Hobbing Aplications

Hobbing Applications
Presented by:
Gleason Cutting Tools

Corporation
1 / CDG / Master Slides / Christian Albrecht

Topics for discussion
•Systematic Approach to Optimize

•Hob Opt Program
•Tool Design Considerations
•Opti-Gash® Program

Systematic Approach
•Full understanding of current process parameters

•Costs
•Failure modes
•Set goals - What do you want to achieve?

Types of Tooth Wear
Periphery Wear Corner Wear
Chipping
Cratering
Gouging
Lower Flank
Wear

Hob Opt Program
•Program to determine fastest cycle times

•Looks at 20 various hob diameter options
•Machine constraints
•1 - 5 thread designs
Gear School 5
Climb Hobbing
 Climb Hobbing - Feed up through part.

 Chip starts out thick and gets progressively thinner near root
 Tends to increase rigidity of part clamping
 Possibility to pressure weld chips

Conventional Hobbing
 Conventional Hobbing - Feed down through part

 Chips start out thin and get progressively thicker
 Reduces tendency for pressure welds to occur

Common Multiple Ratio Example 22Teeth, 4 threads
Thread 1 & 3
22 tooth gear (red & orange)
are associated
with every other
4 thread hob space.
Thread 2& 4
(blue and tan) are
associated with
the other spaces.

Prime Ratio Example 21Teeth, 4 threads - AKA “Hunting Tooth” ratio
21 tooth gear
Each hob thread
becomes associated
with each space in
4 thread hob the gear.
Each revolution of
the gear associates
the next thread into
the next adjacent
space

Feed Marks from Hobbing

Even and Prime Ratio Scallops
Feed marks cut with a two thread hob,

cutting an even ratio number of part
teeth. One thread stays in same
space.
Feed marks cut with a two thread hob,

cutting a non even ratio number of part
teeth. Each thread cuts in each gear
space.

Index errors with multi- thread hobs
If the number of threads is evenly divisible into the

number of part teeth, a repetitive index error pattern
can develop, as shown above.
The pattern is approximately equal to the thread to
thread error in the hob.

Feed Scallop, 3 thread hob, Prime ratio
With a prime ratio, all threads go through all spaces. Therefore each thread
makes a scallop along the lead.
A lead check of one side of a tooth is shown above.
If one thread is thicker or out of position to another it will make the deeper
scallop, such as thread # three above.
(With an even ratio, the thread to thread hob error is not imparted into the part
lead, since each thread associates with its own spaces)

Summary Multiple Thread Hobs
 Multiple thread hobs have advantages when used

properly
 Remember - Thread spacing errors in a hob come from 3

things:
 accuracy of the hob
 mounting error
 sharpening error

Optigash® Program
 Allows you to look at costs associated with hobbing

 Calculations of cutting parameters
 Tool life factor
 Shift strategy
 Feed rate - chip thickness - scallop size
 Climb vs. Conventional
 Power consumption
 Material removal rate

Hob Opt Inputs (Finish)
General Data: 2/1/02 0:00

Customer Gear School Example
Part # 99 Tooth Gear
4140 Mat'l
Work: 285 Bhn
Gen. N. Module 1.0106 mm 25.1336 ndp
# of teeth 99 teeth 99 teeth
Gen. NPA 20 deg 20.0000 deg
Helix angle 0 deg 0.0000 deg
Outside diameter 102.050 mm 4.0177 inch
Face width 25.4 mm 1.0000 inch
Profile x-factor 0 0.0000
Addendum + dedendum 2.3292 mm 0.0917 inch
Max. scallop height on finished flank 0.0020 mm 0.0001 inch

Hob Opt Inputs (Finish cont.)

Hob Opt Inputs (Finish cont.)
Machine Constraints
Max hob spindle rpm 900 RPM

Max table rpm 125 RPM
Max Hob O.D. 85 mm 3.3465 inch
Material Specifications
Material from table 8 Bhn Range
8 Chrome-Moly stls, 41XX, 190 to 320
Brinell Hardness within range shown 285 Bhn
%Machineability Rating 52 %
SMM uncoated tool (guideline for above) 62.53 SMM 205.1 SFM
K factor (speed multiplier for coated tool) 1.2833
SMM coated tool (guideline for above) 80.25 SMM 263.2 SFM
Above speeds are conservative recommendations for M35 material, uncoated or TiNite coated.
Performance factors can be applied to this speed to reflect other hob materials or coatings. This should be
considered a starting point for speed, which can be adjusted based on wear observed. Operating parameters
from current successful applications should be taken into consideration to establish the speed to input under
"Process Data" section above.

