74 for Cle arance at the

-

inner en d The crank pl ate is gradu ated for these adju stment s
. .

The t ool po st trip s on the return stroke as in an ordin ary plan er

-
.

The stop Q Fig 1 70 mu st be set so as to bring the clapper block

,
.
,
.

to it s pro per po sition before t aking each cut T is a leve r for

. .

throwing out the power feed .

Table s are provided for the Ch ange ge ars for speeds an d feeds ,

an d an indexing t able for sp acing the number of te e th re qui red .

The worm an d stud gears an d the c rank are indic ated ”

,
“
,

in Fig 1 7 1 The clutch R on the index mechani sm is m arked

. .
, ,

with four equ ally spaced lines an d the part of the clutch ,

which is keyed t o the sh aft is provided with a zero m ark These .

clutches mu st be set on zero an d now the m achine is re ady fo r the ,

roughing out -
.
1 96 GEA R CUTTING

thickness the cut s can be t aken all round with thi s setting fin ishing ,

the gear .

The photograph Fig 1 7 6 A shows a speci al intern al bevel ge ar

, .
, ,

which w as cut by Me ssrs E A rnold Pochin Bro s of Ma nchester . .

, .

Fig . 1 76 .

AS it not to
h ad de lt with in qu tity an
be a rig Up an , e mergency -

w as arr anged on a fo rmer type Gle ason bevel g ear sh aper

-
The -
.

g e ar w as mounted with th e t ee th tow ard s the h e ads tock of th e

m achine t he oppo site to the usu al w ay of mounting blanks an d

—
,

a s pe ci al L sh a pe d tool w as m ade with the Sho rt l ength suf

-
fi ci e ntly
long to cle ar the full width of the f ace of the gear The clapper .

box w as tightened secu rely so th at it could not move ,

n d thi e n t ail d h an d feedi n g

a s e .

The Oerliko bev l gear form pl aners h ave been m anu

n e -

fact ure d for a gre at m any

years in several di fferent
models The l atest 1 9 1 3 .

de sign is Shown by the

photograph Fig 1 77 Sub , . .

e quent fi u res illu st rate

g s

the method of ope ration

f the m ach ine an d the o

tool with the mountings s, .

Fig 1 76 A I t l B l G Cu b y M
— n e rn a e ve The le ading fe ature s of
ea r t e ssrs
P m
.
.
,

m oc
t he O e rlikon pl aners are
these : They re built rigidly to elimin ate vib ration an d Secu re a
a ,

large output Two to ls t ravel Simult aneou sly fini shing each Side of
. o ,

a tooth Th e tooth sh ape is produced by the guid ance of o n e edge

.

of a templet or form rep resenting one fl ank of a toot h enlarged , .

O n e templet only i requi red fo r all ge ars of the same number of

s

t eeth an d of the same pitch line angle no m att er of wh at pitch an d

-
,
 FOR M PLA NING 1 97

di ameter the wheels are With a set of 35 templet s all gears from
.

the sm alle st up to the l argest within the limit s of the m achine an d a ,

ratio of 1 : 1 U p to ma y be cut The sh aping of all the teeth of

.

a ge ar is eff ected autom atic ally the work of the operator being
,

limited to the setting up an d ob servation of the m achine s the re ,

mov al of the ge ars an d replacing them wit h bl ank s The m achine .

gashe s the gears prelimin ary to finishing them The se m achines are .

Fig 1 7 7 . .

m ade in five Sizes with a c ap acity up to 6ft 6in pitch di ameter

,
. . .

They are of the horizont al type The whole of the mech anism is
.

c arried on a box b ase in the sm alle r size s ; in the l arger one s it is

placed on a floor plate an d is driven by the fast pulley (with a
,

loo se one adj acent ) Seen at the left of Fig 1 7 7 making 500 rev olu .
,

tions per minut e .

The wo rk he ad or poppet A Figs 1 7 8 1 7 9 is c arried on an d

-
,
.
, , ,

adju st able along a swivel b ase B Fig 1 8 1 swivelling around the

, .
,

c o ne centre 0 of the m achine The tool s are carried in holders

.

C C Figs 1 7 8 1 7 9 in Slide s D D mov able along the guide s E E

’ ’ ’
.
, , , , , , ,

which are adjust able for fl ank angle s on the tool head F an d are -
,

counter weighted to relieve the load on the form an d to reproduce

-
‘

co rrectlv the form of the tooth fl ank The other references on the .
1 98 GEA R C UTTING

drawings will be noted in connection with the setting up of the work

an d the tool s.

The bl ank has to be tu rned to the co rrect dimen sion s especi all y
,

t o the out side cone angle d which co rresponds with the an gle of the
,

a ddendum of the tooth an d the out side di amete r Fig 1 8 1

,
. A l so
.

t he angle of the pitch ci rcle b an d the angle of the root o r dede ndum
,
.

c mu st be known as in all b evel ge ar bl ank s

,
-
.

Moun tin gthe Blan ks The bl ank b eing mounted on the m andrel
—
2 00 GEA R CUTTING

The Tool Slides The me an s of regul ation of the course of the

.
—

slide s on their guide s is seen in Fig 1 80 By tri al the pin N has to . .

be set so that the travel of the sl ides is about fiin more than the tot al .

length of the teeth to be cut The Slides are brought into the ex .

treme position in front to the point of reversal of the movement '

.

The tool holders h ave to be advanced until the tool will Cle ar the
-

bl ank suffi ciently ( Figs 1 83 Then the tool holde rs are fixed by
.
,
-

Fig 18 0
. .

the bolt s g g Fig 1 79 A fte r th at the slide s are brought into the
, ,
’
. .

extreme hinder po sition to the point of reversal of the movement .

The templet slide p h as th en to be lowered by me an s of the little

h an d wheel M so that the pin can p ass over it freely
,
.

D ep th ofCut To regul ate the depth of cut of the teeth a ratchet

.
—
,

k Fig 1 8 0 is lifted
,
.
,
The tool he ad F is adv anced by the h and wheel
.
-

G until the sc ale is set to the angle of the root c Fig 1 8 1 The dog , . .

m is then moved in the slot of the wheel K Fig 1 8 0 governing the , .

,

depth of cut as far as the lever L an d fi xed The tool he ad is , .

-

returned as far as the angle of the addendum of the tooth g Fig ,

.

1 8 1 plu s the cle arance nece ssary to p ass the tool s over
,
For this .

the prevention of cont act de pends on the cle arance a Fig 1 84 , .

,
 FO R M P LA NING 2 01

which can be regul ated by moving the dog n round the slot in
the wheel to the lever L The clearance mu st not be too
. It

Fig 1 8 3
. .

Fig . 184 .

Fig 18 1
. .

is nece ssary to fix the dog n securely The Speed of cutting. is

regul ated by sund ry leve rs an d ge ars the latter bein g enclo se d
, .

Fig 1 8 2
.

Fig
.

. 185 .

Cashin g
— Fig 1 8 5 Shows the p arallel gashing tool for straight
.

cutting with the cutting angle s adopted Fig 1 86 is one u sed for
,
. .

gashin g approxim ately to the tooth curve s cutting in step s Its ,

.

dimen sion s depend on the depth of the teeth measured on the minor
2 02 GEA R CUTTING

diameter an d leaving enough m ateri al for the correct finishi g of

, n

the teeth The depth of the teeth is drawn on the inte rior an d
.

e xte rior di ameters as in dic ated in Fig

,
1 86 This repre se nt s a
. .

tracin g of a ge ar of 30 t eeth module 6 with a pitch cone of 4 5

, ,
°

( mitre s)
. A g ashing tool suit able for al l ge ar s of the sa m e mod u l e

Fig.

is obt ained by drawing it out for mitres of l argest po ssible t he

500 m / m m ax d ia
n umber of teeth For module 6 for in st ance
. .

.
,
module 6 ,

8 0 teeth drawn out for the interior di ameter an d t aking the length
,

Fig 18 7
. .

Fig 1 8 8 . .

of teeth to be equal to the module multiplied by 1 5 The height of .

the serration s or steps is given by the di st ance k Fig 1 8 6 no rm al to , .

,

the radiu s r .

When two tool s are u sed for roughin g as in Fig 1 87 they are, ,

drawn out for the minor di ameter an d are set or bent to h alf the
,

an gl e m ade by the centre s of adj acent tooth sp aces with the cone

c ent re ( Fig To obt ain the mo st suit able sh ape the se are m ade
.
 2 04 GEA R CUTTING

Fin ishin g—
The tool s for m achining the flank s are seen in Fig
.

1 91 The amount of bend is about sin ( 1 6

.
being bent or .

hollowed suffi ciently to clear the teeth The cutting angle is .

The point s are rounded at a Fig 1 2 to the gauge Oil is recom

'

9 , .
, .

mended for lubric ant when cutting .

Fig
. 19 0. Fig 19 1
. .

The tool s which fini sh the t eet h h ave to be set with gre at c are ,

t hu s The upper tool is set in the horizo nt al direction Fig 1 93 as

—
, .
,

indicated by the dotted lin es A fterwards the gauge for se tting

.

the point is adv ance d until the point

of the tool is loc ated over the point
of the indic ato r an d the tool holder ,
-

is lowered until the z e ro line (0) of the

indic ator corre spo nds exactly with the
ze ro line
(0) of the gauge for se tting
Fig 1 9 2
the point The lower tool is set in
. .

rel ation to the upper one so that there is no space left be tween
the two .

When the wheel bl ank has been roughed out by a Single tool the
gash is m ade in the horizont al direction ( Fig To fini sh the .

wheel it has therefore to be moved round until the tooth is set exactly
between the two fini shin g tool s Thi s should n ot be done by tum
.

ing it on the arbor or on the face plate but by turning the wo rm ,

of the dividing wheel Me an s are provided to rele ase an y undue

.

pressure of the dividing app aratu s during this operation Now the .
 FO R M P LA NING 2 05

m achine is st arted by shiftingthe leve r x Fig 1 7 8 until one divi sion , .

,

is completed so as to elimin ate an y b ackl ash th at m ay be in the

,

g e a ring A. fterw ard s one or t he othe r of t he O pe ration s previou sly

described follows for cutting the teeth .

The thickne ss of the chip is regul ated by the h and wheel M On e .

g r adu ation indic ate s a vertic al dis p l acement of the form ; e ach arrow

o n the di sc rep re sent s 004in The actu al displ acement of the tool
. .

can be c alcul ated by the formul a :

Vari ation in thickness of the tooth

2 x Di spl acement of the form D i st ance x a

Di st ance A of the form

,

(see Fig .

If the form is set correctly an d for st andard involute gears that

, ,

is if the dis
t ance a Fig ,
.

1 96 ,
t aken
o n the pitch

circle rep re
,

se nt s ex ac tly

o n e h alf the
-

tooth thick Fig 1 9 3 . .

n e SS b the
height 0 the thickness of the tooth will
,

be produced correctly on th e m achine The .

thickne sse s are given in a t able for different

n umber s of tee th an d di fe
f r ent module s A s .

the se are right for spur gears the teeth h ave to be proj ct d for e e

i
b evel ge ar s on the b ack con e di st ance by the method d c bed e s r

in a former ch apt er (p .

The roughing out with t w o tool s simult neou ly

- a s is prefer blea

wh en m anuf actu ri ng wheel s in qu antitie s a s the output of t h e

,

ma chine can be much inc rease d In thi s c as e . a ll the wheel s ar e

fi sr t roughed out a n d afte r

-w a r d s fi ni shed one a ft e r the oth e r s o th a t ,

the time for setting the m achine is reduced .

Thirty fiv e fo rm s are supplied selection of which for an y ge ar

-
,

i s m ad e from a t able provided Fig 1 9 7 Show . s the method . of

s etting up Thu s to pl ane a p air of ge of
.
,
a rs 2 6 an d 57 teeth the
rel ation gives the cone angl of 4 e s 2 an d 6 5 The
°
ne a re st °

a ngle s to the se in the t able p rovided are a No 1 fo m for the p n on

1 r i i . ,
2 06 GEA R C UTTING

an d a NO . 11 , A form for the gear

The fi rst h as a limit of angle of.

22
°
1 8 to 2 4
’ °
the second of
67 4 2 to 65 The angle is ° ’ °

Set by the g uide 1 Fig ,

.

1 7
9 The Setting angle .

for the pinion as given ,

by the t able is 1 9 ,
°

an d th at for the ge ar is

3 A fter setting by °

the m ark s on the guide

1 the screw 2 fi xes it .

Usu ally the fo rm is not

utilized alon g it s whole
lengt h but a radiu s is
cut at the roo t of the
Fig 19 4 teeth
.
To
,
pe rmit thi s a .

guide limit 3 is employed .

The tool is thu s stopped at T th of the depth ( Fig

L by stopping .

the advance by the guide limit 3 For the vertic al setting of the .

form holder 4 the set screw 5 is u se d

-
.

r
-
w

Fig . 19 5 .

Fig 1 98 illustrates the setting of the gauge B on the tool

.

holder A to the half a ngle of a ( Fig wh ere it is fi xed .

by the screws The upper tool holder rests in pl ace in front

.
-
,

a n d Fig 1 99 show s how to cut the tooth exactly in the c e n tre

.

between the two tools .

The se m achines are designed an d m anufactured by the Schwei

zeriSche Werkzeugm aschinenfab rik Oerlikon ( Soci ét é Sui sse de
Machines Outils) at Oerlikon ne ar Zurich ( Switzerland)
, ,
.

The Green wood <3 B atley Machin e The form planer of Messrs .
—

Greenwood B atley Limited of Leeds represent s a type which

, , ,

h as been f amili ar for m any ye ars O ri gin ally indexed by h an d it is

.
,
2 08 GEA R CUTTING

Movemen ts ofthe Blan k The bl ank having been Set at the angle
—

corresponding with the tooth point s Is fed upwards towards the

,

reciproc ating tool by the radi al adju stment s of the l arger or hinder
sector pl ate Th is .

feed is de rived from

a crank di sc at the

right h and en d of
-

the m achine h aving ,

a connecting ro d
with p rovi sion fo ran
adju st able st roke ,

actu ating the p awl

an d ratchet below ,

Fig 19 8 . .
whenc e through
wo rm ge ars a pinio n
engages with the teeth out on the periphery of the l arge secto r .

A n autom atic trip is combined with thi s mech ani sm which , ,

by me ans of the adj ustment of a dog in the annul ar groove

on the face of the
wo rm wheel seen ,

in Fig 2 00 can be
.
,

s et t o autom atic ally

di sengage the feed

as soon as the tooth

h as b een cut to
the desired depth .

Where the feed

mech ani sm is di s

engaged by the t rip ,

the sector counte r

,

b alanced fo r the purpo se return s to its origin al position re ady

,

for the commencement of the next tooth at which st age the feed
,

is autom atic ally re engaged

-
.

While the feed is in Operation the blank is also being rolled in

the interval s of cutting by the co ercion of the fo rm acting aroun d
the axi s of the spindle an d bl ank It is seen in both illu stration s
.

b olted to a b racket at the upper end of the radi al qu ad rant bar .

The edge s are pull ed into cont act with one of the two guide plate s ,

which co rre spond with the two sides of the teeth by the ten sion of
,

th e weighted co rd p assing ove r the guide pulley s seen att ached t o

,
 FO R M P LA NING 2 09

t he liding bracket in which the guide plate s are held The radial
S .

b ar is adj ust able in the socket in which it is c arried in order th at the

height of the fo rm may be regulated to sui t the size of the gear bl ank
being cut .

In dexin g The dividing mech ani sm is driven by a pulley at the

.
—

re ar of the m achine an d therefore not visible through a friction

, ,

Fig 200
.
—
The G ree n w o o d B at l yF
e or m P l i g M hi
an n ac n e.

di sc h ange ge ars It is controlled by a locking cam which is

an d C .
,

rele ased on the return movement of the se ctor pl at e a t ri p lever ,

o per ating again st an a dju st able stop which is c arried on the radi al

b ar seen ne ar the bottom of the m achine

, When a dividing ope ra .

tion is completed the mech ani sm is autom atic ally locked with the
b l ank in th e co rrect po sition fo r cutting the succeeding tooth .

Tool B ox The tool box seen in both photog raphs is recip ro

.
—

cat ed by a crank di sc h aving provi sion fo r v a rying the stroke to

,

suit the gear being cut A d riving cone at the re ar of the m achine
.

p rovide s th ree ch ange s of speed The tool box h as vertic al ho

. ri ,

zon t al an d angul ar a dj ustment s an d is hinge d to relieve the tool

, , .

A fixture is supplied seen in Fig 2 00 by me an s of which the cutting

, .
,

o
210 GEA R C UTTING

edge of the tool is set to coincide with the centre of the pin around ,

which the sector plate s swivel It therefore alway s planes tow ard s
.

the cone apex The m achine is m ade in three size s the l arge st ge ars
. .
,

cut in each being 8in 1 8in an d 2 5in in di ameter re spectively

.
,
.
,
. .

Fig 201 — Too Bo x

. . l o fG reen w o o d l y M hi
Bat e ac n e.

The B ouhey (F ren ch ) M

Thi s (Fig 2 02 ) plane s single
a chin e .
—
.

helic al bevel teeth It is a modific ation of a t ype of m achine which

.

is ve ry common in Fran ce an d B elgium an d which is repre se nted ,

here by the m achine ju st desc ribed m ade by Me ssrs Greenwoo d 8c ,

B atley Ltd
, . With minor difference s in det ail it s general con st ruction
is as follow s
It is a form m achine the teeth being planed under the guid ance
,

of an enlarged tooth form the curve of which is about three times

,
212 GEA R C UTTING

an d the ctor is returned to it s origin al po sition the blank is in

se ,

dex ed an d the cycle recommenced A l l the tee th are fini shed o n

.

one Side first an d then all their other o pposite Sides

, .

The Helical A ttachmen t Thu s far the B ouhey m achine is lik e

—

m any other form pl aners But it has in addition mechani sm fo r

.

cutting the helic al teeth A connection is made between the ih

.

dexing mechanism an d the crank shaft which drive s the connecting

rod to the tool slide Thi s con si st s of change ge ars by which the
.

work is rot ated Slightly in a definite ratio to the c rank du ring the
cutting with the re sult that the curved tooth space is cut by the
,

planer tool The amount of twist can be v aried by the ch ange gears
. .

Teeth of the reverse h and to me sh with the fi rst are cut by reversin g
the connection between the c rank an d the work .
 CHA PT ER XIII
MA CHINES THA T GENERA TE B Y P LA NING TO O LS

THE SUND E R L A ND SP UR -GEA R

GENER A TING MA CHINE .
— ThlS is
m anufactured by Messrs J Parkin son Son of Shipley Y ork shire
.
, , ,

an dis designed to include t he cutting of spiral as well as spur ge ars by ,

which it s value is greatly enhan ced The illu stration ( Fig 2 03) shows
. .

it performing the fi rs t of the se two function s an d this will enable ,

an accurate underst anding t o be gained of the gene ral de sign and

‘

method of it s operation the principle of which w as described on p 94

,
. .

R el ation ofCutter t B a
o l n k — The rel ative action of the cutter an d
the blank is as follow s : The bl ank being mounted on an arbor in,

the spin dl e of the dividing wheel is controlled by a rot ation al an d

,

a divi ding motion The rack Shap ed c utter (see p 94 ) has a linear
.
-
.

m otion corre spo nding with the rot ation al movement an d at inter ,

val s it has a reciprocating motion for cutting In the fi rst position .

of the blank an d cutter ( see Fig 2 04) the l atter mounted on a vertic al
.
,

Slide is brough t into cont act with the top of the bl ank
,
Then the .

latter is fed to the proper depth while the tooth spaces are being
,

sh aped by the reciprocating cutter the slide c arrying which move s

,

U pw ard s while the cuttin gis being done to the proper depth wh ich ,

O peration te r m in ates with a movement of the bl an k equ al to the pitch .

A t thi s st age the bl ank is withd rawn f rom t he cutter an d it s rot ation ,

arre sted wh ile the cutter is re turn e d t o it s st arting point which -

, ,

t ake s pl ace through a di st anc e equ al to the pitch The bl ank is .

then returned to the cutte r an d its rotary motion recommence s with

,

the U pward movement of the cutter slide when the previou s proce ss ,

is repe ated This goes on autom atic ally until the blank is co m
.

p l et ely cut . Thi s in b ald outline st ate s the rel ative O peration of t he

cutter an d bl ank The methods by which these are accompli shed

.
,

an d the general de sign of the m achine m ay be studied in the draw ings

,

an d di agram s al ong with the photogr aphic illu stration .

MethodofD rivin g A ll the motion s except the return of the cutter

—

slide are obt ained f rom the four stepped cone A Figs 2 05 an d 2 06
-
.
, .

It drives fi rst the cutter slide B acro ss the face of the bl an k through ,

the medium of ch ange gears an d a worm ge ar drive to the crank

,

2 13
2 14 GEA R CUTTING

disc from which a connecting rod actu ates the slide B The det ail s
, .

im mediately following are not Shown in these drawings but they ,

will be re adily understood A rack behind the reciproc ating slide

.

engage s with a pinion which is driven by a rack an d pin ion at the

other end of t he pinion shaft This second rack derive s it s motion
.

from the crank disc being cut on one Side of the connecting rod It
, .

is so arranged th at the di st ance from the di sc centre to the point o f

Fig
. 203 .
— The Sun d l d Spu g
e r an i g M hi
r- e ar Ge n e ra t n ac ne .

c onnection with the rack can be varied t he reby alt e ring the l e n gth
,

o f stroke to suit the width of the bl ank which h as to be cut The .

revolving di sc is encircled by a bearing carrying adju st able bronze

Shoe s an d is driven by a Wh itwo rth quick retu rn motion the con
,
-
,

n ect in
g pin b eing in the worm w h eel which h as,
a quick le ad The .

driving worm sh aft is connected to the cone sh aft by two p airs of

gears either pair of which can be u sed These double the ch anges
, .

g iven by the cone a n d as,

the l atter h as four step s eight spee d s are,

o bt ained for cutting in geometric al progre ssion

,
.
21 6 GEA R CUTTING

Mandrel The bl ank is mou n ted on an arbor which

D rive —

is driven by the worm wheel C an d worm D The worm

.

can be disconnected to
pe rmit the spin dle to be
revolved rapidly in order
to te st the t ruth of an
arbor or a wheel bl ank .

The h and adju stment of

the slide is provided for
by the hand wheel E .

A n outer suppo rt is pro

6
.

v ide d for the bl ank arbor

0
2
,

an d the rim is st ayed by

an adju st able Suppo rt on

the cutter slide In ad .

dition to the se support s

the slide c arrying the
work Spindle can be
se c urely locked in po sition

after adju sting for depth

of cut an d the Slide which

,

give s the in an d out

motion to the blank after
e ach tooth has been cut

is held by a de ad sto p
when in the cutting posi
tion .

When the m achine

is arranged for cutting
Spiral ge ars the cutter ,

c arrying Slide can be

swive lled to an y angle
Up to the action
of the m achine being
ex actly as for spur ge ars ,

e xcept that the ch ange

ge ars m ust be selected
to suit the re al pitch not the no rm al pitch
, .
”

Movemen ts ofCutter an d B lan k The fo regoin gare comp aratively

—

Simple movement s More intricate are t ho se by which the relative

.
 MA CHINES THA T GENER A TE B Y P LA NING TO O LS 217

motion s of the cutter an d blank are produced precisely as though

they were in roll ing cont act Other movement s are tho se by which
.

the blank is withdrawn at the completion of a pitch an d tooth an d ,

retu rned ; an d another the movement by which the cutterslide is

,

returned to it s st arting po sition These can only be understood by

.

a study of th e develo ed di agr am Fig me po tion of which

p ( so r s .

can be comp ared with the drawings ( Figs 2 05 an d wit h the

.
,

photograph ( Fig .

Though the general st atement is m ade that the blank rot ates

Fig 207
. .

during the cutting ope ration uni son

with the upw ard movement of the cutter
slide,
while the reciproc ating movement
of the cutter sh apes the teeth thi s ,

movement is of cou rs e intermitten t during

the cutting . The feed imp arted to the bl ank an d cutter occurs onl y
du ring the return stroke of the l atte r being inope rative du ring the
,

actu al cutting . Thi s as well as the rat e of feed is provided fo r by

, ,

a ratchet an d p awl in the t rain by which t he moveme nt s of the bl ank

,

an d cutter a re ge ared togeth e r The ratchet feed rod is see n at

.

the right hand of Fig 2 06 Thu s in the di agram ( Fig 2 07 ) the

. .
,
.

ch ange ge ars F for the cutter motion are seen to the right an d the ,

change ge ars G fo r rot ating the bl ank are at the left They are .

connected by the shaft s H an d a ; but the ratchet wheel J with its ,

pawl control s their movem ent s an d renders them intermittent

,
.

The shaft which c arrie s the ratchet J c arrie s the gear K at the othe r
21 8 GEA R CUTTING

end which d rive s gear L Gear M which can be clutched to L

, .
, ,

drive s N on a short shaft a an d the l atter carrie s one wheel of the ,

Ch ange e ar train F through which the scre w b is driven by which

g
-
,

the vertic al movement of the cutter Slide is imparted the amount ,

of which movement corre sponds with the pitch of the gear being
out .These motion s are connected with the motion of rot ation of
the blank which is driven by the worm wheel C (comp are wit h
,

Figs 2 05 an d
. through the ch ange ge ars G which rota te the ,

blank th rough an arc corre sponding with the number of teeth t o

be cut .

The feed from the ratchet wheel J is operative only when ge ar

M is clutched with L as shown It is slid along with it s shaft 0 fo r
,
.

clutching either with L or with a worm ge ar d the l atter produci n g ,

the return of the cutter slide to be noticed directly The gear M ,

.

with it s shaft c may also occupy a middle po sition without enga gin g
w ith either L or d .

The gear N driven by Mis provided with a notch in one Side t o

receive the end of a spring plunger e which is c a rri ed in a bo ss P
.

fi xed on the end of the s haft H which h as it s axi s in l ine with th e ,

a xi s of the short Sh aft a While the feed is in the shaft a thu s drive s
.
,

Sh aft H by t he plunger e as indic ated in the enl arge d f ace vie w

( Fig 2 08
. A ) , .

R eturn ofCutter Slide The belt pulley Q is driven directly from —

the countersh aft at a con st ant speed an d is the mean s of return ing ,

the cutter slide Its sh aft gc arries a worm h which drives the worm
.

w heel d with which ge ar M can be clutched while still rem aining

,

in imesh with the wider ge ar N but being out of action as regard s th e ,

feed ratchet wheel J The worm wheel d rot at es in the oppo sit e
.

direction from L for the pu rpose of returning the cutter Slide When .

thi s motion is in then the di rection of rot ation of gear N bein g re

,

versed the plunger e is forced out of engagement with its notch in

,

N with the re sult th at shaft a no longer drive s the sha ft H an d th e

, ,

motion s of the dividing gear an d t he bl ank are therefore arre sted .

