more expensive than hobbing.
17.1.4 Top generating — This is a fabrication option utilizing cutters that
finisb-.cut the outside diameter of the teeth simultaneously with the cutting of
the tooth profiles.
It can be used in both the hobbing and shaping processes, although more
prevalent in hobbing and among the fine pitches. The main advantages of topping
are:
1. Liberal tolerances can be applied to the outside diameter of the blank.
2. The deburring problem is reduced.
3. The gear can be nested on its outside diameter for machining modifications of the
body should such a speaal need arise.
17.2 Gear Grinding
Although grinding is often associated with quantity fabrication of high
quality gears as a secondary refining operation, it is also a basic process for
producing hardened gears. In addition, many high-precision fine-pitch gears have
their teeth entirely ground from the blank state.
Gear-tooth grinding can involve either form grinding or the generating
process. The latter is basically more accurate because the dressing of the
grinding wheel involves a straight-sided tooth.
There are a number of distinct advantages to ground gears. These are listed
as follows:
1. Achievement of high precision is possible because the process can remove very little
material in the final pass.
2. Grinding results in a much finer surface finish than any machining process.
3. Hardened steel alloys can be ground.
4. Residual surface stresses are minimal.
Being able to use heat-treatable hard steel alloys raises the bending stress
and surface endurance
stress levels by very significant amounts. See Table 1.23. Often it is the
difference between a reliable and unreliable gear. In particular, case hardened,
carburized or nitrided gears offer outstanding strengths and performance. They
are typically used for the most demanding tasks, such as aircraft drives.
Ground gears’ superior load carrying capacity is not only due to the
hardened alloys higher mechanical properties, but also because of the finer
surface finish. A fine finish enables maintenance of a good continuous oil film
versus boundary lubrication and breakthrough. The result is higher load capactry
along with reduced wear and longer useful life.
Although there are distinct advantages for ground gears, there are some
limitations and disadvantages. These are:
1. Grinding is limited to ferrous materials.
2. Hard metals grind better than soft ones.
3. Grinding of helicals and worms has limitations that possibly involve profile deviations
and removal.
4. Pro-grind hobbing requires special protruberance hobs to provide grind wheel
clearance at the root
5. Gear grinding machinery is scarcer than hobbing machines.
6. Grinding is a secondary operation which increases total gear cost
Despite involving higher cost and other limitations, ground gears are always
superior in precision
and strength.
T106