Hob Opt Cutting Time (Finish)

Hob Opt Inputs (Pre-Grind/Pre-Shave)
General Data: 2/1/02 0:00

Customer Gear School Example
Part # 99 Tooth Gear
4140 Mat'l
Work: 285 Bhn
Gen. N. Module 1.0106 mm 25.1336 ndp
# of teeth 99 teeth 99 teeth
Gen. NPA 20 deg 20.0000 deg
Helix angle 0 deg 0.0000 deg
Outside diameter 102.050 mm 4.0177 inch
Face width 25.4 mm 1.0000 inch
Profile x-factor 0 0.0000
Addendum + dedendum 2.3292 mm 0.0917 inch
Max. scallop height on finished flank 0.0020 mm 0.0001 inch

Determined hob data:

Min. outside diameter 40 mm 1.575 inch
Max. outside diameter or diameter increment amount 5 mm 0.197 inch
Max. lead angle 10.0 deg 10.000 deg
Min. sharpenable life 5.1 mm 0.200 inch
Designed side clearance angle 3.5 deg 3.500 deg
Process data:
# of cuts 1 cut 1
Cutting speed 1st cut 90 m/min 295.2 sfm
Cutting speed 2nd cut 90 m/min N/A sfm
Radial stock for 2nd cut 0 mm N/A inch
Max. scallop height 1st cut of 2 cut cycle 0 mm N/A inch
Max. tip chip thickness 0.203 mm 0.0080 inch
Max. axial feed 99 mm/rev 3.8976 inch/rev
Process same hand 1
Machine: P200 5

Machine Constraints
Max hob spindle rpm 900 RPM

Max table rpm 125 RPM
Max Hob O.D. 85 mm 3.3465 inch
Material Specifications
Material from table 8 Bhn Range
8 Chrome-Moly stls, 41XX, 190 to 320
Brinell Hardness within range shown 285 Bhn
%Machineability Rating 52 %
SMM uncoated tool (guideline for above) 62.53 SMM 205.1 SFM
K factor (speed multiplier for coated tool) 1.2833
SMM coated tool (guideline for above) 80.25 SMM 263.2 SFM
Above speeds are conservative recommendations for M35 material, uncoated or TiNite coated.
Performance factors can be applied to this speed to reflect other hob materials or coatings. This should be
considered a starting point for speed, which can be adjusted based on wear observed. Operating parameters
from current successful applications should be taken into consideration to establish the speed to input under
"Process Data" section above.

Hob Opt Cutting Time (Pre-Grind/Pre-Shave)

Machinability Graph

Speeds Graph

Cutting Speed guidelines 8620 at 180 - 200 BHN
Think Chip Thickness vs. Axial Feed Scallop Depth
Cutting Speed Is In Surface Meters Per Minute
Note: Carbide is not a logical choice for a pre-finishing process because you
most likely would exceed chip thickness of 0.15 mm before you create a flank
scallop depth of 0.015 – 0.020 mm. So faster cutting speed does not necessarily
mean a shorter cycle time while the
carbide hob is 2-3 times more expensive
than a G 50 / REX 76 Tool
120-130 SMM 150 - 180 SMM

Speed Surface 250-300 SMM
Rex 76 TiAlN REX 76 Dry
Meters / Min. Carbide
Coated AlCrN Coated
Chip Thickness, 0.20 to 0.25 0.20 to 0.25 0.05 to 0.15

mm mm mm mm

26
Process Optimization
MOST
ECONOMICAL
COST PER PIECE
PROCESS TOTAL
COST
MACHINING
COST
TOOL COST
MACHINING RATE

Tool Configuration
14 Gashes
.530 Life
35 Sharpenings
Finish vs. Pre Finish
Part Quality vs. Scallop Depths
Number of Threads vs. Part # T
Diameter - # Gashes
24 Gashes
Gash Size .230 Life
-Chip Flow vs. EOL Strength 15 Sharpenings
-Hook Sharpening
-Spiral Gash
Evaluate Static and Dynamic

Cutting Clearance

Hobbing Times
Time 34.51 min.

100%
Time 30.03 min.

87%
Time 25.79 min.

75%
29 / CDG / Master Slides / Christian Albrecht 29

Hobbing Times
Time 10.89 min.

100%
Time 8.27 min. Time 8.27 min.

76 % 76 %
Time 6.18 min.

56.8%

30
Hob Tool Life Variables
 Tool Material, Hardness, and Coating

 Part Material and Hardness
 Hob Speeds and Feeds
 Hob Shifting Procedure, # of passes
 Heat dissipation
 Hob Clamping
 Chip evacuation
 Wear Criteria
 ??? LM/T is achievable

Tool Life Measurement
Evaluate in Terms of :
Linear Meters Per Hob Tooth

or
Linear Inches Per Hob Tooth
Not in terms of Parts / Sharpening !