The plunger is forced out bec au se one side of the notch is ch amfered
as indic ated in Fig 2 07 This reversal of direction of drive is in
. .

dicated in the enl arged face view ( Fig 2 08 B ) .

, .

The clutching of Mto d for the retu rn of the cutter slide is accom
p lish ed t hu s z The movement s t aking pl ace in the mech ani sm whic h
—

lies between the work Slide lever S an d the sliding clutch gear M -
,
-
.

A lever bar 0 is att ached to the work Slide lever h aving an o ffset -
,
2 20 GEA R CUTTING

th at rot ate s con st antly The p awl is pivoted on a di sc T an d has a

. ,

gear u keyed to it ; u is in me sh with w of twice the size of i t The .

re sult is that when the p awl s e ngage s with the ratchet t the disc ,

T an d ge ar u m ake one revolution an d w m ake s h alf a revolution ,

.

In the revolution of t the projection x on th e disc T lift s the bar R

,

to its o rigin al height where it is su st ained by the lever r When the

,
.

revolution is completed the t ail of the p awl s strike s an inclined f ace

on the bar R an d is thu s released from engagement with it s ratchet
,

The h alf revolution of the ge ar w is t ran smitt e d by an eccentric on

its sh aft through link s an d lever to the work slide U on which t he ,

bl ank is mounted The half ratio ju st now noticed give s one with
.

draw al from an d one return of the slide an d bl ank to the cutte r

, ,

during one cycle .

B ackl ash B ackl ash in the cutter sli de is t aken up thus z The
— —

gear N Fig 2 07 is sm aller th an M ,

.
,
.

When therefore the work slide is , ,

w ithdraw n an d the cutter Slide re ,

turn ed the ge ar M m akes one re ,

v olution but N more th an one ; yet , ,

as alre ady expl ained ,

without t ran smitting

motion to the shaft
H The notch in the .

f ac e of ge ar N in
F g 209 i
,

which the plunger e

. .

enters is chamfered on one side as already st ated in order to

, , ,

force the plunge r out when the cutter slide is being retu rned ,

an d all owing the sh aft H to rem ain inoperative The cam k .

then releases the Shaft c as already explained its spring putting ,

ge ar M into engagement with gear L an d commencing the

upward motion of the cutter slide to t ake up the b ackl ash This .

movemen t continue s u n til the projection p on N produce s the drop

ping of the bar R with the re sulting return of the work slide to the
,

po sition for cutting Then the plunge r e enters the notch in the
.

gear N an d the feed of the blank an d of the cutte r slide again t ake
,

place .

The Fellows Gear Shap er Thi s is m ade by the Fellow s Ge ar .

-

Sh aper Comp any Springfield V e rmont , It is Shown by the four , .

views Figs 2 1 0 to 2 1 3 Fig 2 1 0 is a front elevation Fig 2 1 1 a

, . . .
, .

pl an view Fig 2 1 2 a re ar elevation Fig 2 1 3 a po rtion of one end

, .
, .
 MA CHINES THA T GENER A TE B Y P LA NING TO O LS 221

e nlarged to Show cert ain det ails of the mech anism The principle .

o f it s O peration is de scribed on p 9 2 The general de sign of the

. .

m achine is as foll ows :

MethodofDrivin g It is driven from a countershaft to the stepped
—

cone A on the Sh aft B The movement s of the cutte r are derived

.

from thi s through a pini o n C of 30 teeth on thi s Sh aft which is ,

brought into engagement with the intern al gear D for quick motion ,

Fig 210
. .

or with the extern al ge ar E through an intermediate ge ar C for slow 1

motion (comp are with Figs 2 1 1 an d 2 1 3 the relation s ofthese gears

.

are outlined in the l atter) The intern al gear D is thrown into an d

.

o ut of eng agement with C by an eccentric fitting of it s sh aft These .

movement s are produced by the yoke F which is provided with a

,

han dl e an d has it s eye s fitting over the Sh aft G which is rot ated
, ,

by the gears D an d E .

A slotted crank H t the oppo site end of the sh aft G t ran smit s
a
222 GEA R C UTTING

motion to a rack bar J the length of st roke of which is adju st ab le

,

in the slotted c rank by the c re w K turned by it s squ ared end an d

s ,

clamped by the block seen encircling K The length of stroke is

.

set by the gradu ation s on the f ace of the crank seen in Fig 2 1 3 .
,

which h as divi sion s of the inch on one edge an d millimetres on th e

other In thi s w ay the length of stroke of the cutte r is v aried t o
.

suit ge ars of di ffere nt depth s of face A llowance is m ade by th e

.

gradu ation s for the cle arance of the cutter above an d below the bl ank ,

w hich is much le ss th an th at required for circul ar rot ating cutters .

Fig 21 1
. .

The movement is tran smitted from the rack bar through a pinion L
engaging with the rack teeth on a sleeve encircling the bar J Fig 2 1 3 , . .

The pinion is on the end of a rock sh aft M at the oppo site end of ,

which an othe r pinion actu ate s a rack ( not seen ) behind the cutte r
Slide N which reciproc ate s in the cutter guide 0 The rate of re .

cip rocatio n is v aried by pl acing the belt on the di fferent step s of

t he con e A an d by the engagement of the fi rst pinion C with the ring
,

of teeth D directly o r with E through the intermedi ate C A

,
1
.

downw ard movem ent of the yoke F puts in the slow motio n with
ge ar E; an Upward movement t hrows in the quick motion with
the gear D Squ are he aded bin ding Screws over the be ari ngs hold
.
-

the yoke f ast in either po sition .

The depth of cut th at is for the depth of teeth is set by gradu a

, , ,

tion s on the pe riphery of a pilot wheel P the settings being given

,
2 24 GEA R C UTTING

so imparting an arc movement to the cutter in addition to the vertica l

stroke s ju st noted Hand rot ation s can be e ffected by mean s of a
.

crank put on the squ ared end d of the shaft S .

In dexin g Moti0n to the index wheel for the blank the lowe r
.
— —

o r wo rk index wh eel U on the bo ttom end of the work arbo r is com —

mun icated al so from the Sh aft S but through bevel gears drivin g
,

through the change ge ars V A con st ant ratio is m aintained be

.

tween one ofthe gears u se d termed the pitch gear an d the cutter
, ,
”
,

Fig
. 21 3 .

by making the number of teeth in the pitch gear twice th at in th e

cutt e r This is placed on the qu adrant stud
. .

The Fellow s Company lay st re ss U pon the fact that the in

dexing mechani sm Shown diagramm atic ally in Fig 2 1 4 h as a
, .
,

tran smitted to the index wheel an d the gears There is no h alt in .

the running of the index gears but they continue to revo l ve,

q ui etly at slow spe ed connecting the wo rk an d t e cutter so th a t

, h
they revolve in uni so n as though they were a p air of ge ars in me sh .

Work Spin dle The apron W in which the work spindl e is c arrie d
.
—

is hinged an d h as to be swung outw ard s to permit of putting t h e

,
 MA CHINES THA T GENER A TE B Y P LA NING TO O LS 2 25

bl ank on it s arbor It is al so reciprocated Slightly between the cut

.

ting an d return stroke s to relieve the cutter on the latter stroke .

There are two plungers at the re ar of the m achine by which the apron ,

is locked an d which when withdrawn le ave it free

, A work Support .

X is set on the top edge of the rim of the bl ank in oppo sition to the
m m mm M M
cutter which is drawn up
" :
,

m W 0“
wards Z is a tray which .

recei ve s oil an d chips The .

pu mp arrangement s will be
ob served in Fig 2 1 2 . .

Supp ort to the B lan k .

The method of support

whi ch is afforded to the
C UTT ER
blank is termed the
face plate system -
.

The:arbor has an
SELF-
w
LOC KING o inverted t aper an d ,

being pl aced in the

" w W
m
“
m
“
a S
,“pin dl e from the
pi 214 wider n
a
side
.
it is .
,

then drawn in to
it s seat an integral p art of the spin dle When a face plate is .

Screwed to thi s arbor an d the work cl amped to it as in Fig 2 1 5

, .
,

the Support afforded is very good The cut t aken is when p os .

s ible a draw cut th at is in an —

,

U pw ard direction an d again st ,

the support X ( Figs 2 1 0 2 1 5 .

, ,

But the action of the

m achine can be reversed for cut
ting intern al gears as in Fig .

2 17 Cutters are supplied in two

.

di ameters 3 m pitch di ameter — .

fo r cutters of seven pitch an d

fi ner an d 4in di ameter for all
, .
Figg m5
co arser one s These m achines .

a re m ade in se ver al size s an d some now are motor d r iven Design s

,
.

a re modified con sider ably with dimen sion s The illustration s given
f

.
,

a re tho se of a 3 6in m achine of the fi rm s No 2 model

’
. . .
,

The B ilgram Machin e The Bilgram spur gear plan ing m achine .
— -

( Fig . which h as bee n b rou ht out by

g J E R ein ecke r of . .
,

P
2 26 GEA R CUTTING

Chemnitz Gablenz (for whom Messrs Pfeil CO of Clerkenwell E C

-
.
, ,
.

are the Engli sh agent s) gene rate s the t eeth on the same p rinciple as
,

the older bevel ge ar pl aner ( see p

-
Modi fied by the e ssential.

diffe rences between spu rs an d bevel s they are de signed Similarly ,

.

A roll cylinder is sub stituted for a roll cone an d the horizo nt al for ,

the angular po sition of the work arbor The tool ram is reciproc ated .

simil arly in both an d the tool is o f wedge sh aped section h aving it s

,
-
,

flanks inclined at 75 to the horizont al It cut s on Sides an d bottom

°
. .

There are however three such tool s u se d di fferently ground as will

, , , ,

be described pre sently The co st of such cutters is sm al l while

.
,

gears with different pre ssure angle s an d with co rrected height s above
,

an d below pitch line f o r sm all pinion s are re adily cut by virtue of ,

the mech ani sm embodied in the m achine without the sub stitution
of other cutters .

Fig 2 16
. . Fig 217
. .

Mode ofA ction The outline drawings of the m achine ( Figs 2 1 9

—
.

an d 22 0) will su ffi ce to render its general de sign an d mode of action

intell igible A ll the motion s which are full y autom atic are ope rated
.
, ,

from the belt pull ey A This is dri ven from the pull ey on the
.

seven speed countersh aft ( Fig

-
A d ri ve s the ram B c arrying t he
.

tool a at its O ppo site extremity The length of stroke is adju st e d

.

for ge ars of different widths of face acro ss a slotted disc within the
pulley the ram being Slotted as seen in Fig 2 1 9 fo r the adju stment
,
.

of the bolt which clamp s the connecting rod The movement of .

the ram is con st ant along a straight line p aral lel with the b ase of the
m achine The tool a with it s holder is lifted from the work on its
.

return stroke when the dividing is al so effected A cam rece ss C

, .

within the pull ey A receive s a roller which actu ates the cam shaft D
which is connected to the tool box an d lifts it .

The B lan k The mechani sm for de al ing with the bl ank is c arried
—

on the knee E which is adju sted vertic ally by the screw b an d locked
, ,

in position by me an s of the screw c The screw b has a gradu ated .

di al by which the correct height is se t before the cutting commences .

2 28 GEA R CUTTING

turning it to right or left according to the direction required a ,

point which will be reverted to again K indic ate s ratchet gears

.

which work the cro ss feed of the Slide .

In dexin g . The
dividing movement s
to the blank are
tran smitted th rough
theuniversal jointed
sh aft L to the other

end of the m achine ,

where the dividing

gears M an d an chor
wheel N with its
p awl are c arried .

The function of the

l atter is that of
holdingthe bl ank in
po sition during the
forward stroke of
the ram which cor
,

responds with the

cutting The divid
.

in g or pitching
ch ange gears seen
at M are set up to

give the correct

number of teeth .

P is a ge ar box the ,

function of which
is to convert the
con st ant rot ation
of the shaft L
into an intermit
tent one for ope
rating the anchor
wheel an d the di
v idin g ge a rs at an
,

interval which is regulated by the speed of the d riving pulley A

an d the stroke of the ram B .

P itchin gTooth Sp aces

. To set accurately the dist ance bet ween
—
 MA CHINES THA T GENERA TE B Y P LA NING TO OLS 2 29

the teeth a divi sion plate or disc which is fixed having 99 hole s an d
, , , ,

a second pl ate mov able h aving 1 00 hole s forming together a vernier

, , ,

adju stment are seen at Q

, The second plate O perates upon the work
.

arbor an d blank Correct setting is loc ated by a pin put through the
.

two disc s This setting which is varied to give stronger teeth to

.
,

small pinion s is an i m port ant fe ature which will be refe rred to again
, .

R oun din g There is a rounding device at T for impa rting a

—

slight co n vexity to the top s of teeth ( adju st able for var i ou s teeth
by mean s of a gradu ated sc rew) by preventing the tool box from
falling to its no rmal po sition when cutting above the pitch line in ,

increasing proportion as it appro aches the top of the tooth Thi s .

is determined by a po sitive connectio n with the cro ss slide by me an s

of bevel gears U On the bo ss of the .

last bevel gear there is a Se ries of hole s

t aking a pin which presses an elect ric
pu sh h at an y desired point in the
traverse of the cro ss slide F so that ,

a bell rings an d w arn s the operator of

the completion of the necessary travel

of the slide .

Op eration The action of the

. Fig 22 1 . .

m achine may now be summ arized .

The blank outlined at R being set on it s arbor the outer end of the
, , ,

l atter is carried in the support S which is it se lf held by two Shaft s ,

cl amped by the split bearings g g The dividing chan ge ge ars at .

M an d the ch ange gears at H connecting the cro ss Slide an d roll

,

cylinder an d the vernier adju stment at Q having been correctly

, ,

placed an d Set the ram c arrying the tool is reciproc ated by the rot a
,

tion of the pulley A an d the tool a m akes a out while the anchor
,

wheel with its pawl holds the ge ar in po sition The thrust of the .

tool is resisted by a ste ady bracket V when l arge ge ars are being cut .

On the return stroke of the ram with the lifting of the t ool a effected
, ,

by the cam within C the anchor wheel rele ases the gear bl ank an d
, ,

the division to the next tooth t ake s pl ace .

The method of fee d by the cro ss slide F an d roll cylinde r G is like

that of the B ilgram bevel gear generator in thi s re spect th at there
- —

is no ve rtic al fee d A l so it is of no con sequence whether the c ro ss

.
,

slide tr avel s from right to left or f rom left to right The expl an ation .

of this fact is as follows

There is a line engraved on the cro ss Slide an d a corre sponding ,
2 30 GEA R CUTTING

line on it s bed When the se two lines are oppo sit e the centre of
.
,

the work arbor is in the sam e vertic al pl ane as the centre of t he tool ,

an d thi s is t he lowe st p o int to which the to o l can re ach when cutting

the bl ank an d in this po sition therefo re the depth of the tool is set
, , , .

A movement of the slide in e ithe r di rection roll s the ge ar bl ank

gradu ally into a po sition in which the tool can p ass right ove r the
bl ank It will be seen therefore th at if the ram is now st a rted
.
, , ,

an d t he feed eng aged O p e rating in t hat di rection which will gr adu

,

ally c au se t he line s on the slide an d it s bed t o mee t the tool will go ,

deepe r with every st roke until the lin es coincide when the tool will ,

have re ached the lowest p art of the tooth depth The feed being .

continued the tool will gradu ally come to the top of the blank on
,

t he other side until it is cle ar of t he bl ank The cro ss Slide will then .

h ave travelled to the sam e di st ance f rom it s central po sition on t he

farthe r Side as it occupied on the n ear side when the cut commenced .

A lthough wh en the slide w as in it s central po sition the tool w as a t

, ,

the lowest depth of the tooth the tooth w as n o t completed until ,

the c ro ss Slide had completed its trave rse .

The V ern ier The width of the sp ace to be cut is Set by me an s

.
—

of the vernie r Q A t able is p rovided fo r thi s bec au se the width of

.
,

the sp ac e is v arie d according to the numbe rs of teeth required .

Con sid e rable stre ss is l aid on thi s fe ature sinc e it m akes the t eeth ,

of the sm all pinion s st ronger than they would otherwi se be It is .

obviou sly undesi rable to have a pinion which h as to m ake say fi v e , ,

or six re volution s to one of its m ating wheel o f the same thick ness ,

of tooth B y the p rovision m ade at the vernie r the thickn ess of

.

the wheel teeth is reduced an d th at o f the pinion teeth incre ased

, ,

the amount t aken from one being added to the other A t able .

Supplied with t h e m achine give svernier setting s f o r c o rrect e d t h ick

nesses fo r numbers of teeth ranging from 1 1 to 1 00 .

In setting the po sition of the bl ank for cutting the method i , s

to put the vernier ove r by h alf the di st ance given in the t able supplied
wit h the m achine when roughing out The vernier is then put b ack
,
-
.

to zero for the right h and cut an d is set ove r the full di st an ce fo r
-
,

the left h and cut

-
.

Tools With regard to the tool s an d their method of settin g

.
—
,

there are as st at ed th ree tool s u sed a roughin g out tool ground

, ,
— -

at right angle s with it s length a fi ni shing tool ground at an a cute ,

angle to it s right side an d anoth e r fi ni shing t o ol ground at an acut e

,

angle to it s le ft Side the th ree b e ing shown in Fig 2 2 2

, The rough . .
 CHA PT ER XI V
MA CHINES THA T GENERA TE B E ELS B Y V P LA NING

THE P R INCIP L E STA being helpful to the Clear under

TED . — AS
st an ding o fthe subject the relation of a m aster ge ar to the ge ar being

cut is po stulated That is every bevel ge ar being cut is related to the

.
,

crown bevel through a master gear meshing with the crown gear an d
c arryingon its axis the ge ar to be cut (Fig The relation s are .

t ho se of pitch cone angle an d number of t eeth but not of pitch If , .

the crown ge ar is rot ated to roll the m aster ge ar a planer tool co rre ,

spo n din g with the fl ank of the crown ge ar tooth will pro duce an

involute shaped tooth on the gear being cut ope rating under the
-
,

coercion of the m aster gear an d p art akin g of its movement This

, .

prin ciple is adopted in several m achines though not in this p articul ar

form It is suffi cient if the rolling action of the pitch surface is
.

produced without tooth engagement In the B ilgram bevel ge ar .

-

generator for ex ample the roll cones represent the pitch surf aces of
, ,

m aster gears an d the flat surface they roll on is the pitch surface of
,

the cro wn ge ar A n d in stead of a fixed angle such as would be

.

m aint ained in a rigid frame the vertic al angle is adju sted in qu ad

rant pl ate s A gain in order to p roduce the curve of the teeth the
.
, ,

m aster gear o r its equivalent an d the bl ank mu st be rolled laterally

around the axi s of the crow n ge ar or altern atively the l atter mu st be

rolled the m aste r ge ar an d the gear being cut rotating on their

,

axi s only In the B ilgram m achine the bl ank swings around the
.

vertic al axis of the im agin ary crown ge ar .

The B ilgram Machin e A mong the b evel ge ar generating

.
—

m achine s the Bilgram is prope rly accorded the fi rst place bec au se ,

it w as the first in point of time an d is st ill more largely u sed than an y

,

other For m any ye ars it was m ade Semi autom atic only (Fig
.
-
.

the indexing being done by h and but it is now m ade of fully auto ,

m atic design .

P rin cip le of A ction The principle of the m achine is th at one

—

rack tooth generate s all ge ars of one pitch by a reciproc ating action ,

cuttin g in the interv als of the movement s of the blan k which o sc ill ates
in the pl ane of the cone an gles an d rolls on the pitch surface (see
,

232
 MA CHINES THA T GENERA TE B E ELS B Y P LA NING V 2 33

Fig 8 2 p. These motion s are produced by the mechanism

, .

of the m achine which embodies the generating action as follows

, ,

( Fig s 2 2 7 an d
. 2 2 8 which Show the s emi ,
autom atic m ac h ine in -

longitudin al elevation with part sections an d in plan respectively )

,
.

This represent s the m achine as m ade bv J E Rein ecker A G . . , . .

,

of Chemnitz .

St arting with the too l A whic h repre sent s a rack t ooth thi s does
, ,

not occupy the entire width of the tooth (see Fig But it s .

side s which do the cutting are incli n ed at the angle of 1 5 ( or o ther

°
, ,

Fig 225
. .

an gle) It is the form of tooth which is identic al in a straight rack

.
,

an d in the teeth of a crown bevel g e af t he pitch pl an e of which is flat

’

The tooth face s lie at right angles with the angle of pres sure of the
ge ar The tool reciproc ates only it has no lateral feed an d there
.
, ,

fore the o scillations an d the rolling of the blank provide the feeds .

Vertic al an d lateral adju stment s of the tool are provided but once , ,

set it reciproc ates only lifting on the return stroke Sundry ad

, , .

justment s of the tool are e ssenti al That for length of stroke is pro .

v ided by a Slotted di sc an d connectin grod B ( Figs 2 2 7 an d It .

is adj usted bodily in the vertic al an d l ateral direction s in its holder C ,

which is att ached to an ap ron D The l atter is hinged on a pin E .

,

t apered for t ake Up for wear an d c arried at the end of an arm or

-
, ,

ram F to which the connecting rod is fitted

, The tool lift s on the .

return st roke The tool is adju sted by the screws A an d B

.
’ ’
.

The B lan k an d its Movemen t The mechan ism for carrying the .
—
2 34 GEA R C UTTING

blank an d feeding an d indexin g comprises the follow in gz A n arbo r

, ,
—

G c arried in a holder h aving provi sion for angul ar adju stment s in a

vertic al plane between two U pright s H H being cl amped therein , ,

by the nut s seen A vernie r provides for ex act settin g The o scil
. .

l at io n s of thi s element provide for the angle s of the teeth in t he pl ane

of the cone se ction .

The U pright s are c arried by a h orizont al pl ate J which move s ,

about a vertic al axi s _ th at which intersect s the apex of the cone

-

Fig 226
.
—The B ilg ra m Be v e lg
-
ea r Ge n e ra t i g Pl
n an e r.

of the gear By this mean s a l at eral movement is imp arted to th e

.

bl ank corresponding with the flank angles of the t eeth The genera .

tion of the involute curve s is produced by the coercion _o f the roll

cone K on the upper en d of the arbor mech ani sm which produce s ,

a rol ling of the ge ar corre sponding with it s di ameter A s the am ount .

of roll varie s in every different size of gear a set of twenty two roll ,
-

cones is Supplied ranging from 1 1 3 to 7 5 of angle which provide

,
° °
,

e x act or approxim ate angle s for a complete range of ge ars The cone s .

supplied are m arked with the following angle s :

°
12
° ° °
22 i . z7 é , 32 9 , 4 z é .

7 0
°
The se provide average an gle s cove ring
an d

the whole ran ge of ge ars th at may be cut on the m achine A n y .

 MA CHINES THA T GENERA TE B EVELS B Y PLA NI G N 2 37

in termediate bevel is obt ained by t aking the nearest roll cone thereto .

Each fo rm s a portion of a conic frustum corre sponding with the ,

cone angle of a wheel an d they are compell ed to roll on the han ds

,

bec au se coerced by the movement of the head to which t hey are

bolted O n e of these is Shown at K in Fig 2 30 resting on a cone
.
.
,

Fig 229
. .

bl ock with the flexible steel bands d d ancho red at each end
, , ,

wh ich coerce the movement s of the cone .

The belt pulley L which reciproc ates the cutter al so actu ates
, ,

the feed through a connecting rod M adjust able in a Slotted cran k ,

disc This actuate s a ratchet wheel N on the end of a cro ss shaft

.
,

an d thence bevel ge ars O O P tr an smit the arc movement s to the

, ,

plate J which c arries the inclined

,

arbor These movement s are pro

.

duced to both right an d left ao ,

cording to which sides of the teeth

are being pl aned A t the same time .

the roll cone is coercing the arbor in

its l ateral roll The indexin g is lo
.

cated at the U pper end of the arbo r

Fig 23 0 . .

Spindle ( Fig either change

.

gears are u sed or an index plate an d peg The worm wheel is

, .

carried on a Sleeve which encircles the arbor spindle A s the roll .

cone s pull laterally plates are provided with curved faces seen in
,

Fig 2 2 7 otherwise the mech anism could not accommodate it se lf to

.
,

the rolling action produced by the cone s .

Settin gUp In the fixing up of work on the m achine c al cul ation s

.
—

are b ased upon the st an dard proportion s shown in Fig 2 2 9 The . .

b asis is the modul or equivalent of the Brown Sharpe dia

,
”

meter pitch s (see p an d which is the di st ance from pitch

.

line to point the addendum me asured on the m ajor di ameter of a

—

bevel gear The pitch equ als the modul

. so th at x or,

P itCh
Modul
an d
Pitch = Mo du1 x
2 38 GEA R C UTTING

The di st ance from pitch line to root = Mo dul to give x

root cle arance .

The basi s rack teeth h ave an an gle of 1 5 with the pe rpendicular °

,

or 7 5 with the pitch plane

°
.

The B lan k Beginning with the tu rned bl ank the fo rmula

—
,

u sed are given below fo r Sh afts at right angles Compare with the .

d rawing (Fig .

Ow

Fig. 23 1 .

m be the Modul .

Number of teeth of wheel .

pinion .

P itch di amete r of wheel .

pinion .

P itch angle of wheel .

pinio n .

D i st ance from apex to pitch circle .

A ngle of top of wheel an d pinion tooth .

b ase
Height of teeth ( out side) .

Out side di ameter of wheel .

pinion .

P it ch = Mo dul x
2 40 GEA R C UTTING

Di st ance 8
5 3 .1 in .

Height of too th .
53 1 in .

Out side
d iamete r 1 0 2 57 in . . 6 4 2 8 in
. .

Ch ange
( hole s) 3 8 3 6

( R efer ring to the index pl ate s which are supplied with the m achine ) .

Settin g Up First the index plate is .

—

put on Then the wheel bl ank is placed

.

on the arbor which is set to the pitch ,

.

angle A ( Fig The

w ge ar bl ank
. s are

held endwise by me an s of washers an d by ,

the nut s a an d b (Fig Fin al adju st .

ment of the gears is made by in serting an

adju sting coll ar c ( Fig 2 34) between the .

blank an d the spindl e head The roll cone .

which comes nearest to the pitch angle rest s

on the cone block ( Fig The pitch .

angle A in Fig 2 33 is now reduced by 1 °

w .

that is the arbor is set to the angle A

a —
, w

so lowering the roll cone which will ,

impart a trifle more of rounding to the

tooth flank than is theoretic all y correct ,

but which is conducive to smooth working .

