Chamfer Cut Method of Cylindrical Gear Based on Tooth Profile Generated by Cutter Edge with Two-parameter

doi:10.3901/JME.2025.05.191

Abstract

Abstract: The process of gear chamfering is widely employed in manufacturing to effectively eliminate or roll sharp edges from gear parts using a specialized cutter, thereby reducing burrs and minimizing stress concentration damage on the tooth surface. In recent years, gear chamfering has become an essential step in high-performance gear manufacturing for new energy vehicles. A chamfer cut method for cylindrical gears is proposed based on the principle of tooth profile generation by a cutter edge with two-parameter. By establishing a geometric model of the tooth profile generated by the cutter edge with two-parameter, we calculate the chamfering cutter edge and analyze its influence on the results by considering its relationship with the sweeping surface of cutter edges and the gear tooth profile. A numerical method is proposed to analyze involute helicoids of the chamfering cutter without cutting interference. Additionally, how variations in regrinding thickness can affect chamfering consistency by developing a mathematical model for regrinding cutters is discussed. Finally, simulation and experiment verify that the proposed gear chamfering method is feasible. The results provide both theoretical support for optimizing cylindrical gear chamfering processes and guidance for designing chamfering cutters.

Key words: cylindrical gears, meshing theory with two-parameter, gear chamfering, tool design

CLC Number:

TG61

GUO Erkuo, ZHANG Hongchuan, ZHOU Yihan, CHEN Ming. Chamfer Cut Method of Cylindrical Gear Based on Tooth Profile Generated by Cutter Edge with Two-parameter[J]. Journal of Mechanical Engineering, 2025, 61(5): 191-201.

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