Meters Per Hob Tooth [or Inches / Hob Tooth]
 Calculate The Linear Meters [or Inches] of Gear Teeth

 Calculate The Usable Number of Hob Teeth
 Estimate the Parts/Sharpening for a given Life Factor

 or
 Determine the Life Factor for a given Parts/Sharpening
* Life Factor: 2-6 Meters/Tooth or 80-250 Inches/Tooth

Linear Meters of Gear Teeth
= N x NPPC x FW / Cos (HA)
 N = Number of Gear Teeth

 NPPC = Parts/Cycle
 FW = Face Width
 HA = Helix Angle

Usable Number of Hob Teeth
= (USELEN / NCP) x FLUTES
 USELEN = Usable Length of Hob

= [Length between Shift
Limits]
 NCP = Normal Circular Pitch
 FLUTES = Number of Flutes or
Gashes in the Hob

Parts/Sharpening
= LF x USEN x NPPC / LIN
Life Factor
=LIN x PARTS / (USEN x NPPC)
 LF = Life Factor
 USEN = Usable No. of Hob Teeth
 NPPC = Parts/Cycle
 LIN = Linear Meters
 PARTS = Parts/Sharpening

Example Hob Print and Calculating The Number Of Useable Number Of Teeth
If you do not have a hob to count the

number of teeth in a gash you can
divide the useable width of the hob by
the axial lead (.241797” in this case)
and then drop one tooth from each
end. Those two teeth are most likely
incomplete and will not produce a
quality involute. So, the width is 2.25”
divided by .241797” = 9.3 teeth.
Dropping out 2.3 teeth you end up
with 7 usable teeth per gash. 14
gashes time 7 equals 98 teeth in this
hob.

37
Example Of Cutting Tool Life Calculation or Estimation
-This example gear has 46 teeth and a facewidth of 30.5

mm at a helix angle of 29.5 deg. The actual facewidth is
30.5 mm divided by the cosine of a 29.5 deg. helix .8703
results in an adjusted facewidth length of 35.045 mm.
-Each gear has a total linear mm length of 1612.07 mm (46

x 35.045 = 1612.07 mm)
-If the customer is able to cut 200 parts per sharpening they
are obtaining 3.29 meters per tooth of this hob. 200 x
1612.07 = 322,414 linear mm cut. Divide this number by 98
teeth in the hob results in 3,289 mm, 3.29 meter per tooth of
hob
- We need to stress that the base line for pulling the hob
needs to be understood. For example, did they decide to
pull the hob for loss of involute or verifiable wear or? Not
just that we always pull the hob after 8 hours of use.

38
Shifting Strategies for Wet vs. Dry
Single Pass Incremental shift for wet
• Multi-pass Circular Pitch shifting for Dry

• Offset after each pass, NCP/# passes
• Observe wear development
NCP NCP NCP NCP

The Generating Process of Hobbing
GEAR
Hob Base
Pitch
HOB

40
Shift Direction
 2 Options
 Shift in the direction that unused sharp teeth move
first into the finishing zone, then the roughing zone.
Good for finishing hobbing were surface finish is
important. Shift against the rotation of the part. This
is recommended.
 Shift direction such that unused sharp teeth move first
into the roughing zone, then into the finishing zone.
This would produce honed or dulled teeth producing
the finished profile. Shift with the rotation of the part.

Feed Rate
 Many factors go into determining feed rate.

 Hob Material, Design
 Application - Finish or Pre-Finish
 Part Quality
 Limiting Factors
 Chip thickness - HSS .008 - .012”, Carbide .006”
 Scallop size
 Machine Constraints
 Material removal rate
The definition of feed in gear hobbing is the advance of the hob along the gear
axis in one revolution of the gear. Usually labeled IPR, inches per revolution.

Machine Considerations
 Small hob diameters are used to increase hob speed, therefore

high speed hob heads may be required. (Verify Max hob speed)
 If cutting small number of teeth, table speed can be quite high

when using multi-thread hobs. (Verify max table speed.)
 More threads increases the chip thickness and therefore the

load on the machine. (Verify Kw or HP capacity of hob head
motor.)
 The higher load requires a rigid setup. Hob and part clamping
must be accurate and rigid.
 Due to addition of thread to thread feature, the hob must be

ground, and maintained accurately. Accurate mounting on the
machine is critical.