Next the flexible steel b ands are cl amped

Fig 23 2 . .

on Then the angle of the b ase box is Set

.

to the an gle C of the b ase o r root of the tooth less

", This is done ,

with the gradu ated hand wheel seen at the rear in Figs 2 2 7 an d .

2 28, moving a di agon al screw in it s bo ss the point of which screw ,

re st s on a bevelled end of the bed of the m achine .

A djustmen t ofB l an k The wheel blank h as now to be adju sted

—

to the height of the tooth B ottom block s of a definite thickn ess

.
,

hardened an d ground are u sed for thi s purpo se They range from
,
.

.2 7 sin to 3 7 5in
. . in steps of 001 in These are laid in the gauge
. .

( Fig 2
.
3 )
5 at the end of the sc ale bar in the axis of the m achine The .

measuring c aliper ( Fig . which is set to the exact height of the

tooth is then set on top of the bottom block an d the wheel is moved
, ,

into that po sition in which the jaw of the c aliper will rest on the
U pper Circumference of the edge of the whee l as shown ,
.

The di st ance piece is next put into the gauge of the scale bar
an d moved up to t he whee l ( Fig When it touches notice
.
,

mu st be t aken ofthe dist ance indic at ed on the scale at the back of

 MA C HIN ES THA T GENERA TE B EVELS B Y P LA NIN G 2 41

the bar ( see Fig . This sc ale bar is a v alu able adjunct to the
machine It is adj ust able by me an s of a vernier to a thou sandth of
.

an inch — three pl aces of decim als ; an d

is u se d for setting the ex act di ameter
of the rim of the wheel in the manner
shown in Fig 2 3 6 by which mean s t he
.
,

ri ms of wheel an d pinions are in sured be

in gflu sh when put together for ge aring .

Note is next t aken whether the wheel

run s truly on the arbor te sting it by ,

me an s of the indic ator in Fig 2 37 .

,

which m agnifies an y erro r largely at its

free end .

Cuttin g Everyt hing is now fixed

—
Fig 23 3 . .

up ready for cutting The first tool .

stock s out the met al with a cent ral cut f ollowed by finishing the
,

flank s to right an d left For t aking the roughing cut the tool is ad
.
,

ju sted vertic ally by me an s of the bottom block which has to pass ,

e asily between the tool point an d the gauge

F
( g 3
i 2 8 A ) The. centr
,
al po.s ition is o b
t ain ed by p assing a side block on e ach side
bet wee n the too l an d the gauge as in Fig 2 38 ,
.
,

B Th e tool is afterward s f astened for t aking

.

the right h and cut It is adju sted vertic ally

-
.

to the bottom block an d side ,

ways to the side block as in ,

Fig 2 38 C The exact ad .

,
.

ju stment of the side blocks is

very import ant since a little ,

difference would m ake the

tool cut the t oo th flank s
thinner or thicker than the
Fig 23 4 . ,
speci fi ed st and ard The index .

pl ate is turned round eighteen

holes to bring the tool into the po sition Iin Fig 2 39 an d the cutting .
,

proceed s For cutting the left h and tool flank the tool is fastened
.
-

for the left h and in the same w ay as for the right an d the di al is ,

turned b ack in the oppo site direction thirty seven hole s which brings -
,

the tool into the po sition II in Figs 2 39 an d 2 40 The three tools

. .

u sed are shown in Fig 2 4 1 one for roughing out parallel an d one
.
,
-
,

Q
2 42 GEA R C U TTI NG
right an d one left for finishing t he flank s The roughing tool is .

ground st raight acro ss the end the fi ni shing tool s h ave side front
,

rake .
Te mplet block s are sent with the m achine to en u re uni s

fo rmity in grinding the

end s of t he tool s which ,

are th e only p art s

ground These block s
.

are re ce se d to receive
s

the planing tool the ,

cutting ends alone pro

je ct in g , to be p asse d M M “ , ,

under the eme ry wheel .

Corrected Teeth — In .

wheels of less th an 3 0
teeth undercutting oc
cu rs (see p an d the worm thre ad s mu st be rounded or el se the
.
,

wheels be m ade of l arge r di amet e r by incre asing the length of

the addenda The l atter is adopted in the case of sm all bevel
.

pinion s In such pinion s the undercutting is a sou rce of we ak ne ss

. .

This is avoided an d the labour of asce rt aining the exact rel ation s
,

of pitch line an d addenda required to avoid undercutting is saved

by the use of t able s supplied with this machine In gears th at .

h ave a less number of teeth th an those given in the t ab le below the ,

gears are sized di ffere n tly th an by the formulae ju st now given :

28 20 Io teeth .

The height of the wheel tooth

above t he pitch circle is reduced ,

an d the depth be low the circle in

creased co rre spondingly so keeping ,

t he tot al he i ght unch anged Thu s .

the angle of top B in the previou s

SC A L E B A R

Fig 23 6 . . Fig 23 7
. .

o rmul a
e , an d of the base C , are re duced respectively by a ce rt ain
2 44 GEA R C UTTIN G
reduced an gle of wheel which will not require th at the pinion s
,

sh all be undercut The di fference between the two angle s is

.

the theo retic al correcting angle Practical ly two thirds of this .

-

angle are found su f fi cient Fig 2 44 is only a di agram which

. .
,

represent s on a very small sc ale the large di agram of curves

an d line s an d divided edge s all the det ail s of which are omitted
,

from thi s figure .

Example A s an ex ample of thi s correction t ake a p air of

—
,

wheels of 37 an d 1 4 teet h of 8th pitch with axe s at right angles

, , .

Referring to the rule s previou sly given

. 62 5in .

. 1 98 5in .

dw = 7 361 in
. . d, = 2 7 8 5in . .

A = 69 A , = 2o
° °
< <

E= 3 93 5in
. h = 4 2 1 5in . .

C= 3
°
< B <

Fig 24 2
. . Fig 24 3. .

To fin d the correcting angle in the origin al of the dia gram

Fig follow c t in line th rough say 3 7 f rom left to right an d
( . a e r a , , ,

th rough line 1 4 downwards The poi n t where these line s m eet lie s
.

in the circle which repre sent s the ordin ary top angle B of 2 54 ° ’

an d is al so between the st raight line s representing angl e s of 1

°

3 0
’
an d 1
°
T h e ex act angle would therefo re be 1 Two °

t hirds of thi s angle give the correcting angle a = o Hence : °

Whe l e A ngl of top

e B = 2 54 ° ’
o
°
7 2 -
°
o ’
.

A ngle of base Cw = 3
°
 MA CHINES THA T GENERA TE B EV ELS B Y PLA NING 2 45

P inion A ngle of top B, = 2 °

o
°

A n gle of base C, = 3 ° °
’
15 o
d

The out side diameters of wheel an d pinion are obt ained by the
following formulae
Wheel B co s A w ) w x .

P inion D, = d, ( 2 x E t B
g , x co s . x

A n d the order goes into the shop as below in conjunction with ,

Fig 2 45
. .

NUMB ER OF7 5 5 7” OF WHEEL

Fig 244
. .

Modul . 1 98 5in .

Number o f teeth 37 14

P itch angle °
69 1 6
’ °
2 0 44
'

A ngle of b ase ° ’ ° '

4 9 2 21

Dist anc e 3 9 3 5 i
-n .

Height of tooth 4 5
.2 1 in .

Out side di ameter 7 4s

. 8 in .
3 . 2 7 4in .

Ch ange ( holes) 39 35

( R efer ing as before

r index plate s ) .
2 46 GEA R C U TTI NG

Se qu of Op eration s
en ce When the m achi n e is set up the
—
,

dutie s of the attendant are as follows z When one side of a —

single tooth has been cut an d the pointer in the plan view
,

( Fig 2 2 8
.
) i n dic ate s on t h e s c a le th a t the prope r depth is

re ached the operating pinion is disengaged The wo rm is

,
.

then tu rned round to give the pitch di st ance for the next
tooth The pinion is then put into gear again by the knob
.

fo r the autom atic cutting of the next tooth flank When all .

the flank s on one side have been cut the other pinion is put ,

into gear an d the same se rie s of oper a

,

tions gone through for the othe r side s

of the teeth The B ilgram m achine there .

fore with the exerci se of ordin ary c are

,

an d attention give s result s which are as ,

near perfection as it is po ssible to get

them ; an d fo r several years a good
bu sine ss has been done in cutting the
best ge ars for the trade on these m achine s .

The m achine s are supplied with co m

p le t e a cce ss orie s in e v e ry det ail which ,

en able s t he u se r of the same to operate

them without h aving to m ak e an y new

tool s etc Mo st of the m achine s as now
,
.
,

m ade are fully autom atic ,

.

The R obey Smith Mw hin e This gener- —

ate s t eeth the cu rve s of wh ich are ,

arc s of circle s The indexing t akes pl ace .

Fig 24 5 .

between e ach stroke of the tool s of

.

which two are cutting simult aneou sly The movement s of the se .

are link ed with tho se of the blank so th at as t he l atter is fed

,

inward s for depth the tool slides open to imp art the incre ase in
,

the thickness of the t eeth from point s to root s .

Gen ral D esigne The m achine ( Fig 2 4 6 s ee also Figs 2 48

.
—
.
, .
,

2 49 p 2 53 ) is driven by a st epped c one whence a cam actu

,
.
,

ates the work t able On thi s the be aring s for the work spindle
-
.

an d the dividing wheel are c arried The t able is mounted on .

a horizo n t al bed which fo rm s the b ase of the m achine an d ,

has an angul ar motion on it in a h rizont al pl ane by a cir o

cular rack with a knock out motion It is set on the bed so

-
.
,

that the reciproc ating tools begi n to operate at the point s

2 48 GEA R C U TTI NG

( Smith fr Covent ry L imite

,
d ) .

GR ESL EY I RON WO R K S ,

Salford

P INIO N WHEEL

No . of Teeth
P itch A ngle
A ngle of B ase

Di st ance

Out side Di ameter

Turning A ngle

No . ofGea rs

Drawin g

reviou s to turning an y pair of beve l wheel bl ank s the turner

P ,

should be supplied with a p aper cont aining the following p a rticul ars

o f the whee l s :

( )
1 O ut s id e D i am e t e r .

( )
2 F a c e A ngl e .

( 3) B ack A ngl e .

methods of m aking the c alculation s necessary to obt ain

Tw o
these qu antities a re given one worked out arithmetical ly an d the
,

other trigonometric ally .

 MA CHINES THA T GENERA TE B EVELS B Y P L A NING 2 49

D I A GRA M O F A P A I R O F B EV EL GEA R S ( FIG .

WI TH NOTATI O N USED IN FO R MULZE .

Fig. 24 7 .

Letter n = No of teeth in jp in ion

. .

N= No of teeth in wheel
. .

a =
§ angle of pitch cone of pinion .

D = A pex di st ance .

P = Diamet ral pitch .

p = Circ ul ar pitch .

7 = A ngle of circu l ar pitch .

A = R adius of pinion pitch cone .

B = R adius of wheel pitch cone .

h = Height o f tooth above pitch line .

h = De p th of tooth below pit ch line .

A R ITHMETICA L FO RMULIE .

P inion teeth
iWh
15
Example: R atio 2 to 1 3 pitch , .

t eth
.
,

ee l 3 0 e

( )
1 Outside Diameter .

For pin ion For wheel

3 o + 2

( )
2 Face A n gl e —
To obt ain this dimen sion there must first ,
2 50 GEA R C U TTI NG
be calculated t hepitch cone angle the apex dist ance the , ,
an gle of
circular pitch , an d the angle of top of t he tooth .

P itch Con e A n gle

n
For pinion . Tan a For wheel .
5 pitch cone angl e of wheel

A p ex distan ce
D :
J A 2
+ B = 2
J z.

J 5
6 2. 25

J3 5I 2 .

56 90

A n gl e ofcircul ar p itch
1 89 57 2 5
951
P D . D
1 80 80
1
_1 0 7 3 3 = 1 044
.

3 x 1 6 -7 7

}
A ngle o f p
to o ftooth = 7 x
;
1044 x
3 33

Fro m th ese d at a the f ace angles of ,

t he w heel an d pinion are

c alcul ate d by t he following formula :

Face A n gle h
(
Face A n le
)
h (
g < f)
2 2
0 x
9 a
7
W E
a x
7 h el
ofP in i n of e

26 34 24
90 3
665°

( 3) B ack A ngle .

( 3) For pin ion = 90 °

a For w he el = a

26 34 3 63
20 = 26 34

TR I GO NO M ETR I CA L Fo R MULAs .

Ex amp le . Ra tio , 2 to p it Ch
:
$ 112? is£222
( )
1 revio
Outs ide Diameter u s to m aking thi s c a
.lcul ation
— the
P ,

pitch cone angle mu st be obt ained .

2 52 GEA R C UTTI NG
were required in the c alcul ations for the turnin g angle s , an d the
fo rmula nece ssary to o bt ain them were given .

6
( ) B ase A n gle .

efo re obt aining this angle the pitch cone angle the angle of
B , ,

circular pitch an d the angle of the bottom of tooth mu st first be

k nown ; of the se the pitch c one an gle an d the an gle of circul ar pitch
,

have already bee n calculat ed .

h
"

A n gle of bottom of tooth 7 x

1
)

( )
IO
:H 68
x x .
3

it
6
( ) B ase A n gle

—
ofP in ion = a

2634
( 7 x

)
6
( ) B ase A ngle o f Wheel = 90

8
( ) A ngl e f
oFormer A rm .

The angle of circul ar pitch ( 7 ) is u sed al so in this formula .

8
( ) A ngl e o fFormer A rm =

1044
5
4
2 “

T R IGO NO METRICA L FO R MULE .

The qu antitie s ( 4) A pex distan ce ( 2) Face angle an d 5) P itch , ,

co ne angle were required in the c alculation s for the turning angle s

an d the form ula nece ssary to obt ain them we re gi ve n .

6
( ) B ase A ngl e .

If h = depth of
’
tooth below pitch line .

B angle of tooth below pitch line or root angle

= ’
.
,

’
h
6
I
t an
D
A ngle of base of teeth or base angle , .

pitch an gle root angle of t ooth .

B for pinion ( 90 for wh l °

B
’ ’
a
) .ee a .

8
( ) A ngl e f
oFormer A rm .

2 7 00
_ _
_ 2 7 00

PD 3 x
 MA CHINES V
THA T GENERA TE B E EL S B Y P LA NING

Settin g
Wheel B l an k .

Two gauge s are

necessary for set
ting the wheel
bl ank in its pro
p e r po si tion rel a

tive to the centre

of the m achine
( Fig s .2 4 8 ,

The gauge ( Fig .

2 50) is use d for

this set ti ng ,

w h i c h c o r re
spo n ds with the

ap e x of t he

wheel The rod

.

in the gauge is
adju sted till the

vernier re ads t he
di st ance ( quan
tity 4) on the
sc ale an d is then
,

locked in po si
tion The wheel
.

blank is set back

from the centre
Fg 249
by withdrawing ' ' ‘

the slide B ( Fig 2 49) until the b ack

.

face of the wheel j ust t ouches the

pointer of the gauge Th gauge is . e

then swung out of the w ay on to the

back o f the machine an d t he slide ,

B mu st not be di sturbe d again .

On the top of the m achi n e

t able is a sc al e m arked in degree s .

which is u sed for reading the

pitch face an d base angles of the wheel ( qu antit ie s 5 2 an d
, ,

The an gle of the blank is read on th i s sc ale by vernie r C wh ich ,

is
divided to read to five minut es as well as the degree s .

Move n ow the t able sl ide by the handle D until the ve rnier C

2 54 GEA R C U TTI NG
re ads the face angle of the bl ank If the wheel is truly tu rned an d ,

the blank accurate ly set to di st ance gauge the f ace of the whee l should
,

be pe rfectly p arallel with the too l slide s B To test this the gauge
. ,

( Fig 2 5 )
1 .is supplied which s
,h ould ju st fill the di st an ce be

tween the tool slide an d the face ofthe wheel at every po int .

Settin gofDividin gA pp aratus The wheel is divided

—
,

with regard to the number of teeth to be cut by me an s of ,

a p awl an d dividing pl ate Twenty one dividing pl ates are

.
-

supplied an d a reference to the following T able will show

,

which plate is to be u sed for a given numbe r of teeth .

The pl ate is placed in position on the spindle sleeve

ecurely by the split

s This
11 u t 1 0 c k s gether the dividing plate the split ,

m andrel If the nut is not securely

.

will move while being cut .

lowing adju stment s in order given

spindl e until the plunger 8 Fig 2 8 )
( 4 .

fall s into a notch in the dividing plate .

slot N in an upright po sition a s

sh o wn in the illu stration ( Fig .

3 S
. et the con n ec t in g rod 0 to t ake the re

quired number of teeth

4 B ri ng
. the beve lled end of t he slipper plate J right up to the
roller K but not touching it
, .

5 A dj us
. t the pawl L by mean s of the screw M until it almo st
touche s the face of the tooth in the dividing plate which conclude s ,

the se tt ing .
2 56 GEA R C U TTI NG

From ii "
to 1 1 pitch ‘
, use 325
”
radius
5 II 0

Ire I i

Settin f g o ce
Tools the
. to
—
o lP1a
s in the holder s with the r adiu s

edges facing each other an d nip them up lightly by me ans of the

,

t aper bolt s at the back of the holder .

The gauge (Fig 2 52 ) is then held again st .

the su rface of the tool slide (Fig 2 49) an d the .

too ls are adju sted forward in the holders by

the smal l set screw until they ju st touch th e
surface st amped with the si ze of radiu s of t h e

tool being set then tighten up , .

The gauge ( Fig 2 53 ) is then place d u p on .

the t able of the m achine an d the upper tool ,

holder adju sted vertic all y by the screw T

( Fig 2 4 )
8 until the cutting
. edge of the t o o l
Fig :25 1 . .
ju st touche s t he ground surface U of the g au g e ,

then tighten in this po sition .

Tre at the lower tool holder simil arly setting to the su rface P
-
,
.

For convenience in the last sett ing the tool holder may be move d ,
-

in turn along the slide E so as to be out of the way of the other

,

tool holder
-
.

In opening out the former arm s for the thickne ss of tooth the ,

following deduction from the angle given on the in struction sheet

should be m ade .

For tools with 3 radiu s deduct 3 min 1 ”

7 .

l n

4
“

fa
”
l
a 5
k 6

Use ofTools . radiu s edge of the tool is always the cuttin g

—
The
edge A ll bevel pinion s h aving less than 2 0 teeth an d of a ratio
.
,

of 2 to 1 or greater mu st be cut with the tool which has its radiu s

,

on the hollow side .

A ll mit re s an d bevel wheels mu st be cut with the tool h aving it s

radiu s on the straight side .

Settin gthe Machin e It is u su al to pe rform two di stinct O pera

.
—

tion s in the cutting of an y wheel ( a) R oughing out of the space an d — -

b
( ) the forming or fi ni shing of the s ide s of t he tooth The m achin e .

has a di fferent setting for e ach operation .

 MA CHINES THA T GENERA TE B E EL S B Y V PLA NING 2 57

R oughin g . When roughin g out the spac es

- -
forme r aim s Q Q , t he , ,

Fig 2 48 are set so that the pointers R R re ad 1 § time s the angle to

.
, ,

which the arm s are set when fi nishing the t eeth For example if .
,

t he angle of the former a rm s w as given on the p aper qu antity 8

( )
the roughing ope ration
°
as 1

would be m ade with the pointe rs

R R re ading
,
The k n oCk off -

motion is then set by winding the

saddle round until the tool t ouche s

the f ace of the blank ; it will then be

found that the vernier C doe s not Fig 25 2
re ad the same angle as the in st ruc
. .

tion sheet ; whatever the difference is m ake the same allowance on ,

the b ase angle C re ads the b ase angle ( qu antity

. When in this
po sition the stop bracket X is moved to touch the en d of the knock
of f rod an d bolted securely
,
Th e stroke of t he tool sh ould be Iiin
. .

longer than the face of the wheel teeth ,

a n d m ay be m ade still l onger in the

c ase of a l arge heavy wheel The ,

.

stroke is regul ate d by the po sition of

t he connecting rod bolt in the slot of the -

di sc Z The disc is m arked with a sc ale

.

by which the stroke can be imme di

ately set to an y length d e sired The .

overrun of the tools after cutting

through the bl ank should not be more
than iin This completes t he setting .

for the roughing operation s ; c are being

t aken to see th at screw I is unlocked .

Fin ishin g Wh en setting for the .

—

forming or finishing of the teeth wind ,

the saddl e round un til the vernier C

read s the pitch angle ( qu antity
Fig 25 3 .
Then se t
.
the connecting rod II ( Fig 2 48) .

to the pitch angle s on sc al e s III an d IV .

Sc ale V I is moved by me an s of the lever III until the pointer

re ads the pitch angle A t thi s st age lock the bolt I on the saddl e
. .

A fter thi s is done rele ase the bolt s an d adju st the former

arm s Q Q until
, the pointer s R R re ad t he co rrect
, angle of the
former arm s ( qu antity To adju st the former arm s use the ,

R
2 58 GEA R C U TTI NG
lever att ached to the pulley over which the b and for b alancin g
the arm s passes an d fin ally lock up the bolt s
, ,

To te st the accuracy of the settings wind the saddle outward s ,

an d then brin git b ack to the pitch angle when the pointers should ,

give the same sc ale readings as at first The settings for the stroke .

an d knock o ff motion rem ain undisturbed from the roughing opera

-

Fig 254
. .
— Sun d l dB
er an ev e lg
-
ear Gen e rat i g Pl
n an e r ( Fro n t V i e w ) .

tion Before st arting to cut the saddle should be wound b ack t o

.
,

allow the vernier C to re ad th e f ace angle plu s h alf a degree If a .

little more or less curve is required to the fo rm of the teeth it can be ,

g o t by ch anging the po sition of the connecting rod II on le ver III .

The Sun derlan d B evel gear Gen erator P lan er Th i s ( Figs 2 54

-
.
—
.
,

2 55) is m anuf actured by the Churchill M achine Tool Co Ltd of .

,

Manchester It po sse sse s the advant age th at gears can be gashed at

.

o n e setting before the tooth form s are generated thu s avoiding t he ,

n ece ssity for setting them on another m achine for gashing P rovi sio n .

is include d for imp arting a slight addition al convexity to the toot h

 MA CHINES THA T GENERA TE B E ELS B Y V PLA NING Z OI

By me an s of slot s an d stops in the dividing whee l G ge ars can be ,

cut h aving pre ssure angle s of

°
2 0 an d

Settin g Uf a The setting up an d method of O peration of the

—

m achine is as follows The gear blank is carried on an arbor Hin the

—

work head B which head is c arried as st ated on the swivellin gslide C

-
, ,

the centre of sw ivel of which coincides with the cone cent re 0 of the
m achine the apex of the gear B y t he angular movement imparted
— .

to thi s sli de the depth of cut of the teeth is adju sted The feeding in
.
-

movement is transmitt ed by a connecting rod J an d crank at th e side

Fig 25 7
. .

of the m achine an d actu ated by trains of ge ars from the single pulley
drive The cran k pin for the rod J is adju st able by a vernier
. .

Cuttin g The relative po sition s of the bl ank an d t ool at the com

.
-

men cemen t of cutting are shown in the plan view Fig 2 57 He re the, . .

blan k has been brought up to the tool by moving the work head along -

it s slide an d set by interpo sing a cle ar anc e gauge a between the bl ank
,

an d the po int of the tool The gashing is done first followed by the
.
,

g e n er ation T h
. e tool c arried an d reciproc ated on the slide D Fig 2 56
, ,
.
,

c arried on the vertic al swivel slide E is reciproc ated by a connect

,

ing rod an d crank disc Gradu ation s are provided on the connect
.

ing rod for ex act adju stment of the length of stroke The cut is a .

draw cut an d t ake s pl ace from the l arger end of the tooth to the
,
2 62 GEA R CUTTING

s m aller It is nece ssary in consequ ence of the large angular move

.

ment of the slide when generatin g to see that the gradu atio n s o n
the crank di sc which gove rn the stroke an d those on the connectin g ,

rod which govern the same should correspond when set A lso the , .

stroke of the tool should exceed by or the lengt of f

iin Qin h ace o.f .

the gear blank A little more clearance is left on the out side than
.

on the in side so that the tool can be given full opportunity to re

,

turn to it s cutting position before the commencement of e ach cut .

Cashin g In order to pe rform the p relim in arv g ashing the tool

—
,

sli de is locked in a centr al p sition with a stop pin seen at the left o f
o

Fig 2 57 The work slide which c arrie s the gear is then fed towards the
. .
-

tool autom atically by me ans of a ratchet motion controll ing the pl at e ,

K an d rod J which operate s on the return stroke of the tool When .

the full depth of the tooth space has been cut the wo rk slide is ,
-

autom atic all y withdrawn from the tool The operation of withdrawal.

al so put s into action the dividing motio n wh ich t ake s place simu l ,

t an eously with the othe r movement s of the m achine By the tirn e .

the dividing is completed the ge ar is again being fed forward to the

tool an d these action s are repe ated until all the t ooth spaces h av e
'

been stocked out .

In dexin g The dividing motion is put into actio n autom atically

.
—

by the adju stment of the plunge r b in the slot in front of the m achine ,

about midw ay in the stroke of the swivell ing slide Thi s plunger .
,

by pressing out the rod L put s the dividing motion into action ,

through plates abo ve adju sted so as to withdraw a pin from the stop s .

The feed is regulated on the di sc K through a plate d an d a feed

lever e by which means from one to five ratchet t eeth can be p asse d
,

as required When all the sp ace s h ave been stocked out the m achine
. ,

should be stopped when the gear bl ank is at it s outer po sitio n cle a r

of the tool The pawl will then be rai se d out of engagement

.

w ith the ratchet wheel aft e r which the fi ni shing cut s are t ake n
,
.

To st art the fi ni shing cut s the stop pin which lock s the tool slide -

is withdr awn le aving it free to swivel

,
A plunger above P is al so .

withdrawn A plun ger which govern s the fast motion is then

.

operated through the bell c rank lever an d friction cam which is

-

operated through the ordinary reversing mechani sm for the gen erat
ing motion The t oo l F is adju sted for t aking the fini shin g cut s Thi s
. .

is done by me an s of a tool setting gauge (Fig 2 57 ) -

O n e side of all the .

t eeth are first fini shed an d afterwards all the other sides It is im
. .

m aterial whichi s done first but the direction of rot ation of the dividi n g
,
2 64 GEA R C UTTING

by a series of twenty eight bev l gear segmen t s in the 1 8in m achine

-
e -
.
,

an d t he se being f astene d to an o scill ating element termed a yoke ”

,

control the movement s of the bl ank an d of the cutter slide s The se .

e lement s with the other e ssenti al p arts of the m achine may be studie d
, ,

in the subsequent outline drawings aided by the photograph ( Fig 2 58 ) , .

