All cutting and machining operations produce some type of burr or leave sharp edges on metal components. These unwanted byproducts are especially troublesome when producing precision components such as gears. The burrs can loosen from
the gear - either during assembly or later when the gear is in operation - and damage components or lead to critical part failure.
Deburring or chamfering of gear teeth is gaining attention in practical settings. And with a view to make the production sequence as efficient as possible, it is becoming increasingly important to be able to implement the deburring tasks directly on the cutting machine after spiral cutting.
Chamfering and deburring of
cylindrical gears does not get
much love from manufacturers.
The process is seen as a necessary evil
since it is adding cost without adding
value. However, there are good reasons
for not underrating this important auxiliary
process. Chamfering and deburring
takes care of several issues which
may come up during the manufacture of
The objective, according to Dr.-
Ing. Hansjörg Geiser, head of development and design for gear machines at Liebherr, was to develop and design a combined turning and hobbing machine in which turning, drilling and hobbing work could be carried out in the same clamping arrangement as the hobbing of the gearings and the subsequent chamfering and deburring processes.
This report presents some interim results from an ongoing project being performed by INFAC, the Instrumented Factory for Gears. The purposes of this initial phase of the project were to demonstrate the feasibility of robotic automated deburring of aerospace gears, and to develop a research agenda for future work in that area.
The chamfering and deburring operations on gear teeth have become more important as the automation of gear manufacturing lines in the automotive industry have steadily increased. Quieter gears require more accurate chamfers. This operation also translates into significant coast savings by avoiding costly rework operations. This article discusses the different types of chamfers on gear teeth and outlines manufacturing methods and guidelines to determine chamfer sizes and angles for the product and process engineer.