Created on 2025.09.02
Gear shaper
Gear shaper is a gear processing machine tool that primarily uses the reciprocating cutting motion of a gear shaper and the meshing motion of the workpiece and cutter to produce tooth profiles on various types of gears, including internal and external gears, racks, and sector gears. It is particularly adept at processing internal gears and duplex gears (structures with very close spacing between adjacent gears), which are difficult for hobbing machines to handle.
The gear shaper's machining process relies on four coordinated motions, simulating the meshing transmission of a pair of gears to produce precise tooth profiles:
- Main Motion (Cutting Stroke)
The gear shaper cutter performs a high-speed, up-and-down reciprocating motion along the axial direction, cutting the workpiece material with its cutting edge. This is the core motion for material removal.
- Generating Motion
The gear shaper cutter and workpiece rotate synchronously according to the gear meshing ratio (e.g., if the cutter has Z1 teeth and the workpiece has Z2 teeth, the speed ratio is Z2:Z1). This ensures that the cutter's tooth profile is gradually "copied" onto the workpiece, forming a standard tooth profile. 3. Radial Feed
In the initial machining process, the gear shaping cutter feeds slowly along the radius of the workpiece until the cutting edge reaches the root depth. The radial feed then ceases, leaving only the main and generating motions.
- Circular Feed
The minute amount of circumferential rotation of the workpiece (or cutter) with each reciprocating stroke of the gear shaping cutter determines machining efficiency and tooth surface roughness (the smaller the feed rate, the smoother the tooth surface).
- Wide Processing Range: It can process internal and external gears, racks, and sector gears. It is particularly suitable for internal gears that cannot be machined using a gear hobbing machine (because the hobbing cutter must cut from the outside and cannot penetrate deep into the internal hole).
- High Processing Precision: It can achieve tooth profile accuracy of IT6-IT8 (precision grade), with tooth surface roughness Ra values as low as 1.6-3.2μm, making it suitable for applications requiring high tooth surface finish.
- Relatively Complex Structure: Compared to gear hobbing machines, these machines require synchronized control of multiple motions, particularly the high precision required for the generating motion. Consequently, their manufacturing costs and maintenance requirements are slightly higher.
- Moderate Efficiency: The primary motion is reciprocating (not continuous rotary cutting), resulting in slightly lower processing efficiency than gear hobbing machines. However, they offer advantages in processing high-variety, low-volume production or specialized gears.
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