In the plan view (Fig o the centre of the m achine is the

.
, ,

cone centre ; A is the bl an k an d b one of the cutting tool s

, The tool .

Fig 25 8. .
— The G l easo n A uto mat i c Ge n erat i g
n Be ve lg
-
ear P l an e r .

s lide s c arried on guide s d d on a turret B ( comp are with

c, c are ,

Fig . which swivel s about t he cone cent re 0 in order to bring

the tools into the correct cone angular or section al relation s to the ,

ge ar bl ank A The angul ar rel ation s in the other direction tho se

.
—
,

n amely for the tooth flan k s are obt ained by the movement s of
,
—

the slides around the centre 0 in Figs 2 6 1 an d 2 62 which is plumb

’
.
,

over 0 in Fig 2 60 The yoke C is the element through which the

. .

o scill ation s of the bl ank an d tool s are produced it s centre of o scill a ,

t ion being the axi s e of the wo rk arbor The wo rk m andrel D ( Fig . .

2 60) is engaged by a fe ather at the right h and end of the yoke which -
,
 MA CHINES THA T GENER A TE B E ELS B Y V P LA NING 2 65

isconsequently compelled to oscill ate with the yoke This move .

ment is produced by one of the twenty one bevel gear segments - -

supplied one of which is seen at f( comp are wit h the photogr aph
, ,

{ WO QK SP INDI‘
.

Fig 25 9 . .

Fig . which v ary in re spect of the angle g o e ( Fig , The

, ,
.

o n e which h as the same angle as the ge ar to be cut is selected an d

bolted to the in side of the yoke C so that it s pitch line is a continu a

,

tion o f that of the ge ar to be out A se ries of bolt hole s is provided

.

in the yoke ( see Fig 2 58) to accommod ate the r ange of segment s
. .

The sw inging movemen t of the yoke an d segment is communic ated

to a crown wheel segment h which is bolted to the end of
-
,

the swingin g frame that c arrie s the tool slides The cutter slid e
-
.
-
2 66 GEA R C UTTING

an d the ge ar blan k are moved at the same velocity ratio The .

yoke C which operates the movement s is it self o scill ated through

the connecting rod E ( Fig . d riven from the slotted radiu s arm
F which is driven by a cam G
,

behind it The slot in the arm F

.

permit s of variation s being m ade

in the len gth of stroke an d the ,

cam v arie s the speed givin ga slow ,

motion near the pitc h line whe re ,

the cut is he avy an d a relatively ,

rapid motion at the end s of the

tooth where the cut is lighter
, .

The Tools The tools are re

.
—

cip rocated along guide b ars d d , ,

which are att ached to blocks th at

Fig 26 1
. .
c an be swivelled a n d a dju sted
about the centre Fig ’
0 ( .

to suit an y angle of tooth which adju stment s are m ade by the

,

tu rnbuckle O n the ax is 0 an o scill ating sh aft c arrie s a spur

’

Fig 26 2
. .

pinion This pinion engages with a rack on e ach too l slide o n

.
-

it s top an d bottom re sp ectively an d so reciproc ate s the slide s

,

in altern ate di re ction s These are not indic ated in the draw
.

ings A s the axis of the pinion lies in the axis o arou n d

.
'
,
2 68 GEA R C UTTING

chart supplied for the fi nishing out only When t ak ing the stock
, .

ing cut a few minute s of arc are added to the angle to afford the
.

allow ance f o r the fini shing cut The amount to be added varie s
.

accordi n g to the cone di st ance pitch an d qu antity of m ateri al left

Fig 263 . . Fig 26 4

. .

to be removed The amount therefore in an y c ase is left to the j udg

.

ment of the o pe rator .

The R oll The next thing to be done is to set the roll or

—
,

generating motion which is governed by the position of the crank

,

pin t (Fig 2 6 1 ) in the slot F The . .

amount of roll is gove rned by the

pre ssure angle of the teeth an d a ,

pinion require s mo re roll th an it s

m ating wheel The tool s mu st roll .

cle ar of the cut o r ce ase cutting at ,

e ach end of the roll Fig 2 63 repre . .

sent s the gen erating tools beg inning

Fig 265 .
thei.
r wo rk on a roughed out bl ank -
,

the tool s being below the cent re of

the m achine Fig 2 64 represent s them at their cent ral po sition
. .
,

an d Fig 2 65 above the c entre of the m achine at thei r highe st po si

.

tion The bl anks it will be noticed h ave been p reviou sly gashed
.
, ,

out with stocking tools sh aped in trunc ated v ee fo rm s .

The m achine is set for the prop er amount of roll by adju stmen t s
o f line s brought oppo site to e ach other which is done by m e an s of ,

the right an d left h and sc rew E (Fig an d mu st be done wh ile

.

the arm F is resting on the j ack m .

Stockin g Tools The stocking tool s are put in their cl apper

.
-

bl ock s an d f astened in pl ace by tightening binder bolt s

, Next the .

tool gauge u ( Fig 2 66) is tried If the point of the tool eithe r
. .

e xtend s beyond or doe s not re ach the gauge it is adju sted b y ,

 MA CHINES THA T GENER A TE B E EL S B Y V P LA NING 2 69

me ans of sc rews If the cutting slide is too high or too low the
.
,

necessary adju stment is m ade by other screw s When the end of .

the tool an d the cutting slide pass the gauge touching at both the ,

Fig . 266 .

ide the tool is in the correct po sition The inde x gears

e n d an d s , .

are selected from a t able an d se t according to the references

, ,

stud wor m an d crank in Fig 2 58

” ” ”
. .
, , ,

The ge ar bl ank A ( Fig 2 60) is now mounted selecting as stiff

.
,

an arbor as po ssible The bl ank is .

set in it s proper po sition by me an s

of the cone di st ance gauge J ( Fig .

Thi s is done by setting the

slide of the g auge at zero an d ,

moving both the head D ( Figs 2 60 .

an d 2 67 ) an d t he gauge till the

pointer regi sters zero when the ,

Fig 267
. .
Fig 26 8. °

a rm s are set at t he face angle To move the he ad an d mandrel D

.

lengthwise the bolt s c ( Fig 2 60) are loo sened an d the bindin g
,
.
,

bolt 10 an d the adju stment is m ade by the crank K ( Fig

, .

after which the bolt s 2) ( Fig 2 60) mu st be tightened

. The gauge .

is set on the arm as show n in Fig 26 7 . .

A cam key seen in Fig 2 68 is pulled out an d locked in po sition

,
.
,

by turning a small plate on the side of the key This di sconnects .

2 70 GEA R C UTTING

the generat in g cam an d h as to be do ne while the arm F is on the

,

j ack The finish ing cam G is t aken off an d the roughing cam
.
, ,

put on an d faste ned To t ake o ff the fini shing cam it mu st be

.

reverse d until the slot in the cam is oppo site the roller The stroke .

of the tool is now set according to the length of the tool face to be cut ,

al lowing g in for the cle arance of the tool s

. Thi s is done as st ated .
, ,

by the gradu ation s on the crank plate ( Fig .

The speed Ch ange ge ars k l ( Fig mu st be selected to suit

, , .

Fig 269. . Fig 270 . .

t he length of face an d amount of stock to be cut A t able give s th e .

number of stroke s per minute which e ach ch ange m akes The feed .

chan ge ge ars enclo sed at L ( Figs 2 58 an d 2 68 ) mu st al so be selected

.

to suit the varyin g condition s of size of gear pitch an d amount of , ,

m ateri al to be removed an d n ature of m ateri al b ased on a t able

, ,

furni shed with the m achine The m achine may now be st arted
. .

Th e roughing out
-
is fir st done with the stocking too ls ( Fig after .

which the finishing tool s are put in ; the roughing cam being removed
an d the fini shing c a m put in it s pl a ce The a rm s.being closed to the
p
roper tooth angle the m achine is then re ady for the fini shing cut
, .

Gen eratin g The generating proce ss commence s with the yoke in

—

t he lowe st po sition Thi s then move s upward s to the highest po si

.

t ion ( Fig.s 2 5 8 a n d an d the ge a r bl a nk ro l l s with it at the s ame

ra te ,
me a sured on the pitch line s The cutting tool s reciproc ate
.

s imult a neou sly a n

,
d pl ane e ach s ide of the toot h ne arly to Size .

The first movement from the lowest to the highest po sition t akes a
r oughing cut o ver both side s of one tooth When the tools are at .

the highest po sition they are fed inwards Slightly which feed serve s ,

o n the downw a rd movement to t a ke a light scr aping cut bring ing ,

th e tooth to s ize a n d en suring a smooth surf ace When the Slide s are .
 MA CHINES THA T GENERA TE B E EL S B Y V P LA NING 2 73

Gaugin g Tooth Thickn ess — Themethod of gauging the tooth

thickness is either by a solid gauge or by an adju st able vernier tooth
c al iper the first n amed being more expeditious an d easier to use
,

than the second The tooth thickness is the chord thick ness
.
,

based on a gear about hal f w ay between a pinion an d a rack

-

tooth This thickness would be very Slightly different for gears

.

of different numbers of teeth an d theoretic ally it would not be

,

ab so lutely correct to use the same for al l ge ars of the same pitch .

But practic al ly this difference may be ignored an d a solid gauge ,

would m ake the p inion teeth very slightly thicker than st andard
,
,

an d it s wheel slightly t hinner due to t he di f ferences in curvature

, .

If a solid gauge m ade from a rack tooth were u sed it would m ak e

the teeth of wheel s an d pinion s very slightly thicker than st andard ,

suflicien t to throw a p air of bevel s out of squ are If a vernier is set .

for the thickness to the chord of hal f the circular pitch an d for depth ,

to the adden dum plus the verse d sine the exact thickness o f tooth ,

at the pitch line would be obt ained For methods of c alculation

.

see p 2 8 in connection with Fig 2 0

. . .

P ressure A n gle With regard to the influence of the pressure

—

angle of the teeth on the amou nt of roll the Gleason Works give ,

the following as the practical limit to which the 1 4 5 pre ssure angle °

may be followed on the generato r :

Rat i o s. R at i os .

A ny pinion within the limit s n amed in thi s li st can be cut of

1 4 5 pre ssure angle regardle ss of the pitch up to 3 di ametral pitch
°
, , ,

as th at is the limit of thi s p articul ar m achine provided the bl anks ,

are turned to st and ard proportion s that IS with the u su al addenda

—
, .

But the 1 4 5 pressure angle may be foll owed down to twelve toothed
°

pinion s or less if the bl anks are turned to long addenda an d short ,

fl anks an d vice versa on their m ating gears Or by u sing a 2 0

,
'

.
°

pressure angle with the blanks turned to st and ard proportions gears ,

of an y p raétical limit may be cut Fig 3 1 p 4 2 gives the profil e s

. .
, .
,

of three twelve toothed pinion s of a 4 to 1 ratio A of st andard

- .
,

proportion s h as too much undercut ; B of simil ar proport ion s but of

, ,

S
2 74 GEA R C UTTING

20
°
pre ssure an gle has le ss undercut an d is preferable to A
, ,
.

C has a long addendum an d give s the g re ate st be aring surf a ce

,

an d is strong in the flank The .

CIR C UL A R
m m
r c vt s s
generating m achine produces the true
curve in e ach c ase .

The m achines are now being

equipped with c am s which operate with
o n e gener ating cut on the upw ard ro l l ,

using the downward roll for swin gin g

out an d indexing If preferred the
.
,

m achin e can be arr anged with cam s

to give the roughing cut up an d th e ,

fin i shing cut down The l atter s t y le

.

is recomm e nde d wh e re e xtreme ac

curacy an d a smooth finishing cut is
desi red as in automobile work Mo di
, .

ficatio n s are being frequently m ade in

the Gle as on m achines but the oper atin g
,

inst ructions as given are subst anti al l y

those which underlie the design s .

The Gle ason Wo rks give the following rule for corrected circul a r
t hick n ess of t eeth with re duced adde nda ( Fig .

Let
a = Given pitch depth

an d b= Normal pitch depth .

c= b a .

d= c x t angent pressure angle .

x circular pitch (2 d) x .
 GENER A TING B Y HO B B ING 2 77

an y po sition by holding it securely to the face of the bed The

, .

work t able D revolves in this saddle on a large annular be aring an d

-

, ,

is provided with a t ail pin an d lock nut s t o prevent an

-
lifting -
y
tendency ; it is driven by worm gear ( not indic ated) The steel .

dIi v in g wo rm is h ardened an d g rou n d an d is adju st able with its ,

wheel for wear while b all washers for end thru st are provided
, .

Hob Man drel The hob is adju st able on its m andrel

.
-

carried in a he ad which can be

swivelled th rough a complete

ci rcle by m e an s of a worm O

an d a wheel P an d it s edge is
,

divided by a verni e r sc ale Thi s .

swivel he ad is bolted to a saddle

Q m a de to slide on the he a d B
o f the m achi n e The saddle Q
.

is fi tted with a long n arrow

g uiding strip an d adju st able
t aper gib keep pl ates prevent
,

ing an y tendency to Chatter

when the saddle is sliding an d ,

bolt s are p rovided to lock the

saddle in an y po sition by ,

holding it secu rely again st the

f ace of the he ad B The .

s add l e is moved by a screw ,

turned eithe r by h and o r

power .

Method of D rivin g The .

—

m achine is d riven by a th ree

s peed co n e pulley E which in ,
Fig 279
conjunction with a two Speed
. .

counter sh aft give s Six ch ange s of speed arranged in geometric

-

progre ssion F rom this sh aft the drive is t aken through a worm
.

a n d wheel t o a ho rizont al sh aft which drive s th rough the ch ange

g e ar s F to the t able worm Sh aft G Thi s l as t is key grooved to .

-

permit of the travel of the t able the driving wo rm an d saddle , , .

From the shaft of the cone pulley E the drive is al so t aken through
a worm an d wheel to the vertic al sh aft K outlined in Fig 2 7 7 , .
,

t hen through worm ge ars indic ated at L to the swivel head an d ,

t hrough helic al ge ars to the hob To the end of the pulley sh aft
.
278 GEA R CUTTING

l o are connected two wo rm reductio n ge ars K ; the se drive the

a s

ch ange ge ars N which give the power feed an d the change gears N ,

vary the feed to the vertic al sc rew ( not indic ated) which t ravels the
ho b saddle an d to the horizo n t al screw which tr avel s the t able
,

sadd le
.

When cutting spur or spiral gears the hob is fed acro ss the
face of the wheel bl ank The power feed is controll ed by the
.

h an dl e g operating a sliding clutch ; connected to thi s h andle is

a t rip rod T p assi n g th rough a lug e c ast on the saddle Q
-
When .

the saddle has travelled down to an y de si red point the lug e st rikes ,

a coll ar d an d throw s the power feed out of ge ar Thi s actu ates a .

lever f operating the reve rsing mech anism The collar d m ay be .

moved an d secu red to the trip rod T at an y point A micrometer

-
.

V is provided for me asuring the depth of tooth This m ay .

be secured to the t rip rod U an d the trip rod may be secured

-
,
-

to the t able saddle to t rip out the feed when the correct depth
of tooth h as been cut When cutting worm wheel s the face of
.

the bl ank is fed into the hob A n oil pump supplies lubric ant to
.

the hob .

The hob saddl e is provided with a quick elevating an d lowering

motion controlled by the lever S Thi s motion is independent of .

the above feeds an d is u sed for rapidly setting the hob when com
,

m en cin gto cut a ge a r or returni n g the hob after a ge ar has been cut
, .

The h and wheel W give s motion either to the t able saddl e or to the
hob saddle By drawing the wheel forward ( see Fig 2 78 ) it is
. .

clutched up with the spindle an d by rot ating it to the right or left

,

the t able saddle is moved in or out while by pu shing the h and wheel
,

in it is clutched up with the Sleeve which give s motion to the ho b

saddl e .

The driving an d feed gears which are spurs helical s or wo rm s

, , ,

an d w heel s ( bevel s not being u sed cont ined in the bed d u

) a re a , an r n ,

in a b ath of oil The rem ainder of the bed is utilized as a recept acle
.

for cuttings an d cuttin g lubric ant the hole a being u sed to t ake ,

out the cuttings through A trough run s around the bed to c atch
.

an y drippings .

From three to four wo rk arbors are supplied according to the ,

size of m ach ine These are for use when cutting a gang of gears
.
,

an d are p rovided with t aper end s which by a righ t an d left h an d ,

-

nut are fo rced into the bracket X bolted to the t able The other .

end of the arbor is supported by a movable st ay H This st ay is .

2 80 GEA R C UTTING

be reversed The feed gears rem ain the same in both cases bec ause
.

the hob saddle is alway s fed downwards .

Settin gthe B lan k When setting a blan k on the t able it is adv is

—

able when po ssible to

use the work m andrel

to centre by employ ,

ing a bu sh if necos
sary A fter a bl ank
.

is secured by a nut
on the work man
drel an d supported
on the p arall el p ack
ings ( Fig it s .

truth is checked by an
indicator ( Fig .

This being set against

the rim as the bl ank
revolves show s if the
rim is out of centre ,

an d if set again st
Fig 28 0 . .

the edge it Shows

how much it has been sprung by the bolting down .

i
Sett gn the Ho b The .hob—is next se t by me an s of a vee g auge -
,

a n d al so for angl e On e tooth of the

.

hob Should alway s lie in the centre

o f the vee of the gauge ( Fig 2 8 1 ) .

al so a s the hob is adju st able along

,

it s arbor di ffe rent teeth should be

,

centred on the different occ asion s

w hen the hob is u sed in order to ,

e qu alize the we ar . The angle of the

hob being st amped on it the he ad is ,

s wivelled an d locked to thi s angle so

a s to bring the thre ad s perpendicul ar

w hen cutting spur ge ars This is .

ef fected by the worm ge ar degrees ,

being m arked on the flange of the

saddle , with a zero m ark on the Fig 28 1 . .

flange of the he ad .

D ep th of Cut — The depth of cut is me asured by lo wering the

 GENERA TING B Y HO B B ING 281

h ob d dle until the hob is in line with the cent re of the face of the
sa

wheel bl ank . Then the t able c arriage is moved towards the hob
until the f ace of the ge ar bl ank ju st touches the point s of the hob
teeth The micrometer 0 ( Fig 2 82 ) is now screwe d out to its full
. .

e xtent unt il it re ad s zero when it is lock ed to the trip rod

,
A fter-
.

p ressing it firmly a g ain st the bo ss on t he apron the trip,rod is -

locked to the carriage the depth ofthe tooth to be cut being me asured
,

of f on the micrometer .The hob is now rai sed cle ar of the wheel

Fig 28 2. .

b lank an d the t able c arriage is moved inwards until the micrometer

a gain abut s again st the bo ss on the apron Fi n all y the t able carri age
.

is locked to the bed the co ll ar on the t ri p rod is set to trip out the
,
-

feed when the hob h as p assed through the wheel f ace an d the ,

m achine is then set up re ady to work .

Settin gUp f or Sp iral Gears In hobbing spur ge ars the hob feed s
—

p e rpendicul arly an
, d the r atio between it an d the wo rk t able rem ain s
-

c on st ant . In spi ral gears (Fig 2 83) the feed depends both on the
.

downw ard travel of the he ad stock an d the angle of the tooth The .

l arger thi s angle is the gre ater is the di st ance which the hob mu st
2 82 GEA R C UTTING

travel in rel ation to the travel of the headstock In a 45 angle .

°

spiral the hob cut s 1 4 1 4in per rin of down travel of the headstock
-
. . . .

To produce thi s a differential motion is

,

introduced which impart s a con st ant

acceleration or ret ard atio n to combine ,

with the down feed of the hob in pro

ducin g the angle of Spiral The t able .

movement is the b ase of a tri angle the ,

vertical movement of the hob is the

perpendicular an d the angle of spiral pro
,

duced is the hypotenu se .

Settin g the Headstock The hob he ad .

—

stock is set for Spir al ge a r s to the angle

of the spiral ge ars plu s or minu s the

,

angle of the thre ad s of the hob the ,

latter depending on whether the Spiral

is cut with a ho b of t he same hand
or with one of Oppo site hand The .

formul a for indexing an d feeds with ,

the assist an ce of the di agram s will ,

Fig 28 3
. .
render this cle ar .

R ight h and Spiral cut with right h and hob

- -

Index gears :
Left left
drivers

Le ft h and spiral cut with right han d hob

{R ight }
- -

left
feed driver
lead) driven
15 s
I —

Number of tee th to be cut

feed 600 x le ad driver s
Feed ge ars x
lead Number of teeth to be cut driven
Exampl e
Number of teeth to be cut in blank 7 2 ,
-
.

Le ad 68 ”
Feed say 1 5 1 ”

R ight h and spiral cut with a right h and hob

- -
.

15
In dex Gear Formula —

Number of t eeth
 2 84 GEA R C UTTING

119
From a t able of prime factors it is found th at
se cutiv e numbers which will f actor out e asily .
3 57)
are two co n

The fraction now re ads 11 x 3 x 53

44 1 7 50 44 s x
s x
s x zx 7
9 53
x
45 53
x
_drive rs
Index ge ars
driven
.

1 4 x 1 00 7 0 x 1 00

600 I A P
L
x
Fee d gears X

F 1 7 49 I

L 1 7 50 1 750

3
3 X 89 60 x 89
i“ 5 x 1 10 50 x 22
25 4
» 22

1
— a pprox .

1 7 50 28

L IST O F C HA NGE G EA R WHEELS SUPP L IED WITH G EA R

HO B B ING MA C HINE .

or R otation
Settin gs an dD irection s f Figs 2 84 to 2 87 Show settings — .

fo r angle s minu s or plu s an d the direction s of rot atio n of the t able

, ,

to cut the spirals with left an d right hand hob s Thu s in Fig 2 8 4 . .

a right hand spiral is being cut with a right h and hob an d the swivel
- -
,

he ad is set to the angle of spiral minu s the an gle of the hob If the .

a ngle of the hob is an d the angle of spi ral the swivel he ad is

se t to an d the t able rot at es a s shown by the arrow whil e the ho b .

is being fed downwards In Fig 2 85 a right h and Spi ral is being cut
. .
-

with a left hand hob an d the swivel he ad is set to the angle of spiral
-
,

plu s the angle of the hob Thu s with the same hob an d angle of
.

s piral as b efo re the swivel he ad is set to

,
but the t able is rot ated
in the opposite direction Simil arly Fig 2 86 Show s a left han d spiral
.
, .
-

being cut with a left h and hob with the minu s sett ing of the swive l
-

he ad an d Fig 2 87 th at of a left h and spiral being cut with a right

,
.
-
 GENERA TING B Y HO B B ING 2 85

ha nd hob with a plu s set

,

ting of the swivel head an d ,

the t able is rot ated in

opposite direction s in each
c ase .

The photograph Fig 2 88 , .

,

illustrates the method of

producing the threads of
a multiple worm by hob
l
,
bing on thi s machine a —

rapid mode of production

where qu antities are re
quired NO very gre at de
.

gree of accuracy is wanted

in this inst ance because the
,

worms are subsequently

ground true after the har

Fig 28 4. .

dening which follows this

hobbing The Sides of the
.

hob teeth are l aid out '

with a suit able curve to

produce straight fl anks to
the worm inste ad of the
,

involute form which an

ordin ary hob would gener
ate. This laying out is
done by Messrs Wallwork
On the drawing bo ard an d ,

the hob is m ade accord

in gly .

The Gould ( g Eberhardt .

Machin e Fig 2 89 shows

—
. .

the Gould Eberh ardt

hobbing m achine for spur ,

helic al an d worm gears

, ,
Fig 285
. .
2 86 GEA R C UTTING

the 3 6in by 1 4in Size be

. .

ing represented workin g

,

up to 2 5 pitch in cast
iron an d 3 pitch in steel .

Its p ri ncip al fe atu re s are

as follow s :

The Work table This

—

is m ade in one with the

index worm wheel an d is ,

c arried by one conic al an d

two flat bearings The .

travel of the t able is ar

rested when the desired
depth has been reached ,

while a sc ale an d vernier

are provided for se tting the

correct di st ance as when

,

hobbing worm wheel s The .

Fig
. 28 6 .

top of the work arbor is

ste adied by arm s cl ampe d

to [two pill ars held in an

adju st able bracket which ,

permit s of ge ars of the full

swing being accommod ated .

I n t h e s m a l l e r Si z e d -

m achines the arm s are

cl amped to pill ars held i n

the saddle of the work

t able in stead of i a se parat e
, n

Sl ide .

The D ividin g Gear The .

-

indexing worm wheel is of

the split type hobbed in ,

pl ace an d the worm is of

,

h ardened an d ground st eel ,

with provisio for t aking

n

up back l ash when de si red .

Fig 28 7
. .
2 88 GEA R C UTTING

The Schuchardt é Schutte Machi

The two views Figs 2 90
n e. —
,
.
,

2 9 1 represen t the hobbing of a spiral pinion an d wheel for t urb in e

.

reducing gears of fine pitch w ith a large number of teeth on o n e o f ,

the Schuchardt Schutte m achines A special fixture is u se d o n.

the t able for holding the stem of the pinion shaft the clampin g ,

being performed with bolt s .

Leadin g Features The pri ncipal fe atures of the se hobbin g

.
—

Fig 28 9
. .
— Go u ld b
E e rhard t H bbo er .

m achines are the followin gz The p rinciple of action identic al in

—
,

al l size s comprises the prim ary d rive through the cone pulley
,
-
,

belted from the countershaft an d b ack geared thence p assing the

,
-
,

drive to an intern al bevel t rain The bevel ge ar on the end of the

.

cone pulley shaft drives a wheel which is att ached to the lower en d
-

of a vertic al sh aft that drives the cutter spindle through inter

mediate mitre wheel s on the centre of the swivelling hob headstock .

A nother beve l wheel ge ars into the bevel ge a r on the cone Sh aft ,

an d t hi s wheel is keyed to the end of a split Sh aft c a rrying a set of ,

di fferenti al bevel ge ars a d a worm wheel passing through the

n ,
Fig 290 — Ho
. .
bbi g
n a pi l Pi i
S ra n on o n a Schuchardt 8c Schutte Machi n e .

Fig
. 29 l .
— Hobb i n g a S pi l G
ra ear o n a d
Schuchar t 8: Schutte Machi n e .
2 90 GEA R C UTTING

back of the body an d c arrying the first driving wheel of the prim a ry
,

driving train .

Feed The vertic al feed to the cutter saddle is derived fro m a

.
-

feed bracket through a Ch ain to a wo rm

an d worm wheel which oper ate s a
, nut
working on the vertic al screw of the ho b
saddl e The feed Ch ange s are obt ained
.

by setting up di ffe rent ratio s of ch an ge

gears The horizont al feed to the t able
.

u se d when hobbing worm wheels is

obt ained from the same bracket through
chain worm an d worm wheel with a
, ,

revolving hori z o nt al screw an d fixed n ut .

