Gears are used in a number of applications in manufacturing industries and used extensively in manufacturing machines that depends on them for their fundamental operations. Gear cutting is a process of gear manufacturing. The common processes involved in this are broaching, machining, hobbing, shaping, casting, extruding, forging etc. The materials used for making gears are wood, metal and plastic. Metals are shaped in appropriate sizes and dimensions with these gear cutters. Gear cutter can be of various shapes and sizes according to the requirement of the gear.
The important thing which is kept in mind during the making process that the fit between the gears should be proper and the teeth should be of good quality. Otherwise it will result in quick breakdown and inefficient energy transfer. Gear cutting is a popular way of making gears. Various types of cutters are used in creating gears such as rack shaper. These cutters are straight and move in a direction tangent to the gear. These cutters have six to twelve teeth. After completing the cut they move back to the starting point and begin another cut.
Other type of cutters is pinion shaped cutters. These types of cutters are used in gear shaper machine. These cutters are widely used in the large production units. Another type of cutters is known as hob. They cut the gear by their rotation. In the process the angle between the hob and the gear blank is set up at the minus 90. For this the lead angle of the hob thread should be known. These kinds of cutters is used in all most all the production units but considered best for medium to large size units. After cutting the gear various processes like shaving, grinding, lapping, burnishing etc. are applied for the finishing. Finishing provides smoothness and look to the gear.
There are other kinds of gear cutting tools also which are effectively used in most of the tool industries such as involute gear cutters, these cutters are very well known for producing quality gears. These are used when tooth finishing operation is not required. Involute gears bear a unique stud tooth that cuts all kinds of standard and non-standard involute splines.
Sprocket hobs also come in the category of gear cutter. These are used to cut roller chain sprockets which ranges between 1/4th inch to 3 inches pitch. Gear shapers are also taken as gear cutters which are used to provide appropriate cutting edge and clearance. Shaper cutters are considered as one of the best processes to create gears. Disc shaper cutters are highly effective to cut any type of gear. These are also used to cut sprockets, serrations and splines while to cut internal gears, shank type cutters are used.
Quality matters a lot in the gear cutting tools so a lot of concentration is given there while manufacturing. Various gear cutting tools are used for various purposes and from small to large production runs.
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