2013 PAPERS

13FTM01. Power Skiving of Cylindrical Gears on Different Machine Platforms

Author: H.J. Stadtfeld
Skiving is a cutting process which was first patented in 1910 as an efficient process to manufacture internal ring
gears. Like honing, Power Skiving uses the relative sliding motion between two “cylindrical gears" whose axes are
inclined. The skiving cutter looks like a shaping cutter with a helix angle for example, 20° different than the helix
angle of the cylindrical gear to be machined.
The skiving process is multiple times faster than shaping and more flexible than broaching, due to the continuous
chip removal in skiving, but it presents a challenge to machines and tools. While the roll motion between the
cutting edge and the gear slots occurs with the spindle RPM, the relative axial cutting motion is only about one
third of the circumferential speed of the cutter. The cutting components of rolling and cutting which result in a
“spiral peeling" are represented with the process designation skiving.
Because of the relatively low dynamic stiffness in the gear trains of mechanical machines as well as the fast wear
of uncoated cutters, skiving of cylindrical gears never achieved a breakthrough against shaping or hobbing until
recently. The latest machine tools with direct drive train and stiff electronic gear boxes present an optimal basis for
the skiving process. Complex tool geometry and the latest coating technology were required to give the soft
skiving of cylindrical gears a breakthrough. Gleason has developed a line of dedicated power skiving machines,
which apply solid HSS cutters for small to medium modules.
ISBN: 978-1-61481-058-2 Pages: 18

13FTM02. Performance and Technological Potential of Gears Ground by Dressable cBN Tools
Authors: J. Reimann, F. Klocke, M. Brumm, A. Mehr and K. Finkenwirth
Dressable vitrified bond cBN grinding tools combine the advantages of other common tool systems in generating
gear grinding. The cBN grains are a highly productive cutting material due to their high specific stock removal rate.
Vitrified bonds are dressable and thereby very flexible: By dressing different profile modifications can be set up
and constant gear quality can be guaranteed during the tool life time. Despite those technological advantages
there is only a small market distribution of these grinding tools due to high tool costs. Furthermore, only a few
published scientific analysis of generating gear grinding with dressable cBN exist. Especially, the influence of the
grinding tool system on manufacturing related component properties has not been analyzed yet. The research
objective of this report is to determine the advantages of dressable cBN tools in generating gear grinding.
ISBN: 978-1-61481-059-9 Pages: 12

13FTM03. Analysis of Gear Root Forms: A Review of Designs, Standards and Manufacturing Methods for
Root Forms in Cylindrical Gears
Authors: N. Chaphalkar, G. Hyatt, and N. Bylund
Gear root is an important but often neglected element of the gear. The stress concentration point typically lies in
the tooth to root transition area and it is this point that determines the life or the fatigue life of a gear in many
applications. Specific standards are in place on design of the involute part of a gear tooth, the root area however
is less standardized. New manufacturing methods enable the designer of gears greater latitude in the design of
strong alternative root forms. The standards on design and specification for the root geometry are lax so these
root forms fit into current standards.
This paper reviews the designs of various root forms for the gears. It compares the various root forms on basis of
their strength, fatigue resistance and other parameters. This analysis will be based on compilation of various
research previously conducted on gear root forms.
The paper also discusses current manufacturing methods to produce the roots, and recently introduced
alternatives. It will compare the traditional methods with new methods of gear manufacturing it terms of types of
roots produced and overall control over the root profile.
ISBN: 978-1-61481-060-5 Pages: 9

13FTM04. Best Practices for Gearbox Assembly and Disassembly

Author: J. Bello
When industry is looking at the best ways to increase efficiency, reduce downtime and increase profitability,
gearbox performance and reliability are key factors. In most applications gearbox reliability is critical to the
productivity of the overall plant operation. Repair is often required with a swift turn around, as down time is very
expensive. Designing for repair, and writing effective repair procedures, can speed the service time, and provide a
quality refurbishment. Minimizing down time and extending service life will contribute significantly to achieving the
lowest overall operation costs.

Obsolete documents should not be used; please use replacements. Most obsolete and superseded documents are
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AGMA Publications Catalog 70 April 2020