Each of the se feed motion s is stopped or

st arted as required by me an s of a drop out -

worm .

The differenti al motion is only required

w hen hobbin g spiral ge ars an d has t h e
,

e ffect of accelerating or of ret arding th e

revolution of the blank at a rate which in
conjunction with the down ward feed o f
the hob will produce the desired an gle .

The acceleration or ret ardation is produce d

by the di fferential motion which is placed
on the driving Sh aft .

Wh en worm wheel s are hobbed the ho b

saddle doe s not feed downw ard s but th e ,

t able autom atic all y feeds inwards an d is

t rippe d when the correct depth of teeth is
re ached If spur gears of unu su al pitch
.

h ave to be cut an ordin ary form cutte r

can be e mployed an d the t ab le is irr
,

dex ed for e ach sp ace like th at of an ordi

n ary ge ar cutting m achine the indexing
-
,

arrangement being an extra fitting .

Fig 2 92 ill u strate s the element s of the

.

Wust m achine u sed in cutting double

h elic al ge ar s with h o b s
. The right an d left h and teeth are cut

Simult an eously In this the bl ank A is mounted on the m andrel

. ,

B driven by the f a ce pl ate C fro m the wo rk spindle below ,

2 92 GEA R C UTTING

cut either in l athes or in one of the w orm m illing m achines

-
n ow

numerou s ( see p .

Fig 29 5
. .

The Wallwork Machin e

Figs 2 95 to 2 97 illu strate a worm
.
— .

wheel generating m achine by Me ssrs Henry Wal lwo rk Co

Limit ed of Manchester In this de sign the wheel bl ank is c arried
, .

Fig 296
. .

on top of a vertic al arbor an d the worm hob on a horizont al sh aft

,
,

the axi s of which occupie s t he same position in relation to the

bl ank as the axis of the worm will bear to the wheel Fig 2 95 give s . .
 G ENERA TING B Y HO B B ING 2 93

a plan view of the m achine Fig 2 96 a longitudin al section t aken in

,
.

a vert ic al pl ane an d Fig 2 97 a tran sverse vertic al section th rough

,
.

the work arbor an d its dividing worm wheel .

Method of A ction The movement s are all derived from the

—

stepped con es A which are provided with b ack ge ar an d drive to

,

the Shaft B on which the worm C which is adjust able for we ar

, .

drives the dividing wheel D keyed on the work spindle E m ade of

, ,

high c arbon st eel wit hin which the work arbor F is drawn an d
-
,

tightened by the nut an d t apered neck There are five steps on the .

cone an d two counter Sh aft speeds of 2 40 an d 500 revs p er min

,
- : .
,

so giving te n rate s of revolution .

Fig 297
. .
Fig 298 . .

The cutter arbor G is driven by two set s of Change gears one ,

being the Change ge ars pro per at H for e ffecting the rot ation of
, ,

the arbor with its hob ; the other the change feed gears J for impart -

ing the proper rate of endlong motion to the hob whic h is set into ,

correct centres before cutting commence s The latte r is effected .

through the screw K which t raverse s the cutter slide The motion .

is t aken through the worm ge ars L seen in Figs 2 96 an d 2 97 driv .

,

ing through the ge ars on the qu adrant pl ate to the last wheel J on
the end of the screw K The qu adrant slot seen in th at end of the
.

bed pe rmit s of the swivel motion o f t he qu adrant Thi s in brief

'

st ate s t he e sse nti al s of the m achine .

D etails
.
—
With regard to these the sh ape s an d proportion s of ,

the m ain c astings are app arent from the drawin gs The cutt e r .
2 94 GEA R C UTTING

s lide has a long be aring on its saddle M an d the feed screw K is ,

l oc ated centrall y to avoid twi sting action The nut on the fee d .

scre w has adju stment for we ar The cutte r spindle G is of high

.

c arbon steel an d r un s in be arings of phosphor bronze The nose is

, .

bored to a B rown Sharpe t aper an d the arbor is held in place with ,

a draw bolt-
The saddl e M is moved towards or from the wo rk
.

spindle for adju stment of centre s by the screw N an d it is ste adied ,

by tongue s in the tee grove s which c arry the clamping bolt s

- .

Me asurement for centre s is provided for by a steel sc ale which

is let into the bed The driving worm C is h ardened an d
.

Fig 299 . .
— Ge n erat i g n a Ho ll o w faced Spi ral Gear w i th Fly Cutters
-

on a Wa ll w o rk Machi n e .

ground an d run s in oil A qu adrant worm wheel 0 the worm

,
.
,

of wh ich is actu ated from the ends P P o f the Shaft is used whe n , ,
‘

m aking adju stment s of ge ars on the qu adrant pl ate of the ge ars H .

Fig 2 98 illustrat es diagramm atic ally the action of a single toot h

.

cutter which feeds across the f ace of the blank The movement s .

being controlled by the gearing t he results are as perfect as those ,

produced by hobbing while the cost of the cutter is very much less
,

than that of a hob but the operation is slower

,
.

A n exte nsion of t he fly cutter principle is see n i Fig 2 99 whe re

-
n .
,

a hollow f ac e d spiral ge ar is being ge n erated on the Wallwork worm

-

wheel generating m achine A row of fly cutters is bolted up around

.
2 96 GEA R C UTTING

Fig 3 02
. .
—
Ho bbi n g a Wo rm Whe el on a Wall w ork Machi n e .

Fig 303. .
— Ge n erat i g
n a Wo rm Whee l i
w th a Fly Cut ter o n a

d
Schuchar t Sc Sch ut te Machi n e .
 GENER A TING B Y HO B B ING 2 97

impart to the wheel the nece ssary rot ative motion to compen sate
for the sliding of the hob Thi s is done by e mploying a differenti al
.

ge ar box which is connected to the feed screw of the hob slide

through change gears an d so alters the speed of the work to suit
,

the travel of the hob The feed to the hob slide is obt ained from
.

t he t able d rivin g sh aft to whic h is fitted an eccentric di sc coupled

-
, ,

Fig 3 04
. .

by a lever to a silent ratchet fee d which through bevels an d chan ge

,

gears O perate s the feed screw in the hob slide Sm all er m achine s
.

wo rking in the same m anner are built but with the difference th at
,

the work is c arried on a sliding t able by which adju stment to or '

from the hob for di ameter an d depth of cut is m ade in place of

, ,

adju sting the cutter he ad

-
.

The setting up fo r ge nerating a worm wheel with a sliding

t apered hob on the Wallwork m achine is shown in Fig 302 It . .
2 98 GEA R CUTTING

will be observed that the cutter arbor is ste adied with a sma l l
be aring block m aint ained in cont act with its top Side by the shor t
horizont al pressure arm an d screw pillar this arrangement act ing in
,

much the same m anner as a lathe work ste ady .

Fig 3 05
. .

worm wheel bein g hobbed with a fly cutter is Show n in Fig 303

A . ,

thi s being done on a Schuch ardt 8c Schutte hobbing m achine This .

h appen s to be a c ase where the work would not pay for a proper hob .

The two illustrations Figs 304 a d 305 repre sent the mode of
,
. n ,

gene rating the Hindley wheel an d worm on one of the Newt on

Machine Tool Works worm wheel hobbing machines The wheel is
-
.

hobbed with a worm hob as seen in the first figure an d the worm is,

generated with a Special type of cutter he ad ~ .

3 00 GEA R C UTTING

on a beari n g K secured in the hollow shank D Within the l atte r a

.

hollow sleeve f receive s a spri ng pre ssed plunger g bearing again st

-
,

the re ar end of the spindle a with a hardened b all pivot .

Cle arly now if the tool c arrier is fed fo rward the rot ation of the
, ,

Fig 3 06
. .

Spin dl e a e ffected by its pre ssu re into the t apered hole in the stock
b ar will rot ate the screw thre ad b an d with it the wo rm ge ar 0 an d
, , ,

thence the train of ge ars to the cutter J The movement of the cutter
.

sl ide roll s the cutter in correct rel ation to the bl ank preci sely as in

a p air of fini shed ge ars. The precision of the se movement s is not

af fected bymovement s of the cutte r slide o r by it s stoppage becau se
, ,
 GENER A TING B Y MILLING 3 0 1

the ge ar ratio s rem ain un affected Hence reciproc at ion s of the

.

cutter slide go on as the cutter is forced in to the work until when

, ,

the cutter has completed its traverse the cutting of the ge ar will be
,

completed .

Millin g B evel Gears The B eale Machin e The illu stration s

.
,

Figs 307 to 3 1 0 are tho se of a m achine by the late Mr O J Be ale

.
,
. .
,

bu ilt by the B rown Sh arpe Manuf acturing Comp any It will

.

cut teeth of di fferent pressure angle s by simple angular adju stment s

of the cutters On e p air of cutters will cover a moderate range of
.
3 02 GEA R C UTTING

p itche s but not al l bec au se as the p air h ave to occupy the tooth
, ,

s pace s a p air which would fill a sm all tooth sp ace would be too far
,

a p art for a l arge sp ace Fig 307 is a front elevation of the m ach ine
. . ,

Fig 3 08
. partial re ar elevation Fig 3 09 a pl an view of the cutter
a , .

carrying arrangement s Fig 3 1 0 a ve rtic al section through the in

,
.

de x ing an d generating he ad an d Fig 3 1 1 a det ail of a cutter

, . . The
following are the princip al elem ent s :
The motion s are derived from two pulleys The cone pulley B
.

drive s the cutters the pl ain pulley C the rolling an d the indexin g
,
3 4
0 GEA R C UTTING

block Q which c arrie s the spindle R of the work arbor ; the arbor
,

an d bl ank are rolled The angle of the block Q is adju st able by

.

me ans of its cu rved se ating an d the gradu ation s indic ated in Fig 307
, . .

Fig 3 10
. .

The ge ars O are ch ange gears altered to suit the size s of blank s being
,

cut But as the indexing ge ar an d the ge ar D is an integral portion

.

of the bevel gear E a ch ange in the ge ars 0 would affect the index
,

ing Hence a compen sating train S ( Fig 3 08 ) is in serted between

.
,
.

the indexing train T an d the ch ange gears O The ge ars S are the
.

s ame as the ge ar s 0 but are arranged in reverse order

,
. Tho se at O
are c al cul ated fi rst an d then a simil ar se t reversed are in serted at
,
 GENER A TING B Y MILLING 3 5
0

S .
that wh atever rate of movement is imparted by the ge ars T
So
is tran smitted to the ge ar bl ank through the sh aft P The ge ars S .

are station ar
y except when actu al indexing is t akin g pl ace an d
, ,

therefore they do not affect the rolling action of the bl ank imparted
by the ge ars O .

A djustmen t ofCutters The n retho ds of adju stment of the cutters

.
—

are outlined in the pl an View Fig 0 with which comp ri on may

3 9 ,a s .
,

be m ade with Fig 307 The support s for the cutter arbors are
. .

mounted on guide s U U h aving cu rve d edge s along which they are

, , ,

adju sted by a wrench at c c an d set by t he gradu ation s at d d

, , .
,

Thi s adjustment is only ch an ged when the angle of obliquity an d

Fig 3 1 1
. .

p ressure of the teeth are ch anged as say from 1 4 5 to 2 0 or , , ,

°

The adj ustment s for the cone angle which vary with every different ,

si ze of ge ar are e f, fected by virtue of the arc Shape given to the

guide s V at e e adju stment s being m ade by a wrench applied at
, ,

f f
, The a
.n gle s ar e re ad by gr adu ation s at g g P ro vi sion for , .

vertic al adju stment s of the cutter head is m ade at the h and wheel -

W This is nece ssary in order to b ring the intersection of the pl ane s

.

of the cutters to meet in the horizont al centre line of the inde x wheel
D which is the apex of all pitch cone s
, The precise me asurement .

is t aken with a c al iper gauge an d te st arbor the lower c aliper j aw ,

resting on the m ajor di ameter of the bl ank at the pitch line an d the ,

upper jaw on the hori zont al centre of the index wheel an d apex
of the pitch cone of the ge ar to be cut .

The Chambon Machin e R eference w as m ade on p 1 05 to the

— .

Ch ambon hob for bevel ge ars an d the photograph Fig 3 1 2 illus , , .

,

U
3 06 GEA R C UTTING

tes the machine in which it is employed m ade by Messrs J E

t ra ,
. .

R ein eck er A kt Ges

, . It is especi ally adapted for automatic ally
.

roughing out the ge ars by the self generating process In comparison

- - .

with the ordin ary milling method the hobbing process offers in —

Fig 3 1
. 2 — The Cham
. b on B e ve lg
-
ea r Gen era to r .

a ddition to increased rate of cutting the advant age th at the thick

—

ness of tooth is reduced tow ards the apex of the gear in an al most
t heoretic ally correct m ann er thus le aving a fini shing cut of uniform
,

t hickn ess for the bevel ge ar pl aning m achine to t ak e o ff the t o oth

-

fl ank .

The number of necessary hobs is ve ry sm all as these are inde ,

p e ndent of the numb e r of t eeth in a ge ar ; thu s a hob c arrying for ,

in st ance t he m ark L arge Modul 6 Sm al l Modul 4 can cut all ge ars

, ,

w ith out side an d in side pitch lying between Modul 6 a n d Modul 4 .

In general these hobs are arranged for ge ars with a length of tooth
n ot exceeding o n e third of t he he ight of t he pitch cone
-
For greater .

l engt hs thi s method is not suit able .

 S ECT I O N l V .
—
MA T ER I A L S ,

MA NU FA C T UR E , A ND S T R ENG T H

CHA P T ER XV II
THE MA NUFA CTUR E O F GEA R S

V A STLY more c are is exerci sed in the m anuf acture of ge ar blank s

th an formerly The dem and s of the m achi n e tool an d automobile
.
-

builders h ave met with a re spon se in the se direction s Increase d —

accuracy in the teeth an d the suppre ssion of noi se the employment ,

of h arder tougher more durable m ateri al s an d in the practice o f

, , ,

c ase h ardening an d of grinding The l arge numbers required h ave

- .

given ri se not only to a gre at inc re ase in the number of m achine

tools but also to the adoption of m any labour saving economie s
,
-

in the preparation of the bl anks The following is a summ ary of .

the leading fe ature s of the existin gp ractice .

Materials The se include c ast iron gun met al pho sphor bronze
.
—
, ,

a n d other copper alloy s c ast steel fo rged steel alloy steel s as nickel
, , , , ,

chrome van adium an d nickel chrome ste els ; rawhide an d p aper

-
,
-

al so are u sed for cert ain kind s of ge a rs Each met al o r al loy di ffers .

fro m the others in toughne ss we aring qu alitie s method of tre atment

, ,

an d co st For al l ordin ary pu rpo se s good c ast iron gun met al an d

.
,

c arbon steel are suit able enough B ut fo r the sm allest gears which .

are worked h arde st at the highe st spee d s one of the alloy steel s

mu st be u sed if durability is requi red The m ajority of the sm all .

g e ar s are m ade now of stee l e ither o f c arb on or o f the

, alloy ,

kinds The slow runnin g ge ars are still of c ast iron which c alls
.
-
,

fo r no Speci al ob se rv ation e xcept th at it should be of good ,

tough highly mottled quality to be st ron g enou gh an d to endure

,
-
,

we ar Con st ant vigil ance is necessary in de aling with the steel

.

g e a r s from
, t he s election of the m ateri al to t h e fi n al h a rdening ,

if good re sult s are to be secured Nickel steel which is chiefly . .

used cont ain s from

, to 5 pe r cent nickel from to per .
,

c ent of c arbon an d sm al l pe rcen tages o f m anganese an d Silicon

.
,
'

an d trace s only of pho spho ru s an d sulphur .

3 08
 THE MA NUFA CTUR E O F GEA RS 3 09

Man ufacture The ge ar bl an ks are either used as out from th e

—

b ar or drop forged in die s the l atter le ssening the w ast e of m ateri al

,
-
,

a n d co st of m achining ag ai n st which the expen se of the die s h as t o

,

be set Two p airs of di es are usually n e ce ssary the fi rst for roughing
.
, ,

the second for fini shing followed by trimming die s to remove the
,

fin B efo re an y m achining is done the bl ank is anne aled Thi s

. .

is done in a mu ffle or box so th at fl ame doe s not come into cont act
,

w ith the met al The bl ank s are packed in powdered Ch arco al or in

.

ch arre d le ather ( not in bon e) an d he ated to a tem perature of about

r6oo F ahr an d allowed to rem ain at th at for two or three hours

°
.
,

the period depending on the dimen sion s The box is then removed .

a n d allowed to cool before it s enc l o sed content s are th rown out The .

s t eel is thu s softened an d some of the initi al intern al strain s are re

,

moved The rough m achining follow s This remove s such surface

. .

s train s as rem ain an d afte rw ard s another anne al ing is done before
,

the fin ish tooling which is of a very light character

-
,
.

Toolin g The me thod of tooling adopted is very much th at

.
—

o f the general pr actice of the shop s V ery ligh t bl ank s some time s
.

h ave their rim s milled but generally the turret l athe u sing a
, ,

chuck with j aw s speci ally m ade to suit t he bl ank an d a speci al

set of tool s fixe d U pon the turret is employed If the bores , .

h ave to fit over c astell ated sh aft s the hole is bro ached out ,

o n a L apoint e m achine or simil a r type o r on a key grooving -

,

m achine The teeth are cut on an y of the m achines de scri bed

.

in the p reviou s p age s The cheaper or the more expensive

.

m ethod s are sel ected according to the st and ard of accuracy which
is so ught But when ge ars are generated it is very u su ally the
.

p ractice to g ash out the teeth with rot ary cutters or with a pl an in g

cut previou s to fini shing them by generating It is becomin g .

increasingly common to harden ge ars after cutting A s all the .

inte rn al stra in s h ave been p ractic ally removed by previou s an ne aling

the risk of di stortion is but slight The ge ars are first washed in .

h ot soda w ater to free them from o il an d chip s an d dried They are , .

p acked in boxe s with c arbonizin g m ateri al an d placed in a furn ace

rai se d to a temperature of abo u t 1 700 F ahr at which they rem ain °

from ten to twelve hours The boxes are then t aken out an d allowed
.

t o cool before the ge ars are removed .

So ex ac ting are the dem an ds now m ade on st rong durable an d ,

q uiet ge ars for automobile s th at the whole practice rel ating to sm al l

fast running gears is being modified

- R eferring here to the m ateri als
.
3 1 0 GEA R CUTTING

u sed the variou s alloy steel s are employed in preference to the c arbo n
,

stee l s not only for automobile ge ars but often al so for tho se ut
,
p
into the feed an d speed gear boxes of m achine tools There are .

hundreds of v ari eties of alloy steels m ade Of nickel steel s alo n e .

,

Mr Mathews says there are at least fifty seven varieties Such -

.

being the case it appe ars that the u se r has to rely on the met all ur gist
,

to supply ju st what is wanted A n d as in the c ast iron s an d t he .

carbon steels so the behaviour of a sm all test piece may be misle adin g
, ,

if applied too slav islrly to the beh aviour of a l arger m ass w het h e r ,

c asting or forgin g subjected to heat tre atment annealing hardeni n g

, , , ,

or c ase h ardening -
.

The al loy steels embrace the nickel steels the nickel van adiu m ,
-
,

the chrome vanadium an d the chrome nickel steel s A vast num be r

-
,
-
.

of experiment s have been put on record of the ten sile stren gth ,

elastic strengt h an d elongation of each of these in vari ation s o f

,

percent age compo sition There is little advant age in quoting the se .

becau se the purchaser general ly goe s to the met allurgi st an d buy s

a stee l of som e recognized brand A few typic al re sult s are ho w .
,

ever t abulated as a general guide (p

, .

These result s which were given among others by Mr John A

,
.

Mathews in a paper re ad befo re the Franklin In stitute indic ate

, , ,

if they Show nothing else that the generic term s nickel stee l , ,

nickel van adium steel etc tell not hin g whatever of the physical
-
,

qu alitie s Even chemic al an al ysi s is misleading Since result s depen d

.
,

as much on treatment as on th at This explain s the reason why .

steel m ak ers att ach s uch vit al import ance to the exact m ethods o f
-

treatment to be given to different brand s The c ase is p arall eled .

with th at of the high speed tool steel s -

.

Carbon pl ays an impo rt ant p art in the alloy steel s bec au se th at

element affect s the h ardening The higher c arbon is u sed for oil .

hardened gears the lower for c ase hardened gears The first m ay
,
-
.

cont ain from about to per cent of c arbon the second from .
,

to The choice between oil hardened an d c ase hardened - -

gears has been a m atter of controversy In quenching in oil from .

a bright red a thin surface h ardening is imp arted le aving the in ,

te rio r un affected In case hardened gears the h ardening is deeper

.
-
.

Experiment s h ave shown th at the l atter are more durable th an t he

other The objection to c ase hardening is the uncert ainty of the
.
-

depth an d the risks of distortion Dr Guillet says with refere n ce .

,

to the proper procedure in c ase hardening -

3 2
1 GEA R CUTTING

wel l known the operation of c ase hardening con si st s of

A s is ,
-

pl acing a steel in so me mediu m c apable of i mp arting c arbon to it at ,

a suit able temper ature ; after a su f fi cient interval a steel is obt ained ,

the interior of which po ssesse s the same percent age of c arbon as before
c ase h ardening but the exterior of which is much higher
-
,
to
per cent ) On quenching such a steel an extremely high degree
.

of mineral ogic al hardne ss is obt ained on the surface while the centre ,

of the piece is non brittle if t hat is the operation has been properly
-
, , ,

c arried out On e generally u ses steel s cont aining 1 0 to 25 per cent

. . . .

of c arbon for c ase h ardening In order to avoid all brittleness in

-
.

the inte rior an d ext erior of the piece an d at the same time to obt ain , , ,

a high de g ree of superficial h ardne ss an d a very regular degree of

c arburization ( in c arbon steel s) it is nece ssary ,

1 To use a steel cont aining le ss than

. per cent of c arbon .
,

a n d with a low percen tage of m angane se ( le ss th an per

an d

2 To c ase h arden with a chemic ally definite m ate rial such a s

.
-

a mixture of 60 p art s ch arco al an d 4 0 p art s o f b arium c arbon ate at a

temperature between 850 C an d IO5O C the highe r the tempera °

.
°
.
—

ture the mo re rapid the c ase h ardening an d allow it afte r the opera - —
,

tion to cool down ju st below the t ran sfo rm ation point ( about
,

3 To .rehe at the pi e ce an d quench it at 9 0 0 C ( ju st a bov e the °

.

t ransformation point of the cent re) thi s operation h aving the effect ,

o f rendering the cent re fi brou s

”
.

Thi s O peration h as the effect of toughening the centre but the ,

o ut side will be co arse grained an d brittle The next ope ration

-
.

according to Guill e t is : ,

4 To quench
. for a se cond tim e at 8 O O G ( above the tra n sfo rm a
°
.

tion point of the exterio r) to render the Skin non b rittle ,

-
.

In an y c ase the method s by which it is po ssible to obt ain

, ,

w ith low c arbon steel c ase h ardened piece s which sh all not be brittle
-
,
-
,

a re e xceedingly delic ate

”
.

Mr Mathews say s that an ide al w ay to m ake a nickel steel ge ar -

is to first anneal the bl ank then rough m achine approxim ately to ,

-

s ize then give a light re anne al ing before t aking the l ast fini shing -
,

cut . Then p ack in a suit able mixture an d c arbo nize to a depth

o f 3 1 m to g m according to requirement s at a tempe rature of
1 1
.
5 .
,

a bout 1 62 5 to 1 650 F Cool in the pot s he at to about 1 500 F

° °
.
,
°
.
,

a n d quench in a hot brine or c alcium chlo ride so lution This will .

p ut the core into excel lent phy sic al condition Fin a lly re he at to .
,
-
 THE MA NUFA CTURE O F GEA R S 3 3
1

1 37 5
°
to 1 400 F an d quench in oil Thi s last operation will refi ne
°
.

t he grain of the c ase an d h arden it with be st re sult s The temper .

n ee d not be drawn It will be noticed th at the temperatures for

.

t re ating nickel steel s are con siderably lower th an tho se advoc at e d

b y Guillet for c arbon steel s .

The S A E Stan dard Sp ecification s f

. . or Steel The foll owing is a .
—

s election of st and ard al loy steel s suit able for t ran smrssron ge a rs all of ,

w hich mu st be u se d when they h ave been subjected to he at tre atment

a n d not in a n atural or anne aled condition , .

Nickel Steels c arbon 3 5 p er cent nickel steel

.
, . .

The following compo sition is desired :

C b 10 p t t 2 0p p d i d e r ce n t
)
'
ar o n e r ce n . o . er cen t e s re
Man gan ese
.
.

to 80
“
65
°

p
P hos ho rus, n o t to ex cee d 04
lp
Su hur, n o t to e x cee d 04
Ni ck l
e 3 2 5 p er cen t . to 5

Steel of this kind if prope rly carbo nized an d he at treated will

,
-
,

p roduce a ge a r h a ving a very tough an d strong core together with ,

t he de sired high c arbon exterior The best heat treatment is as .

follow s
A fter fo rging or m achining :

( )
1 C b iz t t m
ar o np t u b et w al 600 d ” 50 F ( 1650
a e e ra re e een
°
an
° °

1 7 OO F d i d )
.
°
. es re .

( )
2 C l l w ly i t h
oo b izi
s o g m t i l n e car o n n a er a .

( 3) R ehe at to
( )
4 Q ue n ch .

( )
5 R ehea t to
( 6) Q
ue n ch .

( 7 ) R eh ea t to a p
te m erature of fro m ( in acco r an ce d i
w th the
n e cess it i es o ft he case ) an d coo l l w ly
S o .

The second quench ( No 6) mu st be conducted at the lowe st .

p o ssible temperature at which the m ate ri al w ill h arden It will be .

found th at sometime s thi s is lowe r th an 1 3 00 F

°
.

A nickel steel with a slightly higher c arbon content is al so

used .

Nickel Chromium Steels These include low nickel medium

-
.
—
,

n ickel an d high nickel chromium steel s

,
A sample specific ation for
-
.

a low nickel chromiu m steel is given

-

C b 45 p t t 55 p t d i d °

3
ar o n t p er cen . o e r ce n e r cen es re
Man gan ese
. . 1

50 to
‘
80
p
Pho s ho rus, n o t to ex cee d °
04
lp
Su h ur, n o t to e x cee d °
O4
Ni k l
c e l 00pe r cen t to
‘
.

C hro m um i 30 to 7 5
3 4
1 GEA R C UTTING

The heat treatment after forging or m achining , , is

( )1 H ea t to 1 500 -
1 5 5 0F
° °
.