Tool Wear Criteria
 Maximum Allowable Amount of Wear should be established

and the hob sharpened when the wear reaches the established
limit
 0.10mm [0.004”] Wear for Carbide is Recommended.
 0.15mm [0.006”] Often Used in the Field
 Same guideline for Dry HSS tools
 Wet HSS up to .254mm [.010”]

Conclusion
 Multi-thread hobbing can be

a key factor in optimizing a
process.
 Careful consideration of the
variables of the hob, part,
machine and process, will
help assure a successful
implementation of multi-
thread hobbing.
 The affect on finished part
quality must be determined
and accuracy of the hob, hob
mounting and hob
reconditioning controlled.

Elements of Inspection Charts
DIN / ISO / AGMA 2015 - A fH

Lead & Profile
Lead
Evaluation Range
fHß = Angle Error
Full Tooth Profile

Face Width
f fß = Form Error
Fß = Total Error
or
ff
Profile
fH = Angle Error
ff  = Form Error
F = Total Error F

46
Pressure Angle
Tangent Line
P. A.
P. A.
P.L. P.D.
•
RACK
GEAR
Radial Line

47
3 mm 5 mm 7 mm
Note the length of the base of the right triangle changes with
the pressure angle. We will see later the significance of this
change to the quality of the involute form error ff alpha when
machining low numbers of teeth (15 and less spurs) with a
higher pressure angles, 19 and higher

Each tooth of the hob makes a flat cut with an accumulation

of these cuts making an involute curve.
First two gashes cutting

roughing zone

49
Chip size
and shape

50
The Generating Process of Hobbing - Roughing
“Roughing Zone”
Leading corner
removes most
of the material

51
Are they moving, or stationary?

52

Hobbing Aplications

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Hobbing Aplications

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Hobbing Applications

Gleason Cutting Tools

1 / CDG / Master Slides / Christian Albrecht

•Systematic Approach to Optimize

2 / CDG / Master Slides / Christian Albrecht

•Full understanding of current process parameters

•Set goals - What do you want to achieve?

3 / CDG / Master Slides / Christian Albrecht

Periphery Wear Corner Wear

4 / CDG / Master Slides / Christian Albrecht

•Program to determine fastest cycle times

 Climb Hobbing - Feed up through part.

6 / CDG / Master Slides / Christian Albrecht

 Conventional Hobbing - Feed down through part

7 / CDG / Master Slides / Christian Albrecht

8 / CDG / Master Slides / Christian Albrecht

9 / CDG / Master Slides / Christian Albrecht

10 / CDG / Master Slides / Christian Albrecht

Feed marks cut with a two thread hob,

Feed marks cut with a two thread hob,

11 / CDG / Master Slides / Christian Albrecht

If the number of threads is evenly divisible into the

12 / CDG / Master Slides / Christian Albrecht

13 / CDG / Master Slides / Christian Albrecht

 Multiple thread hobs have advantages when used

 Remember - Thread spacing errors in a hob come from 3

14 / CDG / Master Slides / Christian Albrecht

 Allows you to look at costs associated with hobbing

15 / CDG / Master Slides / Christian Albrecht

General Data: 2/1/02 0:00

16 / CDG / Master Slides / Christian Albrecht

17 / CDG / Master Slides / Christian Albrecht

Max hob spindle rpm 900 RPM

Brinell Hardness within range shown 285 Bhn

18 / CDG / Master Slides / Christian Albrecht

19 / CDG / Master Slides / Christian Albrecht

General Data: 2/1/02 0:00

20 / CDG / Master Slides / Christian Albrecht

Determined hob data:

21 / CDG / Master Slides / Christian Albrecht

Max hob spindle rpm 900 RPM

Brinell Hardness within range shown 285 Bhn

22 / CDG / Master Slides / Christian Albrecht

23 / CDG / Master Slides / Christian Albrecht

24 / CDG / Master Slides / Christian Albrecht

25 / CDG / Master Slides / Christian Albrecht

120-130 SMM 150 - 180 SMM

Chip Thickness, 0.20 to 0.25 0.20 to 0.25 0.05 to 0.15

26 / CDG / Master Slides / Christian Albrecht

27 / CDG / Master Slides / Christian Albrecht

Part Quality vs. Scallop Depths

Number of Threads vs. Part # T

Evaluate Static and Dynamic

28 / CDG / Master Slides / Christian Albrecht

Time 34.51 min.

Time 30.03 min.

Time 25.79 min.

29 / CDG / Master Slides / Christian Albrecht 29

Time 10.89 min.

Time 8.27 min. Time 8.27 min.

Time 6.18 min.

30 / CDG / Master Slides / Christian Albrecht

 Tool Material, Hardness, and Coating

31 / CDG / Master Slides / Christian Albrecht