( 2 ) uQe n c h .

0F
° °
13 -1 4
( )3 R e h e a t t o 00 0 .

( 4) Q
ue n ch .

5
( ) R e hea t t o a n d coo l l ly
s ow .

A sa m ple speci fi cation for a high nickel chro mium -

s teel is given
Carb on
°
40 p er ce n t to . 5 0 pe r cen t .
pe r cen t . d i d)
es re .

M g
an an ese
°
30 to 60
°

Ph ph
os o rus, n o t to exce e d 04 p e r cen t
°
.

Ni k l
c e pe r ce n t . to
Chrom um i to

This steel is l argely employed for gears in which extreme strength

an d h ardne ss a re n ece ssa ry The c arbon is suff
iciently high to c au se .

the m ate rial in the pre sence of Chromium an d nickel to become

, ,

h ard enough to m ak e a good gear when quenched wi thout case ,

h ardening .

It is difficult to forge an d during the forging Should be kep t ,

at a thoroughly pl astic he at an d not be h ammered or worked afte r ,

fal ling to ordin ary forging temperature s otherwi se cracking is li able ,

to en sue The steel also become s so ve ry hard as to forge with great

.

difi cult y On the other too high a temperature is inadvi sable

.
, ,

bec au se the steel become s red short an d break s The forging tem -
.

er a t ure limit s are thu s n arrow an d the con se quence is th at the

p ,

stee l mu st be rehe ated mo re f re quently th an is nece ssary with othe r

steel s .

The heat treatment for gears is

A fter forgin g

( )
1 R eheat to ( Ho ld at i p
th s t em erature ha lf an ho ur to
en sure t ho ro u gh h ti g ea n .
)
( 2) Co o S o w y l l l .

°
F
°

( )
3 R e h ea t t o 1 4 50 -1500 .

4
( ) u e n Q
ch .

5
( ) R eh ea t to a n d coo l l w ly
s o .

This steel should be thoroughly anne aled before m achining

( O per ation s 1 an d

( The medium nickel chromium of course occupie s an intermedi ate

-

position ) .

The physic al ch aracteri stic s of the high nickel chromium stee l -

ju st given are :
Elasti c li mi t, l b .
pe r sq uare i n ch

d
R e uct i o n o fa re a

El on g tia on in 2in .
3 1 6 GEA R C UTTING

weight s ; D is the tran sverse bar acro ss the furn ace fro n t which can
,

be rocked in it s bracket s a A t about the centre of the tran sverse

.

rocking bar D a vertic al bar E hanging do wn project s in front o f

,

t he furn ace door but being loo sely mounted in its bracket it can be
,

lifted clear of the door A flange b project ing from the fro nt of the
.
,

d oor B a n d at the bottom eng aging with the ba r E, lift s it when the
door is rai sed which fall s again when the door is low ered A h and
,
.

l ev er F is att ache d to the end of t h e b a r D

. A stud c in the lower
 THE MA NUFA CTURE O F GEA R S 3 7
1

end of the lever engages with a Slot in a c atch lever G counter

weighted which c atch lever on being rai sed thu s rele ase s the h and
,

lever F It is pivoted in it s bracket to be re adily adju st able A fte r

. .

t he door B has been lowered it is forced aga in st the furn ace mouth
by moving the hand lever F backw ards an d rocking the bar D to a
Slight extent thu s b ringing the lower end of the bar E ag
,
ain st the

door near it s centre The stud c en gages the notch in the c atch
.

Fig 3 1 4
. .

l ever G , locking the door in position By rai sin g the catch lever
so .

an d freeing t h e stu d c t he doo r is released an d h anging free can be

, ,

raised .

The commonest method of c ase h ardening is in general term s

-
, ,

to heat the pieces in bo xes with suit able m ateri al s for a sufi cien t
l en gth o ftime at a temp e ratu re of about 950 C an d then
°
.

to quench at once in col d w ater The best c ase h ardening is how

.
-
,

ever done in two or more sep arate processes which v ary according
, ,

to Circum st ances B riefly the first process con si st s of c arburizing

.
,

only ; th at is the articles are he ated as above but are t hen allowed
, ,

to cool Slowly or are quenched in oil The pieces so c arburized are

, .
3 1 8 GEA R C UTTING

next he ated to a
t emperature of
ab o u t
°
7 60 C .

an d
q u e n c h e d in
w at e r af t e r
,

whic h they may

be tempered or
further tre ated
in other w ays .

The c arburizing
furn ace is speci
ally ad apted to

the first of the se

proc esses an d ,

is al so suit abl e
for the second
he ating But a
.

further impro ve
ment is e ffected
by u sing a Salt
b at h f urn ace in
t he second pro
c ess for he ating
the c arburized
pieces as the
,

salt b ath en sure s

ab so l ute un ifo r
mity of heating .

The tempera
ture is known
with cert ainty
an d all the el e

men t s o f chance
are removed .

Salt bath Fur

-

n ace. Thi s is
illu strated by
two vertic al sec
tion s ( Figs 3 1 9 .
,
3 2 0 GEA R C UTTING

door The lip of the pot fits closely to the brickwork around the
.

doorway ( Fig so as to prevent the Spl ashing of the salt s aroun d

.

the out side of the pot A perforated tray C su spended by two rod s D
.
, ,

D passing through the cover of the furn ac e receive s the work to b e

, ,

heated ; the rod s afford a mean s of lifting t he tray up O ppo site t he

doorway to receive the work an d to then lower it into the bat h ,
.

Grids with a fork are employed for sm all piec es The pyrometer E . ,

protected with a tube is in serted an d it s re adings are obt ained on a

, ,

Whippl e indic ator or a Callen dar recorder V arious in st rument s

, .

are suppli ed in connection if d esired including thermo couple ,

-

indicators an d thread recorders .

The salt b ath furn ace is heated by co al gas an d is pro vided wit h
-

Fig 3 18 . .

two sets of burn ers one se t for air blast the other a Bunsen burner
, , .

The gas is thu s burnt efli cien t ly Gas t aps e ach with a large .
-

graduat ed qu adrant allow of accurate adjust ment for regulating

the supply The furn ace heat ed by producer gas is similar to
.

the co al gas type but som e necessary modi fic ation s are m ade to
-
,

suit the di fferent gases The c rude oil furn ac e is provided with o n e
.
-

o r more speci al bu rners which are worked with compressed air t he

, ,

oil an d air being regul ated separately The furn ace heated by .

refined oil h as burners compri sing each a v aporizer in which the oil ,

is continuou sly con v ert ed into v apour at a high temperature The .

v apour is di sch arged in a j et suit ably arranged to draw an d mix ,

suf icient air for complet e combu stion

f A clo sed oil t ank is pro .

v ided with an air pump pre ssure gauge an d al l fitting s comple te

-
,
-
,

an d flexibl e ho se for le ading the oil under pre ssure from t he t ank to

the burners No air bl ast is required Th ese furn aces are m ad e

.
-
.

in six size s ranging from 7 in to z4in in side di ameter of the pot

, . .
, ,

an d in dept h s f rom m in to e 4 m of the pot . . .

 THE MA NUFA CTUR E O F GEA R S 32 1

The P rep aration ofB l a n ks .

-
Gang
mills for circular milling on gear
-

blanks are Shown in Fig 3 2 1 In the c ase of the Spur A an d wo rm

. .
,

ge ars B the t wo side cutte rs can be adju sted to cut wider o r n arrower
,

by the interposition of washers of suit able thick ne ss The teeth .

of the two cutters for the bevel ge ar blank C are interlocked so as

-

to mill right up to the sh arp co rner of the blank .

Fig 3 1 9
. . Fig 3 20
. .

Circular Millin g Machin e of these by Me ssrs John Hol

s. —
On e ,

royd CO Limited ( Fig

.
,
is de signed to produce by milling
.
,

g e ar
-
wheel bl ank s an d other circul a r work of so light a ch ar acter

that gripping in chucks would be an extremely delic a te O peration .

These can be done with the exercise of c are in ordin ary lathes ,

but thi s is a m achine built speci ally for the work Two headstocks .

a re mounted on a bed compri sing two b ase s at right angle s with

,

e a ch other The mech anism of one headstock rot ate s the milling
.

cutter The circular feed imparted to the work may be varied '

x
3 2 2 GEA R C TTI N U G
between iin an d 6in per minute The work he ad is c arried o n
. . .
-

compound slide s with adju st able stop s Each slide has a l arge .

hand wheel for m ak ing rapid adju stment s A trip ge ar arre st s the .

circul a r movement O f the wo rk at either a trifle ove r one tu rn or , ,

if de sired ju st ove r two turn s The work is driven by adju st able

,
.

pin dogs which t ake a be aring again st arm s on O ppo site sides O f
,

the centre The work he ad has a c ast iron spindle with necks 6in
.
- -
, .

an d sfiin in di ameter runnin g in c apped be arings The drive is

.
,
.

from a worm wheel bolt ed di rectly to the driving plate Thence t he .

drive is connected through a drop worm an d wheel to the o pe rating

change gears at the b ack end Of the cutter spindle A bracket .

which is bolted to the cutter he ad can i es an adju st able bu sh which

support s the outer end O f the work m andrel The cutte r head is .

Fig 3 21. .

si milar to a l athe head It s spin dle which run s in p arallel gun met al
.
,
-

bearings is driven through back ge ars with a ratio O f 61 to I from

, ,

a three speed cone pulley t aking a 4in

-
belt The cutter spindle . .

m akes 2 1 40 an d 74 revolution s per minute The spindl e is bored

,
.

for the cutter arbors which are supported at their outer ends by an
,

adju st able st ay bar an d bu sh .

B evel gear B l an ks
- Fig 3 23 illu strate s a method Of turning the
.
— .

bevel f ace O f a bl ank on one O f the turret lathe s by Messrs A lfred

Herbert Limited A speci al att achment is employed comprising
,
.
,

a slide moving on a bracket bolted to the turret ; t hi s slide is t ee

slotted an d has bolted to it a h older receiving a s tem which c arrie s

a roughing an d a fini sh ing tool either being brought into use by a ,

h a lf tu rn O f the stem which is then lock

,
e d by the h a ndle A s the .

tu rret moves along the slide is al so moved along the bracket by the
,

c o e rcion O f a h a rdened s teel roller seen in co n t a ct with a c ase h ar dened -

fo r mer pl a te which is,

gripped a t a suit able a ngle in the cro ss sli de -

t urret holder A spring within the slide m aint ain s proper cont act
. .

Th e s qu a re turret a l so c arrie s turning tool s not se en for t he — —

3 4
2 GEA R C UTTING

th an two space s on the m ain sc ale Wh en the 0 line on the vernier .

co rre sponds with the 0 line on the m ain sc ale the edges O f the b a se
an d O f the bl ade are p arallel If the he ad is swivelled until the li n e
.

on the vernier next to the 0 m ark corre sponds with the line that is
next but one to the 0 mark on the m ain sc ale the an gle which is ,

included between the b ase an d the bl ade is TO re ad an angl e ,

therefore read o ff directly on the m ain sc al e the num ber of who le

,

Fig . 3 23 . — i g
Turn n a Bev e lg
-
e ar B l ki
an n a He rbe rt Turre t La the
.

degree s between 0 on the m ain sc ale an d O o n the ve rnier sc ale .

Then count in the same direc tion the number Of Space s from O o f
the vernier sc ale to the line which corresponds with a line on the m ain
scal e an d multiply the number counted by 5
,
Th at will give the .

number Of minutes to be added to the number Of whole degree s .

In Fig 3 2 5 the vernier has moved 1 2 to the righ t O fthe 0 m a rk

.
°

on the m ain sc ale an d the eighth line on the vernier coincide s with
,

a line on the m ain s c ale H ence 8 x =

5 4 O min
. ute s an d the re adin g ,

°
15 1 2

Figs 32 6 to 33 2 Show variou s methods O f mounting bevel ge a r

.
-

bl ank s on the Oerlikon m achines A rbors fit into the spindle O f t he

.

work head an d are tightened with a screw p assing t hrough the cent re
-
.

Fig 32 6 shows a blank centred by its hole again st the face O fa bu sh

.
326 GEA R C UTTING

fit ting in the t aper Fig 3 2 7 is an example O f a ge ar with a ve ry

. .

long bo ss the overh ang O f which is t aken by an adju st able steady

, .

Figs 32 8 an d 3 2 9 Sho w gears with solid stem s which are c arried in

.

speci al bu shes with a pull up screw Sm all ge ars with l arge holes are
-
.

shown in Fig s 3 30 an d 3 3 1 requi ring speci al bu she s

.
, Fig 33 2 is a . .

disc fitting for gripping bevel ge ars such as are used o n automobile s , .

Fig 3 25
. .

Gashin gor S ockin g

t —
Messrs Gould 8cEbe rhardt , Of Newark N J ,
.

build a modification O ftheir regul ar automatic ge ar cutting m achine -

( Fig 1
.
58 see
, p 1 77 ) with.Speci al cutter an d work slide s for the pur ,

pose O f cutting two or th ree gears at one time either spur or bevel ,

ge ars wo rm wheels or , ,

clutche s In the phot o .

graphs Figs 3 33 an d , .

3 34 a 2 4 in by 8,in . .

m achine with two spindles

is seen roughing out three
ge ars O f 5 pitch 1 Uin , , 1
5
—-
.

face preparato ry to their ,

being finished on a bevel

Fig 3 26
g ear pl aner The cutter .

s l i de 15 arra nged to aeco m

. .

mO date one two o r th ree cutters an d the slide be aring is SO con

, , ,

structed th at e ach cutter h as a sep arate be aring on e ach side O fit an d ,

loc ated close to it This kind of bearing is employed on account Ofthe

.

extra number O f cutters u sed which incre ases the torsion an d duty
, ,

required of the arbor The Slide is actu ated on the draw cut
.
-

principle th at is the fee d screw is anchored in the b ase O f the

,

upright SO putting the feed screw into t ension an d overcoming the

,
328 GEA R C UTTING

there is an adju st able brace to support the pe riphery O f e ach blank

being cut ; thi s al so se rve s as a chip chu te an d direct s the O il int o
the po cket loc ated in the b ase O f the m achine where it is separated
an d strained from t he chip s before it re ache s the oil pump again -
.

Thi s m ach ine should be Of e speci al value in auto mobile facto rie s ,

bevel gears are produced l argely It has all hardene d.

-

st eel driving ge a rs an d b al l

be arings .

R oughin g Shawn An —

arrangement O f t he Gould

Eberh ardt sh aping

m achine ( Fig 335 ) has .

been designed to rough o ut -

bevel ge ars q uickly in pl ace ,

of doin g all the cutting on

the more expensive ge ar
plan e r which mu st be
Fig 3 29
. .
employed for finishing the
teeth The Sh aper is p ar
.
;

t icul arly int ended for roughi n g out automobile di ffe renti al ste el
-

bevel gears which have projecting bo sse s O n the sm all end tha t
prevent them from being roughed out in the ordin ary di sc cutter
- -

type Of m achine ( Fig . de scribed on p 3 26 bec au se the rot ary

.
,

cutter would not be able

to cut acro ss the entire
face o w in g to the inter
ference O f the bo ss The
.

s h a per is modi fi ed SO as to

al low one or two bevel

g e ar bl ank s to be held Fig 3 30 . .

a t the proper angle an d

indexed at every return stroke O f t he ram while the sh ape r he ad is

,

a utom atic ally fed down at e ach stroke until the proper depth is

re ached an d then the feed is thrown out autom atically an d the

,

b l ank s remov ed . The m achine m ake s 1 00 st roke s per minute .

The regul ar cro sshe ad slide an d t able are remove d an d a Speci al

w o rk he ad wi th an indexing mech ani sm are sub stitut e d
-
Thi s .

w ork h ead m ay be arr anged so as to cut one or two ge ars at a

-

t im e up to the c ap acity O f the m achine with suit able me an s for

h olding the bl ank s an d lubric ati n g the t OO l S In the photograph
.
 THE MA NUFA CTUR E O F GEA R S 3 9
2

two nickel st eel gears Of 2 0 teeth am pitch are roughed out at

-
,
i
.
,
-

one time in six minute s or three minu te s e ach They h ave

, .

projecti n g bosse s .

Two hOOk t O OlS are provided to remo ve the chip s t hat accumu
l ate in t he groove between the projecting bo ss an d the in side
face O f the gear The hook tools are under Spring tension an d
.
,

can be e asily th rown out O f po sition when t aking O f fthe ge ar .

The indexing O f
the bl ank from t ooth
to tooth t ake s pl ace
when the ram has
b een drawn b ack ,

an d is connected
po sitively to the re Fig 3 3 1 . .

cip rocat io n s A fter

.

th e indexing h as occurred an d before the tool st a rt s to cut the work

, ,

Spindle s are l ocked SO th at the bl ank is Securely held while being cut .

~
A s the ram return s an d the tool is out O f the cut the autom atic ver ,

tic al fee d to the head t ake s place

an d so continue s to O perate until a

sm all trip dog loc ated on one side-

O f the h e ad an d which mu st be ,

previou sly set to feed the tool to

the proper depth di sengage s the ,

feed A foot brake is arranged to

.
-

act on the driving pu lley an d it ,

stop s the m achine in st an tly when

the O perator desire s .

Fig 3 36 illu strates a rapid

.

method O f gashing l arge bevel

gears by the use O fa Speci al fi xtu re
,

with indexing plate being done on ,

Fig 3 3 2
.
“
a H e rbert pl ain mill ing m achine .

Speeds an d Feeds The speed s —

an d feed s which can be used in ge ar cutti n g c annot be st at ed

defi ni tely bec au se so m any v ari able element s enter into the problem
, .

The Brown 8: Sh arpe fi rm give s so me u seful dat a A good range O f .

speeds an d feed s is embodied in ge ar cutting m achine s an d the mo st

-
,

suit able re sult s mu st be O bt ain ed by e xperiment Cast iron can be .

cut more rapidly th an Wrought iron an d the steel s an d brass can

,
Fig 3 33
. .
— ki g B l G
Sto c n e ve ears on a Gould 8 Eb
: d M chi
erhar a ne .

Fig 3 3 4
. .
— ki g B
Sto c n e ve lG
ea rs o n a ld
Go u d t M hi
Eberhar ac n e.
 Fig 3 35
. .
— ki g G
Sto c n ea rs o n a G ou ld E b d
e rhar t Sha p er.

Fig 3 36
. .
— Stoc ki g
n a l
Bev e Gear o n a He rbe rt Milli n g Machi n e .
 THE MA NUFA CTURE O F GEA R S 3 33

N= Number O f teeth to be cut .

L =Number O f turn s O f di sc .

= Number O f te eth at e ach indexing .

D = Ist driver .

F= Ist follower .

d= 2 n d driver .

f= 2 n d follow e r .

In d i g
ex n on e t o o th In d i gm
ex n o re than o n e to o th
at a t im e at a t im e

D x d
—
1 20 Dxd
_ IZ O X M
Fx f N x L Fx f N>< L

Hobbin gSp eeds an d These v ary with the m ate ri als an d

Fcoda —
,

to a con siderable extent on the build Of the m achine u sed a rigid

, ,

m achine as in other kind s O f tooling being c apable O f much larger

output than a we ak o n e Th e fee d is the dist ance traverse d acro ss
.

the face Of the blank du ring one revolution O f the blank The .

co arser the pitch the fi ner mu st the feed be bec au se O f the larger ,

are a O fmet al which h as to be removed In fin e pitche s a O rin fee d . . .

may be adopted e asily in co arse pitche s from

, to 0 06in feed . .

e r revolution
p .

Multiplying the number O f revolution s Of the blank in a minute

by the feed per revolution give s the feed per minute an d the rev o lu ,

tion s per minute O f the hob is to the re volution s per minute Of the
gear blank as the number O f teeth in the blank is to the number O f
t hre ads in the hob SO th at while a single th readed hob mu st m ake
.
,
-

as m any r evolution s to one O f the bl ank as th ere are t eeth in the

l atter a double threaded one will m ake only h alf the number O f
,
-

revolutions .

Thu s let
,

N= Number O f teeth in bl ank .

f = Fee d per r e vo lution O f bl ank .

r= R ev olut ion s per minute O f h O b .

t = Numbe r O f thread s on hO b .

F= Feed pe r minut e .

F _ f . rt .

N
Some examples O f speed s an d feed s u se d on the F at well ge ar
hobber are as follows
 3 34 GEA R C UTTING

P l t Ch . Materi al . R . PM . . Feed .

Tooth R oun din g The qu antity O f gears which require roundin g

—

O f the tee th on one O r both ends in automobile wo rk an d in m achine ,

tool s to permit O f their Sliding e asily into gear has re sulted in the
, ,

use O ft ooth rounding m achine s which accomplish ne atly an d r apidly

-
,

w h at w as formerly done l abo riou sly with ch i sel an d fil e In a .

m achine by the Selson Enginee ring CO Limited the ge ar to be

, ,

rounded is mounted on an arbor an d is rot ated by a worm above .

The reciproc ating movement is imparted by a cam The gear is .

set at a suit able an gl e for rounding by me an s O f Slot hole s in the

-

b ase Of it s bracket The worm an d the cam revolve at the same

.

rate SO th at the slide an d gear m ak e one reciproc ating movement

,

while the ge ar is rot ated through a space equ al to one tooth during ,

w hich the cutter impart s the rounding or the ch amfer a s the c ase ,

may be Thi s difle ren ce in Sh ape is controlled by the sh ape an d

.

rel ation ship O fthe c utte r The mech an i sm is driven by a Single be lt

.

pull ey A separate worm is required for every pitch but one worm
. ,

w ill serve for all num be rs O fteeth O f the sam e pitch Gears from zin . .

to 9 ,
,
1 in pitc h .di am eter an d from 4 to I O di am etr al pitch can b e de alt
w ith in thi s m achin e about 6 tee th per minute being O pe rated on
,
.

The Loren z autom atic tooth rounding machine is Seen in Fig 3 3 7 -

. .

Th e whe e l or wheel s to be rou n d e d a re mounted on an arbor which

is se t betw ee n centre s an d driv e n by a dog from the spindl e O f the
,

driving he ad which is rot ated by worm gear thro ugh t he chan ge

,

ar s seen A slight degree O f circul ar adj u sM en t is pro vided in

g e .

connection with the worm wheel to bring the teeth in exact relation ,

to the cutter The t able c arryin g the heads is arran ged to mov e
.

l ength wise by me an s Of a screw SO th at severa l gears can be m oun ted

,
336 GEA R CUTTING

t able the reciproc ation to an d fro occurring while the tooth under
,

t re atment is travelling round The ge ar is then pitched round for

.

dealin g with another tooth the whole movement being autom a tic
, .

A ste ady br acket is att ached to the t able as see n to support the s h a ft

Fig . 3 38 .
—
R e in eck e r To o th-ro un di g M chi
n a n e.

Of the ge ar ; thi s is especi ally useful when the small er ge ars formed
in the solid are being de alt W ith .

Castell ated Shafts The dem and for these has resulted in special
.
-

machines being constructed for their production In on e O f these .

,

of French origin the shaft is mounted in the Spin dle Of a head

,

stock t he other end being supported by a poppet

, A pair o f tool s .
,

set on oppo site sides O f the sh aft cut s the grooves with a pl anin
,
g
action leaving the ridges or k eys st andin g up A s the tool slide
, .

m akes its backward stroke the shaft is partly ro tated an d locked

,
 THE MA NUFA CTURE O F GEA R S 337

by a pl unger entering one O f a se ries O f hole s in a di sc mounted on

the end of the headstock Spindle The disc thu s act s as a divi sion .

plate having its numbe r of holes corresponding to the number of

,

ridge s on the sh aft .

B uildin g Up A S the co st O f m ateri al put into ge ars incre ase s

.
—
,

the practice also grows of building them up as rings on solid centre s

of cheaper m ateri al These occur in the worm ge ars Of electric
.

cranes an d hoi sting m achine ry ( Figs 33 9 an d in the larger .

ge ars in speed an d feed ch ange

boxe s an d in tho se Of automobile
,

t ran smi ssion gears Worm gears .

for dividing purpo se s are m ade in

h alves an d hobbed twice once ,

ne arly down to the fi ni shed Size ,

followed by a fi n e fi ni shing cor

rect iv e cut .Fig 3 4 1 show s such
.

a ge a r al so mounted on a c ast iron

,
-

c entre Examples O f automobile

.

gears are shown in Figs 3 42 to 345 . .

Sometime s two rings of teeth are

att ached to one common centre ;

sometime s a ring is bolt ed to the

fac e O f a sm alle r solid ge ar In .

other c ases two rin gs are att ached

to fl anges on a common Sleeve .

Many Of the sm all pinion s are Fig 3 3 9 Fig 3 40

fo rged o r c ast in on e with long
. . . .

bo sse s or sleeve s or with sleeve s an d clutche s A gain in the fast

,
.
,

running ge ars the practice Of trusting to a single key is abandoned

in favour Of two or four keys In the Sliding gears too in ste ad .
, ,

of u sing separately fitting loo se keys in the sh aft s they are m ade
solid with thei r Sh aft s as in the four keyed o r c astell ated sy stem -
,

an alt ern ative to which is the squ are sh aft These give rise to a .

Sp eci al de sign of m achine for pl aning the sh aft s unle ss th e y are ,

milled with fo rm cutters The holes are also cut on one of the
.

bro aching m achine s The se are complic ation s which render the pre
.

rat ion O f bl ank s a le ss simple m atter th an it w as a few ye ars ag o

p a .

The y are done in the l athe chiefly working by fi xed c alipers gauge s , ,

an d templet s A l arge volume is don e in t he turret l athe wh en th e

.

numbe r Of identic al piece s is sufficient to ju stify the co st Of the

 33 8 GEA R CUTTING

rig up Some Of the blank s are milled with straddle mill s especi ally
.
,

tho se Of light type .

R awhide ge ars are e m p loyed in Situ ation s where high spe ed s

prevail an d where the noise O f met al ge ars would be Ob
,

j e ct io n able while,the y al so po sse ss t he adv ant age O f re si s t

ing Shocks in a bette r m anner than met al ge ars with the ,

result th at vibr ation is much reduced The action O f

.

the rawhide upon the teeth O f the m ating wheel produce s

a fin e po lished su rface on al l t he tee th an d the friction O f
,

driving is thereby reduce d A rawhide ge ar may be run

.

in mesh with a ge ar of an y O f the usu al met als o r alloys ;

a sm all amount of lubric ation preferably with graphite
—

lubric ant is nece ssary The strength an d c ap acity for

—
.

powe r transmission is approxim ately equ al to that O f c as t

iron gears .

These ge ars are n ecessarily shroude d with brass or

other plates clamping the lamin ations O f hide but the ,

Shrouding must never touch the m ating met al ge ar an d ,

Fig 3 4 1
. . it is essenti al to have the hide po rtion slightly wide r
than the companion ge ar The details of the Shrouding
.

depend upon the size O f ge ar an d its function The simp les t .

method is to rivet the plates through ( Figs 346 . but fo r ,

Fig 3 4 2. .

l arge gears bolts are preferable being a more convenient method

, ,

an d affording opportunity for sub sequent tightening up with faci lity

s hould Shrink age occur Lock nut s may be employed if necessary
-
. .

When there is insufficient sp ace to allow O f the heads projectin g

to thei r full am ount the pl ates can be countersunk ( Fig
, Or .
340 GEA R C UTTING

moisture or Oil c annot be e ffectu ally gu arded against The se

,
.

m ateri als are built up under gre at pressure being subjected there to ,

in hydraulic presses but in other respects the construction of t he

,

gears resembles that of rawhide Graphite lubric ant is applied .

Fig 3 4 5. .

to paper ge ars The necessity for such lub rication is avoided in

.

cotton ge ars by impregn ating them with oil during m anufacture a ,

method which also renders the m impervious to moisture Or atmo s

p her ic con di tion s .

Examp les of Man u/ acture There is no d iffi culty in O bt ainin g

.
—

either approxim ately accurate or abso lutely ac

curate teeth regarded from the practical point
,

O f vie w ,by the systems of cutting employed .

The p ri ncipal difficultie s arise from the fact th at

the teeth have to be h ardened on the wearing
su rface s in order to en sure their durability .

Hardening without some resulting di stortion is

impo ssible an d there is also a risk of cracking
, .

Not only has c are to be exerci sed in h ardening ,

but su bsequent grinding may be necessary The se .

proce sse s are rendered more difficult bec au se the

ge ars are m ade O f highly ten sile steel s which are ,

Fig 3
. 4 6 ,
more li able to su ffer di stortion th an the milder
qu alitie s Looking at O n e O f the se slender gea rs
.

the m arvel is that so high a combin ation of durability an d accuracy

has been att ained A s an illu stration of the care requi red in the
.

manufacture Of ge arwheels a few example s are given

,

In one sy stem the ge ar whee ls are m ade fro m chrome van adiu m -

c ase h ardening steel The blanks are drop forged with a sufli cien t
-
.
-
,
 THE MA NUFA CTUR E O F GEA RS 34 1

a mount left on for cutting down to size They are then anne al ed .

befo re being cut Careful in spection follow s They are turned in

. .

a turre t l athe by me an s of tool s an d fi xture s which are de sign e d

s peci ally for repetition work an d by which more th an one oper ation
,

is performed simult aneou sly .

A bl ank h aving been gripped in a three jaw concentric chuck

,
-
,

is centred with a cent ring tool an d a drill of sm aller Size th an the

, ,

fini shed hole required is st arted While thi s is running through a

,
.
,

ro ughing cut is t aken acro ss the f ace of the bl ank to remo v e the h ard

Fig 3 4 8
. .

Fig 347 . .

c l the two O peration s being completed almo st simult an eou sly

s a e, .

A fixture which c ar rie s a fl at bro ad cutter sh a ped to the correct

profil e O f the face of the gear is next brought into action It is .

bolted to the turret O f the m achine an d beingfed up to the face of , ,

t he ge ar bl ank cut s it accuratel y t o shape an d dimen sion s at one

,

o pe ration A cutte r bar is next put through the h ole boring it to

. ,

within I IOOin of it s fi nished size which amount is ground out after

-
. ,

th e ge a r h as been c a se h a rdened The-

other si de bein gthen finished
.

in a Sim ilar m anner to the fi rst the bl ank is re ady for the cuttin gof
,

t he teeth do n e w ith a single di sc cutter in an y autom atic m achin e

, , .

The c ase h ardening O f the gears is done with c are Since a few
-
,
34 2 GEA R C UTTING

degree s of tempe rature more or le ss has a serious e ffect on thei r

wearing propertie s an d strength A coke or gas he ated mu ffle furn ace .

is u sed which is c aref ully m aint ained at a con st ant temperature b y

,

mean s of prope rly arranged d ampers an d air flues an d a pyrome t e r ,

is employed for re ading the temperature of the furn ace .

The gear wheels after having been cleaned fro m oil or grease
, ,

are placed in boxe s with the c ase hardening medium an d are -

,

hermetic al l y luted with a fire cl ay mixture Te st piece s of Similar

-
.

materi al to the gears an d Sh aft s are placed in the

boxe s which are then put in the furn ace where
, ,

a temperat ure of 800 to IOOO C is m ain t aine d ° °

.

for from six to twelve h ou rs dependin g on t he ,

depth of h ardening required The furn ace is the n .

allowed to cool down the boxe s are withdrawn , ,

an d the piece s removed for rehe ating an d que nch

ing in O il o r water for h ardening The te st pieces .

h aving been h ardened an d broken in order to ,

Fig 349 .
as
.
cert a in if the c a rbonizing is sati sf actory t he ,

gears are c arefully reheated to the pro per tem

e rature an d quenched in oil or w ater The ge ars are g round an d
p .

inspected for assembling .

For se rvice in motor wo rk as used by Messrs John I Tho rn ycro ft

, .

CO Ltd the steel h as a ten sile strength of from 3 7 to 40 tons p e r

.
,

s qu are inch w ith an el astic limit of from 2 7 to 30 ton s

, Th e bl ank s .

are roughed out an d anne aled an d then fini shed in a l athe

-
, The .

teeth are cut on a Fellows gear sh ape r Case h ardening follows the .
-
,

ge ars being p ack ed in Ch arred leather he ated for four hours in a ,

coke fired furnace an d quenched in oil They are ground in a

-
,
.

m achine of special patte rn de signed by the fi rm for thi s work an d ,

inspection for flaws an d inaccuracies precedes the assembling .

The Wol seley Tool an d Motor Car CO Ltd of Birmingh am use .

, .
, ,

st ee l s which are m anuf actured by M e ssrs V ickers Son s Maxim , ,

Ltd of a speci al c ase h ardening brand The part s are m achine d

-
.
,

an d the teeth cut after which they are h ardened an d ground SO

,

c arefull y that interch ange ability is secured in the part s when fitte d
in the gear box They are then te sted for h ardne ss an d st rengt h
.

before being assembled .

The firm has introduced a refinement in a box de signed for a

large car in which the teeth are first roughly cut then hardene d , ,

an d fin ally sh aped after h ardening This is an expensive process .

,
3 44 GEA R C UTTING

in diameter In Fig 3 50 A is the body B the t apering split sleeve

. .
, , ,

C the f alse j aw s D the adju st able j aws

, In thi s gears are chucked
.
,

by three methods The u su al one is th at in which they are held by

.

Fig 3 5 0
. .

Fig 3 5 1
. .

the tops o f t he teeth as in Fig 3 51

, a a The O bjection to thi s
.
, a, ,
.

is the possible want of tru th in the t eeth due to in accurate cutting , ,

o r to di stortion in h ardenin g A nother is th at of cent ring by thre e

.

roll s a a a fitting bet w een the teeth at the pitch circle as in Fig
, , , , .
 THE MA NUFA CTUR E O F GEA R S 3 45

3 52 , dopted very much in consequence of the practice of h arden

a

in g teeth The O bj ection to thi s is the in accuracy developed by

.

h ardening by re ason of which one 1 011 may fi t too tightly an d

,

Fig 3 5 3
. .

a nothe r too freely since tooth sp acings an d pitchings an d the pitch

,

ings of block s of teeth m ay v ary slightly Fig 3 53 shows an im

. .

provement on thi s method two pin s with self adju sting ends being
,
-

s ub stitu ted for a single rigid one The third method is th at in

.
34 6 GEA R C UTTING

which the j aws m ake con t act with the root s of the teeth This is .

not open to either of the foregoing objection s Since if the gear is n ot

,

true on the t op s of the teeth or at the pitch lin e it is set by the root s
, ,

Fig 3 54
. .

Fig 355
. .

from which as a base correction s may be m ade The cont act of

, , .

pin s in the root s may be that of single pin s or of two or three in

,

adj acent tooth Sp ace s

. A dju stment can be m ade by securing the pin s
in a pl ate with a slot hole as in Fig 354 a a a Thi s is necessary
.
, , ,
.
348 GEA R CUTTING

is imp arted by ch ange wheel s Multiple indexing is arranged for if

.

required The t able c arrying the work is fed by belt with a quick
.
,

return in either direction .

The grindin gwheel is c arried on a universal head pe rmitting it ,

to be adju sted to the de sired an gle In the first in st ance the m achin e
.

w as arran ged for grinding the side s of the t hre ad s by t aking succe s
s ive cut s fee ding the whe e l do w n at an angle after e ach stroke of the
,

t able the angle be ing set accordingto the pressure angle of the ge ar
,
.

Thi s m ethod produce s work of the highe st accuracy but is not u se d ,

v ery much becau se it t ake s longer th an the mode f grinding t h e o

Fig 3 57
. .
— Ho l royd Machi n e fo r G ri n di n g Wo rms .

whole depth of f ace at once When foll owing the latte r method a
.

diffi culty is met with in obt aining the correct shape o f grinding
wheel to suit the twi st of the thre ad A special attacM en t is
.

therefore u sed fo r generating the Sh ape of wheel by employing a ,

di amond held an d moved in a p ath corre spondin g to th at describe d

by the f ace of the worm thu s turning up the face of the whee l
,

autom atic ally an d correctly On e side of the thre ad o f the worm is

.

ground at one time .

Testin g The general method of te sting the accuracy or other

—

wi se of toothed wheel s is to run them round on their Sh aft s in place .

In comp aratively few Shop s is an y other method available except ,

 THE MA NUFA CTUR E O F GEA RS 349

ing th at of trying them in ge ar apart from their sh aft s by h and an d , ,

without an y rig up Thi s l atter c rude method shows the cont act
.

of the teeth an d in an approxim ate m anner the dept h O f their

, , ,

cont act an d bottom clearance ; but it tell s nothing of th eir t ruth

whether squ are acro ss the f ace in Spur wheel s or running to the ,

apex in bevel wheel s ; neither doe s it permit of very ex act me asure

ment for centres .

A nother objection to the se rough methods is th at when high cl ass -

work is in question trouble is Often li able to arise at the last moment ,

when mechanism is being put together Fixed centre s an d no flank .

cle arance to the teeth dem and very perfect gears much more exact —

th an is re quired of c ast wheels the teeth of which have flank cle ar

,

ance . So th at at the fin al fitting the ch ance s are th at teeth may

fit too easily or may on the other h and require some correction
, , ,
.

Such Slight difference s in the di ameters of the bl anks an d the depth

ing of the teeth an d in their thickne ss an d slight in accuracie s al so
, ,

in setting on the m achine produce t hese re sult s ; so th at the average

,

Shop method s are not good enough to en sure reli abl e re sult s In .

every Shop therefore there Should be a simple method of testing

, ,

wheels as they le ave the m achine to become a Check on the work ,

of the m achine an d to prevent possible waste of time subse q uen tlv

,
.

It is e asy to fit up adju st able arbors by which to te st gears B riefly .

,

the method adopted by the B rown Sh arpe Manufactu rin g Com

p an y is as follows :
.

For spur wheels a horizont al bed is fitted with two arbo rs or studs
— o n e fixed the other mov able on a slide
, The bed is divided out .

into inches an d parts for the loc ation of ex act centres an d the slide ,

which c arries the movable arbor can be locked in an y po sition The .

difference in the bores of different wheels is met by having a set of

bushings to fit tho se vario us bores an d all to slip ove r the two arbors
, ,

the dev ice being simil ar to that in which bushing s are fitted to the
holes in the t ables of drilling m achine s to receive boring bars of
di ffere n t diameters .

When p airs of wheels are on their bu she s they are tried round by
h and A single wheel is tested with another wheel of the same
.

pitch a st and ard Set of which is kept in a cupbo ard u n der the t able
,

of the m achine .

For testin g sm all bevel wheel s an d worm s a m achine is u sed ,

h aving a horizont al bed an d a vertic al st andard at its end The .

arbors are c arried in slide s which are adju st ed on bed an d st and ard
350 GEA R CUTTING

with screws Wo rm s an d their wheel s are te sted by c arrying the

.

worm in a special sliding bracket the wheel being run on the vertic al
,

slid e Large bevel wheels an d large spurs are te sted on a m achine

.

h aving t wo horizont al bed s situ ated at right angles To accom

, .

modate bevels the axe s of which are at other th an right angle s the
, ,

arbor be aring s are m ade to swivel on the slide s .

Fig . 3 53 — P kiar n so n Test i g M hi

n ac ne p
fo r S ur G e ars .

The P arkin so n
te sting jigs for spur an d spiral ge ars are illu strated
by Figs 358 an d 359 They t ake ge ars ranging from Tl in to 9 in
. .
. .

centres Wheel s are tested in p airs as they h ave to work or one

.
,

wheel can be compared with a m aster gear In either c ase one of .

,

Fig 3 59
. .
— P kiar n so n Test i g M hi
n ac ne pi l G
fo r S ra e a rs .

th e pair is mounted in a fixed position on a c arri age which may be

adju sted along the bed the othe r on a flo ating c arriage which re st s
,

on three steel b alls an d c arries a spring plunger at one end The

,
.

Sp ring in side the plunger m ay be compressed by an adju sting screw

fixed at the end of the bed A nother adjusting screw act s again st
.

the same end of the flo ating c arri age so th at the di st ance between,

the centre s of the gears may be controlled to a definite an d minut e

352 GEA R CUTTING

found on the pinion Chart No 3 is a very bad one as indic ated by

. .
,

the wavy line Thi s was t aken from gears h aving a 4 to 1 ratio an d
.
,

there are four wave s These Show th at the pinion w as out of truth
.

to the extent of about 0 008in A n d further the jump in the curve

. .
, ,

between variou s teeth shows th at the ge ars were rolling badly which ,

w as also bo rne out by the f act th at they ran noi sily A l arge size is .

m ade to take spur Spiral an d bevel ge ars

, , .

N9 3 .

Fig 3 6 1
. .

A ge ar testing m achine by Messrs John Holroyd CO Ltd is

-
.
,

seen in Fig 3 62 an d it is suit able for te sting the running of spur

.
, ,

bevel an d worm ge ars There is a sliding c arri age moved along the
, .

bed by screw an d h andle with micrometer adjustment an d a sc ale

, ,

on the bed is re ad with the aid of a vernier pl ate att ache d to the
c arri age The cross Slide seen at the right hand end of the bed
.
- -

c arries a couple of brackets to receive the m andrel of a worm sho w n ,

in mesh with a wheel Whe n spur gears are being tried a m an dre l
.
,

is stuck vertic ally in thi s cro ss Slide to hold one ge ar an d the othe r
-
,

gear is c arried on a m andrel inse rt ed in the m ain c arri age The up .

right at the left h and end is utilized when testing bevel o r mitre
-
 Fig 3 62
. .
— IIo lr0yd Ge ar tes t
-
i g M hi
n ac ne .

Fig 3 6 3
. .
— G l easo n Test i g M hi
n ac ne p
fo r S ur Gea rs .
3 54 GEA R C UTTING

ge ars Spur gears up to 2 ft 8ln di amete r bevels up to 1 8in worm

. . .
,
.
,

wheels up to 4 ft an d wo rms up to 6in di am et er can be tested o n

.
,
.
,

thi s m achine .

The Gleason Gear testin g Machin es -

These are shown in t he .
—

photographs Figs 3 63 an d 364 fo r spur an d for bevel gears The

,
.
,
.

same general fe ature s a re pre se nt in e ach t ype with necessary ,

modific ation s introduced by the setting of the he ad s p arallel or at ,

ri ght angles to on e anothe r In the spu r gear m achine the he ad s -

.

Fig 3 6 4
. .
—
G leason Te st in g M hi
ac ne l
fo r B ev e Gears .

at the front are c arried upon a cro ss traversing slide by which the -
,

p air of ge ar s m ay be set at ex act centre s the h and wheel of the ,

a dju sting screw being gradu ated The outboard support on thi s
.

slide is adju st able to suit di fferent width s of ge ars The beads .

w hich c arry the arbors h ave their spindle s bored to st andard t apers ,

so t h at arbors as employed on the ge ar cutting m achin e s m ay be -

h eld for te sting ge ars mounted upon them The countersh aft for .

e ither m achine h as a forward an d rev erse drive an d ru ns at 3 50 ,

revolution s per minute There is a wood lined brake on the

.
-
 CHA PT ER XVIII
THE STR ENGTH O F GEA R S

THE Wilfre d Lewis formul a for the strength of gear wheel teeth h a ve -

been generally welcomed an d utilized since their int roduction in

1 8 93
. Some occ a sion al critici sm s an d suggestion s be a ring t hereo n

appe ar fro m time to time but nothing of m ateri al impo rta nce
,

h as be en o ffered to ch allenge the d at a as a whole The gen e r al .

formula t akes account of the variables which occur in gear wheel -

t ran smi ssion s The formul a is :

.

W= s 1) fr
Vi here
W= the wo rking lo ad in pound s .

s= the fibre stress .

p = t he Circul ar pitch .

f = th e width of f ace in inche s .

y = a f actor of stren g t h obt ain ed c alcul ation , em

bodied in a t able .

The t able on p 3 58 gives the factors y for gears with different

.

numbers O f teeth The width acro ss the root is t aken in ste ad of the
.

width at the pitch line Three set s of v alue s are given respectively
.

for the common involute of 1 5 of o bliq uitv the involute of

°

an d for radi la fl a s . e a p
nk A noth r t ble ( 357 ) gives the safe wo rking.

stre sse s s for di fferent speed s The l atter w as b ased on experience s

.

in ge ars u sed in m achin e tool design -

The t able s are employed
.

for bevel gears by an approxim at e formul a :

it

Wh e d
re = t he sm all di ameter of the bevel ge a r D = t he l arge ,

diam et e r
.

Mr Lewis assumed th at in good m achinery the lo ad may be safely

356
 THE STR ENGTH O F GEA R S 3 57

t aken as being dist ri buted ac ro ss the whole width of the toot h ,

in ste ad of being regarded as conc entrated on one corn er as m any ,

writers h ave assu med it to be This is often the c ase when ge ars
.

a re c ast with t ape r but not wh e n t hey are cut accurately

, O n the .

o th er h and he did not con sider th at the lo ad mi ht be reckoned as

g
divided between two teeth but as concentrated on one Tre ating
, .

a sin g le tooth as a beam su st aining the whole of the lo ad he deduced ,

t he ge ne ral formul a given after d rawing v ari ou s size s of involute

,

g e a rs O f 1 5 an d
°
2 0 pre ssu °
re angl e a n d a l so cycloid a l ge
, a rs a n d ,

t aking the width s at t he root s in ste ad of at the pitch line With .

regard to the factor of safety he thought that fo r slow ge aring

, ,

where no se riou s re sult s can en sue from bre akage a factor as ,

low as 3 might be u sed but th at for high speed s an d where great

, ,

ri sks dem and ab solut e secu rity a factor of 1 2 or even I5 should be

,

a dopt ed .

Some inte re sting f act s were collected d uring the prelimin ary
rese arche s u n dert ak en by M r Lewi s He mentioned th at a Mr .

Cooper h ad co hected forty eight well e st abli shed rule s for horse
- -

powe r an d wo rking strengt h sanctioned by some twenty fo ur ,

-

authoritie s an d di f
,
fering from e ach other in extreme c ases by about
5 0 0 per cent N o
. a ttempt w as m ad e in an y formul a to include t he

w orking stre ss an d no account w as t aken of the actu al tooth form s

, ,

th at is of the width at the roo t s but only o f the thickne ss at the

,

pitch line Mr Coo per selected a formul a which he deemed p assably

.

co rrect

x = 2 ooo af .

Where
x = break in glo ad of tooth in pounds .

=
p p it ch of t ee t h in inc h e s .

f= fac e of t e eth in inch e s .

WILFR ED L EWIS TA B L E FO R STR ENGTH O F G EA R S

SA FE WO R K ING STR ESSES, s, FO R D IFFER ENT SP EED S

3 58 GEA R C UTTING

FA C TO R FO R Sl
'

R ENG T H, y

15 In v °l ute
°
No 0f l
l n vo ute 20
°

d di l
Ra a No 0f l n vo ute 20 l °
nd
Ra di al

k
.

bl Fl an
.

Tee th . O iq ui t y .

lg
Cyc ida l .
Fl k an s . Tee th . O bl q utyi i .

f
Cycl oidal .
s.

With regard to the influen ce of the width of t ooth on it s strength ,

it is n ow con sidered gene rally preferable to incre ase stren gth b y

inc re a i g width in preference to employing co arse pitches Fin e
s n .

pitches are preferred for seve ral re ason s chiefly in orde r to keep th e ,

angle of pre ssure low an d to inc re ase the numbe r of teeth in ge a r

,
.

Inc reasing the width of face le ssen s the pre ssure per unit a rea O f
surf ace without incre asing the friction which is propor tion ate t o

tot al pre ssu re The friction p er unit are a is therefo re gre ater wit h
.

n arrow t eeth th an with wide O nes .

The old O bjection to wide tee th when teeth were mo stly c ast w as
the in accu racy due to t ap er rapping an d moulding which O fte n
, ,

c au se d teeth to h ave cont act o ly at one corner until they wore n

them selves to a continuou s beari n g Thi s con sideration n ow has .

rel atively little weight bec au se of the gre atly extended e mploymen t
of goo d cut ge ars in which u ifo rm cont act can be relied on SO
,
n .

th at when desirable the width of face is m ade wider th an p rudenc e

would sanction in the c ase of c ast ge ars .

The c ase of bev el ge ars st ands alone The width c annot be in .

crease d much beyond the common st andard without c au sing diffi

cult ie s in t he use of st and ard rot ary cutter s or of pl aning tool s .

B e side s which t he t eet h be com e ve ry we ak at the sm all e n d .

The Gle ason Wo rk s of R och e st e r N Y e stim at e the stren gt h O f

, ,
. .
,

ge ars as follow s :
P remi in g t hat the lo ad a ge ar will c arry d epend s on it s fi ni sh
s ,

the qu ality of the m aterial the sh ape of the tooth wheth er th e lo ad

, ,

comes o n on e tooth or two the velocity the support s for the ge ar

, , ,
 3 60 GEA R C UTTING

The stub tooth ge ar is so mewh at stronger particul arly for p inion s ,

of a sm all number of teeth In the di agram Fig 365 the lowe r lin e
.
, .
,

NUMBER OFTEETH

Fig 3 6 5
. .

show s the v alue s of the strength factor for an ordin ary 6 pitch gea r ,

as found by dividing t he f actors in Table No 1 by 6 The U pper lin e . .

show s the corre sponding v alu e s for a p tch tub tooth gear
g i S .

TA B L E NO . 1 TA B L E NO . 2

STR ENGT H C
FA TO R S ( V ) FO R GEA R V EL O C IT Y FA C T O R S BA SED O N
H
S A P ER GEA R S 14 5 D EG R EE ST D . MR L Ew rs CA L ULA T IO NS
’
C
No of
X F
.

F
ifi fif tfg
r
Tee th Fa cto r ?
’

.
Facto r
l i
.
/ .

The stre gth of ge ars is obt ained by the ge ar Slide rule inve nted
n -

by Carl G B arth illu strat ed in Fig 366 It utilize s the formul a of

.
, . .
 THE STR ENGTH O F GEA R S 3 6 1

Wilfred Lewis ( as modified by Mr Ba rth) as follow s : The prope r

—

w orking load on a s pu r gear is

n which
v = circumferen t ial velocity of ge ar in fee t pe r minut e .

s = p erm issible stress on t he m ate rial at the given sp eed .

p = circul ar pitch of gear .

f= fa c e of g e a r .

y = st re n gt h f a cto r found in Lewi s s t able s for a gear

’

of the numbe r of teeth an d of the syst em under

con sideration .

Fig 3 66
. .

D irection s f or U Fi
se r—
st in t h
,
e p ro p e r sy stem o n t h e bottom ,

d i sc set t he ride r to coincide with the numb e r of t eeth of the gear

, ,

t h e stren gth of which is to be found Then set the int ermediat e

.
3 6 2 GEA R C UTTING

di sc ( m anipulated through the fi nger slot in the bott om disc ) so

th at the pitch of the gear di ametral or circul ar as the c ase may —
,

be wil l coincide with t he rider thu s set an d the n tighten t h e

—
,

clamping nut at the cen tre Next set the rider to coincide with th e .
,

face of the gear on the intermediat e di sc an d then loo sen the clamp ,

in g nut an d set the top di sc so th at the perm issible st atic stre ss o n .

the m ateri al in the ge ar will coincid e with the ride r in this new
position an d again tighten the cl amping nut
,
.

Fin ally set the rider to coincide with the circumfere n tial velocit y
,

of the gear o n the top disc an d then re ad o ff the correspondin g ,

proper working load for the gear where the re ading on the scale
o f lo ad s on the bottom di sc coincide s w ith th e rider in thi s l a t s

position .

Ex ampl e Wh at will be a p rope r working lo ad for a spur ge a r

—

of the 2 0 involute system when it has 40 t eeth 1 5 per in of dia

°
, ,
.

meter 5 in face an d is m ade of c ast iro n the permi ssible st ati c

,
-
.
,

stre ss of which is 8 ooolb an d run at a circumfe renti al velocity o f

.
,

6ooft per minut e

. Th is is the example for which the in strumen t is
.

set in the accomp anying illu st ration which Show s a lo ad of 52 001b ,

P roportion s for A rms

( FIG 3.67 )

Le t P =circular pit h
c . ik
L e t E : th c n ess o frib n ex t oss b .

ni
p = di a.m e t ra c l pi t h . ik
F=th c n ess o f fla t arm .

A =breadth O fface . G =thick n ess o fv ert ca rib i l .

B =diamete r o f o ss b . id
H=w th O fa rm n ex t rim .

C =thi ck n ess o frim . i

b =b o re in n ch e s .

D th c ik n e ss O frib n ex t ri m .

P =C IR C U L A R P CH
IT

Fo rm o fA rms .

1“ 3 p i n { P zi p
 6
3 4 GEA R C UTTI G N

t he curve s for a tooth the mean of the se are u sed for them all Th e .

rapid growth of generating m achine s du ring recent ye ars will in

time react on all ge ar cutting Designed in the fi rst pl ace to pro
.

duc e pe rfect b evel s they m ay be expect ed to e xt end to include a ll

,

w h ee l s an d to gene rate all st and ard tooth templet s

,
They will t hen .

probably ou st t he odontograph sc ales both in strument s an d t able s , ,

a n d rem ain t he single sourc e of evolution of all toot h sh ape s f rom a

predetermined b ase They will prob ably be the me an s in t hi s an d

.

in other lesser an d rel at e d w ay s of c au sing a g re at revolution in the

e nti re p ractice of gea r cutting .

Looking at the growing speci aliz ation of the m achine s now

a v ail ble for cutting ge ar s it st an ds to re aso n th at as a second ary
a ,

c on side r ation the restriction of t ask s of a given kind to on e kind O f

m achine mu st tend not only to prolong the du rability of the m achine ,

but to prese rve it s accuracy in a gre ater degree th an that of a

m achine which is u sed for u n iversal purpose s Speci aliz ation in .

m an uf actu re has al so a gre at t endency to produce a high degree of

a ccuracy in m ac h in e con st ruction wit h out rende ring p rice s in the
,

least degree prohibitive .

The ve ry rapid development s of n ew an d eve r m o difi ed form s of -

g e ar -
cuttin g m ac h in es in rec e nt y e ars wh il e c re ating a sen se of ,

di ssati sf action with the O ld t end to rende r the question of inter

,

ch ange ability in gearing a mo re comple x on e th an it w as when the

choice of m achines an d methods w as more limit ed Gears cut on .

o n e kind of m achin e c an ot be reli e d on to eng age with tho se p ro

n

duce d o n o n e of anoth er kind e ven though t he tooth p roportion s are

,

identic al A gain the di ffe rence in the co st of cutting in di fferent

.
,

s y stem s is a ve ry m at e ri al o n e an d th at again is influ e nc e d not only

,

by the kind of m achine u sed but al so by the co arseness or fi nene ss of

,

pitch .

Fu rther the use o f rigid st andard cutters an d the employment

,

o f cut ge ars without sid e cle aranc e h as al re ady h ad t he e f fe ct of

developing a clo se r study of the condition s which govern the perfect
mutu al action o f engaged t eeth There is little ch ance to fudge as .
,

t he old millw right s were able to do Teeth mu st either be right or

.

wrong within a very minut e degree an d the study of practic able

, ,

cu rve s h as eng aged t h e l abour s of some of the be st m achini st s with

e xcell ent re sult s We see the effect s of the se things in the high
.

q u a lity of t h e ge a r cutting done now unde r the be st Shop sy st e m s ,

notwithst anding th at the rate of cutting is fairly high not of co urse , , ,

 THE STR ENGTH O F GEA R S 6
3 5
‘
by fo rcin g cutte rs unduly but by duplic ation of the work or of the
,

cutte rs an d rapid autom atic ch anges Wheel t eeth are pitched

,
.

truly cut t ruly an d with excellent fi ni sh A n d hundreds of wheels

, ,
.

will be all al ike in eve ry resp ect bec au se the fo rm s of cutters do not
,

ch ange by regrinding an d the mechani sm of the m achine rem ain s

,

practic ally un affected during m any years .

Fin ally the problem s which de al with the fo rm s of the teeth

,

an d the proportion s of t he whe el s are seen to be e sse nti al ly of a

practic al ch aract er In al mo st an y wheel the sh apes imp art ed are

.

not exactly tho se which would be deduced from strictly theoretical

con sideration s They might not even be tho se which would seem
.

be st for a particul ar pair of wheel s regarded alone For almo st

,
.

every wheel has to be con sidered in regard to m any others The unit .

is rel at ed intim at ely to t he syst e m to m any other unit s an d is

— —

af fected by methods of m anufacture Simplicity in t erchan geabilty

.
, ,

an d work shop an d comme rci al condition s mu st be regarded an d the ,

result is a compromi se Thi s is the reaso n why of so m any sug

.
,

g e sted t oo th form s s
,o fe w h ave survive d in p ractic e .
3 68 GEA R C UTTING

TA B L E OF TO OT H P A R TS FO R CI R CULA R P ITCHES
 A P P END I X

L
R U ES FO R OB A T I NI NG D I A METER S OF SP I R A L GEA R S

( D avid B rown ( 5 Son s ( Huddersfi )

el d , Limited)

Fo rmula : No rmal Diam . P itch x Co s a C ircular D iam . P itch .

C i rcul a r D iam P . it ch An gl es .

No rmal
D i am . Pi t h
c .

° ’ ’
26 3 5 63 °
25

Number of Teeth P1 t Ch D’amet er

Circul . D iam P it ch
.

Pi tch Dram et er + Who l e D Iam et er of t he

2

No rm al D iam P i tch .

bl an ks .

Ex ampl e To fin d the pitch di am an d the whole di am et er for a

— .

whee l with 50 teeth if t he No rm al D iam P itch = 4 an d ,

.

t he angle of the spir al

50
17
0
68 P It ch D ia met er .

2 82 8
.

17 68 = Who le D i am et e r of the b lan k .

37 0 GEA R C UTTING

R ULES FO R O BTA I NI NG D I A METER S O F SP I RA L GEA R S

( D avid B row n 6 Son s

'

( Hudders el
fi ) d , Limited)

Formula : Normal Pitch —

Co s . a = Circula r P itch .

C i l
rcu ar i
P tch A n gl es .

'
26 °
30 63 °
25

3 1 41 6

i am et er 2
P ll C h D x e D i amet e r ,

If a p air of wh eels h ave a ratio of 1 : 2

The Spiral of the wheel with t he l arger number of teeth is
sm a ll e r
T akin g the abo ve Spirals w e fin d th at the di m et er of each a

wheel is n early the same .

Ex amp le To fi n d t he pitch diam eter c entre di st anc e an d whol e

—
,

diam et er of t he blanks fo r a p a ir of Spiral Wheels as follows : ,

( 1 ) 4 0 T eeth N orm al P itch

, S pi r a l A ngl e 2 6 an d
°

°
63
’

( )
2 20 25

4 0 x
10
°
67 = P itch Diam et e r.

3 1 41 6
20 x
(2 ) 10
°
67 = P itch D iamet er .

nt re D ist an c e = 1 0 67 inch es
Ce
°
.

Whole D iam of t he blanks = 1 0 67

.
'

2 X 0 23
’

9 = II I4
‘

in hc es .
 P ITCH A NGLES O F B EVE L GEA R S

( B rown <8
»
Sharpe Man ufacturing Co ) .

W HEEL .

For bevel gears with axes at right angles .

A ngle for whe e l a bove for p in ion below

, .
3 74 GEA R C UTTING

P ITCH A NGLES
WHEEL .

For bevel gears with axes at right angles .

A ngle for w he el above for pinion below

, .
 GEA R CUTTING

P ITCH A NGLES

WHEEL .

For b evel ge ars w it h axes at right angles .

A n gle for wh eel above for pinion below

, .
 A P P END IX 3 77

L
A NG E OF FA CE O F B EVEL GEA R S
A ngle gi en = Face A ngle
°
0 —
9 v .

W HEEL .

For bevel gears with axes at righ t angles .

A n gl e for w heel above fo r pinion below

4

.
,
37 8 GEA R C UTTING

A NGLE O F FA CE
90
°
—
n e
A gl giv en = Face A ngle .

W HEEL .

Fo r bevel gears with axes at right angles .

 GEA R C UTTING

A NG E O F
L F A CE

90 —
°
A ngle giv en = Face A ngle .

W HEEL .

Fo r bevel gears with axes at right angles .

A ngle for w h eel abo v e for pinion b elow

,
.
 A P P END IX 3 8 1

NA TURA L SI NE

6 8 199
‘

NA TU R A L I NE
COS
 G EA R C UTTING

NA TU R A L SI NE

NA TU R A L COS I NE
 GEA R C UTTING

NA TU R A L TA NGENT

NA TU RA L CO A NGEN
T T
 X
A P PEND I

I NCHES TO MI LL I METRES F RA CTI ONS

—
3 88 GEA R CUTTING

i g f d 32 9 3 33
Cut t n ee s, , Gau g es fo r sett n too i g l s, 2 04 , 2 3 1 , 2 4 1 ,
i t lg n ern a 4 ea rs , 1 2 2 56, 2 7 1

ps d 32 9 33 1 3 33
s e s. . fo r teet h , 4 0
b l k milli g 3
.

p lg
s i ra 151 5 ea rs , , 1 2, Gea r an s, n , 21
t th 76ee , cutt i g hi t i l
n , s o r ca , 1
Cycl id l cu
o a 9 rve s, g ug 4
a es , 0
t mpl t f 9 e e s o r, rul es , 36
t eeth , I, 5 9 , sl id 6
e , ru e ,
3 l
cutters fo r, 8 1 tee th , metho s o fcutt n , 7 6 d i g
Gears, abn o rma , 7 3 l
ll
a o y s te e s fo r, 3 10 l
b d
as t ar , 74
beVel , 2 , 6 7
Dar n li g ll
Se ers auto mat c s ur ear i p g bl k
an s f o r, 3 2 2

cutt n i g
mach n e , 1 1 9 i bl k
an s f o r, mo u i g
n t n , 32 4 ,

i
D ame ters o fs irals, 50 , 369 illi g
m n , 30 1 305 -

i
D ametra an l c rcula r tch cutte rs i pi b il i g
u d n up, 3 37
p d
co m are , 8 2 d i g
case- ha r e n n , 34 3

pi
t ch, 2 4 d fi i ti e n 2 on s,

bl li l b
D o u e -he ca eve ears , mach n es l g i G t y t m
ran 8s s e , 1

fo r, 1 79 g i di g f 34 3
rn n o ,

ho bbi g
n , 2 90 h li l 56e ca
Hi dl y w m h bb i g 2 9 8
,

s urp g e ars , mach n es f o r cutt n , i i g n e or -

o n ,

1 52 - 1 63 h bb i g 2 7 5 2 8 5 8 8
o n , , , 2
id l 2 ea ,

i t mi tt t 6 5
n er en ,

i t l 44
n e rn a ,

l w umb
o -n d 7 e re , 1
l g
Ear y ears, 1 m uf tu an f 308 34
ac re o , 0
g
,

l
E emen ts o f ea rs , 2 m t i l f a er a s 3 8 o r, 0
l ip i l g
E l t ca ears , 6 6 m t 23
as e r, 2
n -
ill
E d m cutters, 8 6, 8 7 m illi g 2 99 n ,

i f 354
n o se o ,

q u ill 1 3 , 2
w hid
ra 33 8 e,
pi l 4 7 4 8 368 37
S ra 2, ,
-
0
milli g 99
, ,

g
Face a n l es o f eve l gears, 3 77b pu S r, 2
n , 2

Faces o f tee t h, 5
Fe ed s an d spe ed s 32 9 333
t g h f 356
s ren t o ,
,
uf f
Fe ll o w s cutters, 9 2 , 9 3
s r a ces o , 2
t p h b f 95 2 97
ru esl fo r st ren th g of g ears . 359
a
t ti g 34 8
er o s o r, 2 ,

s pu g r ear g en erat n i gm i
ach n e , 2 20
t
es

mi i
n

33 7
,

Fl an ks o ftee th 5
ran s ss on ,
,
i bl 65
v ar a e,
Form cutters 76-80 ,
w m 59
machi n es, usi n g ,
or 2,
14 6 ,
g ti g m h i
,
1 09 , 1 77 .
en e ra f 29 n ac ne o r, 2,
1 79
2 95
o r fo r mer, 90
pl i g I8 8
g t f 91
en era i o n o , 2
an n ,

co m a re
90 ,
p d w i th y
ro tar cutte rs,
p p ti f 3 7 2 ro or on s o r,
Wii t 58 s ,
9 1 , 92 G ti g by h bbi g 2 7 5 8 5 88
i i
Fr ct on o ftee th, 5
en era n
b y milli g 06 8 99
o n , , 2 ,
2

Furn aces fo r ha r en d i g n , 3 5
1
d ubl h li l g
o e- 9
n
e
,

ca
1 -1 0

ea rs, 2
, 2
0
m hi ac f w ne m g 9 or or e ars, 2 2,

95 2
fw m g
o or 91 e ars , 2

p i ipl f 92
r nc es o ,

g
Gan cutters, 8 3 Gl e aso nb l g f m pl
ev e 1 89 ear o r an er,
i g
Gash n tee th , 8 3 , 3 2 6 b l ge g ev e ti g m chi ar e n e ra n a ne ,
g
Gau es fo r cho r a tch , d l pi 29 2 63
 I ND EX 8
3 9

l
G easo n rul es fo r stren th of ears, 359 g g
ld
Go u 85 E erhar t ho bn mach n e , d bbi g i
2 85 Machi n e s fo r cutt n i g d ubl o e -he li l
ca
s ur p
ear cutt n mach n e, g i g i b l g 79 eve e ars, 1 1 82 ,
1 30 85 87 1 -
1
i
un v e rs a mach l i n e, 1 77 d ubl h li l pu g
o e -
e ca s r ea rs ,
Gran t s y s te m , 1 8
5 6 3 1 2 -1
Green w o o d Ba e ev e tl y b lg e ar p lan et s , fo r milli g w m 47 n or s, 1
206 i g
us n fo rm cutte rs , 1 09 , 1 4 6
Gr n ni di g g
ears , 34 3 Man ufacture of e ars, 308 , 34 0 g
b
ho s an d wo rms , 34 7 Master gears 2 32 ,

Materi al s fo r gears , 308

Metri c pi tches 2 5 ,

Milli n g be v e l gears , 30 1 -
3 5
0
l bl k 3
i
c rcu a r an s, 21
utt c 6 8 3 e rs , 10 -10
, 22

Hard e n i n g furn aces 3 1 5 g t i g 2 99

en e ra n
pu g
,

m hi u d f
,

Heald chuck s fo r gri n di n g 34 3 -

34 7 ac n es se or s r e ars , 1 32
d 4 6 14 7
,

Heat tre atmen t fo r steel s 3 1 3 w m th or rea s, 1 ,

Mi t g bl k 3
,

He li cal gears 56 re ea r an s, 22
M d ul pi t h
,

cut te rs fo r, 84 -8 6 o e 5 c e s, 2

d blo u e , mach n e s f o r cutt i i g

n M u t i g b l g b l k 83
o n n ev e ea r an s, 2 , 32 4
Mul tipl utt
,

I7 9 - 1 8 7 33
e c e rs , 1

i gl
s n e , 14 7 1 -
5 1
Hi n dl ey gear 63
g s h b bi g 9 8
,

ea r , o n , 2

H b d w m g i di g 34 7
o an or rn n ,

H bb i g d ub l h li l g
o n o e- e ca e a rs, 2 90 No i sy g ears 354
g 7 5 98
ears, 2 -
2 No rma l pi tch 4 8 S4
,

55 36 8 36 9
Hi dl y g
, , , :,
n 98 e ears , 2 No rmal s 3
p d d f d f 3 33
s ee s an ee s o r,
, S

H b utt
o c 9 9 00 ers , , 1
ti f 1 00
ac on o ,

c ti h b o rrec ve o s, 1 02

m ki g 0 1 3
bj ti t
a n , 1 2, 0
d g p
O on to ra hs , Will is s , 10
’

th Ch mb
o ec on s o , 1 0 1 , 10 2
lik b l g
O er o n e ve ear an e rs , pl 1 96

Hb t p
o s, 95 97
a
1 5
e r, 2
e a

, 2
on , 0
d i g
O il-har en n , 3 1 0
Hump g h b 104
a e o ,

P th f t t 4
a o co n ac 6
P t utt 97
, ,

In terfe ren ces in n vo utes , i l 14

e rro
Pit h h d l 8
c e r,

i g
In term tten t ears, 6 5
c , c or a
g ug
, 2
fo r,
In te rn a e v elb lg
e a r, 1 9 6
li
a es 29

g ears , 44 pi t
7 n es ,

mach i n es fo r cutti n , 1 4 2 g Pit h mp d 6

o n , 2

l
In v o ute curv es , i n terfe re n ce in , 1 4
c es co
di m t l 4 a e ra
are
2
, 2

t ee th , 1 , 6 , 7
,

m t i 5 e r c, 2
cutters f 80
m d ul
o r,
l
In v o utes , a pp ro x i mate co n struct o n s , i 5 o
m l 4 8 54 55 368 369
n or a
e, 2

, , 9
16
Pl i g g
, ,

an n ti g pu g
-
3
e n e ra n s r e ars , 2 I

pi l gs 5
ra ears , 1 2
t th 90 ee ,

w i th f m 88 or s, 1 -
2 12
d
Lea o fw o rm, 60 P u gl 6 4 3 6 7 3
re ss re an e s, 1, 2 1, 2 1, 2

P p ti f m 36
,

Lo e w e auto mat c i s pu r g ea r cutt n i g ro o r on s o r ar s, 2

i
mach n e , 1 1 8 P ro tracto rs, 3 3
2
390 GEA R C UTTING

ki g
Sto c n tee th , 32 6
g g
Stren th o f ears, 3 56
Qu ill g e ars, 1 3 2 d l d b l g
Sun er an ev e g ear e n era t n i g
i
mach n e, 2 58-2 6 3
Spur gearg i g m
en e ra t n ach n e , i
2 1 3- 2 2 0

R ac k-cutti g tt chm t 1 40
n a a e n s,
m hi 33 ac n es , 1 TA B L ES
h p d cutt
s a e 94 9 5 e rs, , Be ve lg f
ears, g l f 377 3 8 a ce an es o ,
-
0
too th cutte rs , 9 5
p i t h gl f 37 3 37 6
c an es o ,
-

k
R ac s, 51 Ch d l th ck
or a ft th 3 3
i n ess o ee , 0, 1
id g
R aw h e ears, 338 Ci culr pitch mp d w i th di
ar co are a

li
R e efo fcutte rs, 8 3 m t l pi tch 2 3
e ra ,

b
R o ey - Sm th i
ev e b l g
ear en e rat n g i g pi tch 2 es, 2
i
mach n e , 2 4 6-2 57 C utt p p d by Willi 79
ers ro ose s,
Ro nlli g b ev e ear l g bl k
an s, 8 9 Di m ta f pi l g
e e rs o 6
3 9 37s ra e ars, - 0
y
R o tar cut te rs an d fo rm an n co m pl i g Di m t l
a e ra d m d ul pi t ch
an m o e es co

p a re d, 9 9
1 , 2 p d 4 are , 2
di
R o tary sc cutters , 7 7 pi t h mp d w i th ci ul
c co are rc ar

di
R o un ng tee th, 3 34 , 336 pi t h 3 c , 2
Fc a e angl fb l g es o 377 3 80 e ve ears,
G t i
ran l utn vo e, 20
I h t mil l i m t
n c es o f cti 38 5 e res, ra o n s,

L i t fdi idi g pl t u d
s o v n R b y a es se on o e
l b
Sa t- ath furn ace , 3 1 8 3 20 -
Sm i th b lg g ev e t 55 ea r en era o r, 2
Schuchar t dSchutte ear-ho n g bbi g M d ulo d di m t l pi tch
e an m a e ra es co

i
mach n e , 2 88 -2 90 p d 4 are , 2
p
Sha es an d sizes o f n v o ute te eth , i l N tu l i
a ra tu l
s n e, i 38 na ra cos n e, 1,

382
i g
Sho rten n o fteeth , 4 2 , 2 4 2 t g t tu l c t ge t 38 3
an en , na ra o an n , ,

i gl d
S n e curve tee th , 1 , 6 , 7 384
i lg
hel ca e ars , 1 4 7- 1 51 P i tch gl fb l g
an es o 7
3 3 3 76 ev e ears, -

k b l
S ew eve s, 74 P i tch 3 4 es, 2 , 2
p ifi l
S e c cation s fo r s tee s , 3 1 3- 3 1 5 ci ul rc 3 ar, 2
p d d
S ee s an d fee s , 3 2 9 , 33 1 , 33 3 Sizi g n d cutti g fg
an 33 34 n o ears, ,

pi l g
S ra ears, 2 , 4 7 Sp d fee s utti g 33
or c n , 1
cu t t ers fo r, 8 4 Spi l g ra l i f 37
ears , re at o n s o ,
1
cu i g
tt n , 1 5 1 , 1 52 St gth d l i ty f t f
ren an ve oc ac o rs or

l
e e men t s , 4 8 - 56 g 3 6
e ars , 0
illi g
m n , 2 99 T th pi t h
ee f 2
c es o 2
p i g
, ,

l a n n , 1 52 T th p t f ci ul
oo ar s pi t h 36 8 or rc ar c es ,
pi l gl
S ra s , an es o f, 4 8 , 52 f di m t l pi t h or 6
3 7 a e ra c es ,
B ro wn p l
Shar e , fo rmuae fo r, 55 Wil f d L w i f t gth f g
re e s o r s ren o ears ,

diamete rs o f , 50

l
fo rmu ae fo r, 53 56 , 369 , 3 70 -
W m or d w m g
s an g p p or eari n ,
ro or

l i i
v e o c ty rat o s o f , 49 ti f 372
on s o ,

p
S ur an d eveb lg ea r cu tt ingmach n e , i T pe h b
a r o 95s, 2 97 , 2
1 6 5- 1 6 7 T th
ee ,
ti
co rrec f 17 ons o r,

gea r cu i g
tt n i
mach n e , 1 09 , 1 1 8 , curv e s o f 9
13 0 l id l 5 9
cyc o a , 1, ,

utti gc milli g m
n on n i
ach n e , face s ,5
3 1 2 fl k 5an s,
g t i g m hi
en e ra n ac n es, 2 13 f i ti
rc f 5
on o ,

231 m th d
e of utti gs o c n , 76
g ears , 2 o fb lg
ev e 68 ears ,

Ste e l p cifi ti
s e 3 3 3 5
1 1
ca o n s, -
h t i g f 4
s o r en n o , 2

Stee l ll y 3
s, a o , 10 i gl u d 1 6
s n e -c rv e , , , 7
Qh t t
ea tm t f 31 3
rea en o , t cki g 3 6
s o n , 2
Sto c ki g utt 8 3
n c e rs , Testin gg ears, 34 8
 I ND EX TO A D V ER TI SEMENT S

E . A R NO L D P O C HIN 8 B R O :
.

T HE C I TR O EN GEA R CO .
,
L MITED
I

DA R L ING SELL ER S, L IMl Th D

H WO O L L A CO TT
. 8: CO .

TU R B INE G EA R S, L IMITED
SMITH 8: CO V ENTR Y L IMITED
,

WHITELEY BR OS .

DA VID B R O WN SO NS, L IMITE D

NO EL P A T O N, L IM TED I

WM . SHA R PL ES CO .
, L IMITED
J. P A R K INSO N 8 :
SO N

B U FFO L INE NO ISEL ESS G EA R CO .

,
L IM TED
I

A UR O R A STEEL A ND I RON GEA R ING CO .

( WIL MO T NO R T H)
MECHA NICA L WO R L D
MEC HA NICA L WO R L D SER IES OF TEC HNIC A L B O O K S
 MA X I MUM EFFI C I ENCY

CA N O NLY B E O B T A INED FR O M

MO ST SUITA BLE MA TERIA L

BEST P O SSI
BLE WO RKMA NSHIP
MO ST A CCUR A TE SPECIA LISED PLA NT .

THESE WE HA V E ,

SA T ISFY A LL Y O UR R EQUIR EMENT S .

A NY K IND ; A NY MA T ER IA L ; LA R G E O R S MA L L

A RN N8: BRO
OLD POCIII
( Th e Gea r Firm )

3 0 TRA FFO RD P A RK , MA NCHESTER

“ in . PATENT A UTO SPUR GEAR OUTTI
. IIG MACHINE
There are features w hich giv e this
Machin e a distin ct l ead in its f
ield .

A SK U S A B O UT T HEM

We l l
a so sp ecia ize in

HIGH S P EED L A THE S

A ND

MIL L ING MA C HINE S

DA RLING 8: SELLERS L
KEI G HL EY
 Sp e e d in cre a s in g Ge a r w ith
- o
c v e rs
re m ov e d .R e gis t e re d D e s ign .

Se l f o
c n ta in e d R e ductio n Ge ars up to
5 000 H P. .

D o ubl e He licals an d S p ur W he e l s .

Se l f co n tain e d W o rm R e ductio n Ge a rs
fo r a n y p ow e r, fi tte d w ith P ate n t
W ate r cool e d W o rm W he e l
-
.

A D VICE O N GEA R DR IVES BY EX P ER TS

 Coors
ABc 5m E EBERS
n AND LI
.

MA C HINE O UT G EA R S OF EV ER Y D ESC R IP T IO N
.

SUNDEBLA N) PATEN
I TS

m msnows 3 sons Ld Hudde sfield , r

DOUBLE H
ELIGAL GEARS
O UT ON T HIS S YST EM

GI VEMAXI MUME
FFCI
I N
E GY
B EC A US E

The Teet h Con tours are gen erat ed

fro m the Basic Prin cip al o f th e Rack
whi ch b ec o me s t he A ctual Cut t er.

DBROW
DAVI N8 SON
S Ltd , .

HUD DERSFIEL D
FI NE G EA R S P EC I A L I S TS

Gears for Accurate and Delicate M achinery .

Motor Gears in Special Steel Case hardened and Heat-treated

,
- .

GEAR WORKS , DEWSBURY ROAD LEEDS

Te l .
—
332 C ENT R A L . R e g Te l
. . A dd .

HIGHGLASS -
TOOTHED GEARING .

M A C HINE C UT A ND MA C HINE MO U L D ED , IN IR O N, S T EEL,

B R O NZ E O R R A W HID E .

W E MA K E A NY S IZ E U P TO 20 FEET D IA MET ER .

Wheels .

P R IC ES R IG HT —
QUA L IT Y a s s ua s o .

S END Y O UR ENQU IR IES T O

WILLIAMSHARPLES [ TD
R A MS B O
'
IT O
'
M , M A NC H ES T E R
 o f e v e ry d e s c r i p t io n

in C A ST - IR O N, STEEL, G UN -
META L , e tc
.

RAW H
I DE AND PAPER PI NI ONS
WORMREDUCIN
-
D DOUBLEH
G AN E OAI GE
LI ARS .

V
E ER Y G EA R MA NU FA CTU R ED AT O UR OW N WOR KS

L E V ENSHU L M E , M A NC HESTER
 L a rgest Ezzgzheerzhg Circula tion

HE Mo st P ro gr e s siv e P r act ical

T
an d o urn al
J
O f Machin e C o n struct io n ,Me chan ical, Ele ctrical
an d Mo tiv e P o w e r En gin eerin g .

D e als w it h a w ide ra n ge of t o
p ics Of art icu ar
p l
in te rest to En gin ee rs ,
Machi ne To ol Mak ers ,

D raught sme n , e tc .

FUL LY IL LU ST RA T ED

Weekly — O NE Sp ecimen Post

A NNUA L SUB SC R IP T IO N

Ho me ,
Fo r e ign , P o st Fre e .

and P ubli c/ref s

’

P rop n etors

EMMO TT CO .
,
L IMIT ED

6 5 K IN G S T R E E T, M A NC HE ST E R
LO ND O N : 20 BEDFO RD ST R EET, WC . .