HOB SEMINAR

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▣Classification of Gear Cutting Tools▣

n CUTTING METHOD:
m Formed - [cutter profile =gear profile] :
- Milling cutter:
involute,spline(inv,parallel_side),sprocket,worm,
broach, gear endmill, serra. c/t
m Generated- [cutter profile ≠ gear profile] :
hob, pinion c/t ,shv c/t ,rack c/t,bevel gear c/t
n PLASTIC METHOD : generated -rolling dice

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▣Definition & Cutting Theory of hob▣

1. Definition
m External gear cutting tool
m Thread (such as worm shaft)
m Generating cutter

2. Cutting Generating Theory

m Tool turning - Gear fixing(SIMULATION )
m Tool fixing - Gear turning

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▣HOB’s CUTTING ▣
1. Lead Angle
2. Lead(L= starts×axial pitch) •RH HOB
3. Starts(1,2,3..)
4. Direction(LH,RH)

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▣S.T.D RACK&INVOLUTE GEAR CREATION▣

Sm = m Cosαn (π(Zm - 0.5)+Z INV αs)+2 xm Sin αn

Zm = αn Z /180 +0.5
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▣ Comparision of Modification Gear Shape▣

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▣Hob ’ NOMENCLATURE▣

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▣Hob’ Description & Type▣
m Hob material- HSS,POWDER_METAL,CARBIDE
m Structure- solid,built up,planted,stick hob
m Form - arbor(bore),shank
straight flute,helical flute,rake angle,one start,multi_start
m Name of gear-
involute,spline,serration,sprocket,timing
worm,cycloid,ratchet,sign curve,special(except pump...)
m Uses -roughing,finishing,pre-grind,pre-shaving ,semi
topping,topping,modified(BS1,2,w)
m Manufacturing-ground, unground
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▣HOB’S S.T.D PROFILE(involute) ▣

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▣ Nomenclature of Gear profile▣

LENGTH OF ACTION
RANGE OF INSPECTION

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▣Hob NT& Gear Surface Roughness ▣

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▣ Cutting Method of Hob ▣

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▣Comparision of CONVENTIONAL & CLIMB ▣

ITEM CLIMB CUTTING CONVENTIONAL CUTTING

Formulation of chip thicker chip thinner chip
Basic shape of chip same same
Friction force of cutting small big
The wear by sliding small big
The wear by cutting force big small
Hob profile roughness bad good
Workpiece helix angle less than25 is good over than25 is good
The most worn part of a hob left part right part
Cutting speed possible to increase impossible to increase
Cutting a huge gear possible impossible
The clamping condition of strong weak
a work piece
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▣ Consideration As Hob’Selecting▣
m Bore : Standard Table(inch,mm-H5 ISO tolerance)
m Out side dia. : Standard Table .( FOR MASS PRODUCTION :
( EX) M2.5-90x150Lx32-MULTIGASH(17-20))
m Total length : Standard Table or FOR MASS PRODUCTION
- 1.5-2times as long as Out side dia. (150-200mm ±0.8)
m Starts : 1 start -for finishing and with little teeth
multi_start(2STARTS ABOVE) -for roughing and semi-finishing.
(a prime number : relationship starts and gear teeth)
m NT : Standard Table or in case of multi_start select multi_gashed hob
m Rake angle : generally need not
m LA hand : gear helical hand = hob helical hand (RH-RH ,LH-LH)
m GL or not : AS over LA5 - HELICAL FLUTE.
m Class : DIN A(GEAR CLASS:JIS 4-5)
m Material : SKH55(HSS) OR ASP30(PM)- HIGH SPEED,HIGH POWER.
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▣How to Set Up ▣

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▣How to see DRAW. & SIMULATION ▣

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▣Basic formula of hob▣

m Normal Pitch = Mn x π (Mn : Normal module)

m Axial Pitch = Mn x π /COS LA
m Lead =Axial Pitch x STARTS
m LA =SIN -1 (Mn x STARTS/ HOB PCD)
m Cam Amount = Hob out dia. x π x TAN Cam Ang./HOB NT
[Cam Ang. : pa20-10˚, pa14.5-12˚, pa25-9˚]
m Groove Lead =HOB PCD x π / TAN LA
m Flute Depth =HOB tot. height+Cam Amount+1~1.5(as Mn)
m Hob S.relief Ang. =TAN -1 (TAN PA x TAN Cam Ang.)

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▣Hob’ Common Using▣
(the relation of chamfer,tooth thickness & wd )
•big In case of same size of tooth
thickness ,if a cutting hob with
many gear tooth cut a gear
with little tooth,
<--

the chamfer amount will be a

little than applying the
opposite case as mentioned
above
chamfer

•70T

•40T

•25T
little

•20T
•(-) 0 (+)-->modification coefficient

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 HOB의 주요 생산 공정
▣ Hob’ Processing (1)▣

1. BLANK 2. LATHE 3. Key 4.THREAD

5. FLUTE 6. RELIEF 7. DEBURRING 8. HEAT

MILLING THREAD TREATMENT

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 HOB의 주요 생산 공정
▣ Hob’ Processing(2) ▣

9. HARDNESS 10. INTERNAL 11.SHARPENIN 12. RELIEF TOOTH

INSPECTION GRINDING G FORM GRINDING

13.HOB’PROFILE 14.RUNOUT 15. COATING 16. MARKING

INSPECTION CHECK

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▣ Hob’ Heat Treatment ▣
•1180-1210c

•4M
•Quenching •880c

•530c
•500-600c
•8M

•8M
•1-2H
•Pre-heating
•Pre-second heating •SALTed furnace.
•with electric with medium temper. •MAR Q furnace.
•50-60c
furnace.

•Tempering(SALT Q4)
•560c •560c •560c

•2H •2H •2H

•300-380c •300-380c •300-380c

•30- •first •30- •second •30- •third

40M 40M 40M •상온

•HIGH SPEED STEEL -3 CYCLE FOR TEMPERING

•POWDER METAL -4 CYCLE FOR TEMPERING
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▣Hob’s Coating▣
m CVD(chemical Vapour Deposition) -- 900-1000c carbide coating
m PVD(physical Vapour Deposition) -- 550c HSS, Powder metal coating
m Description(kind)
1)TIN : tenacity.wear-resistance,anti-corrosion,non-melting, lubrication.- HV2300-1 layer
2)TICN : high speed ,high power 12 layer - HV2700
3)TIALN: surface AL2O3 layer
high speed -high revolution(HV3000) -dry coating
m Characteristics
1)high -hardness 2)precision keeping (0.002~0.003mm)
3)gold color without brilliance 4)wear resistance
5)anti-corrosion 6)cutting force -low
7)high quality.
m Advantage (merit)
1)long life(first time8-10times, after resharpening 3-4times) 2)increased productivity
3)reduction of cycle time 4)saving cost

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▣Certification of hob quality(PNC33)▣

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▣ Resharpening Error of Hob ▣

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▣ Hob’ Cutting speed ▣

m Cutting speed V= πDN/ 1000 (m/min)

D: Hob out dia. N: Revolution(rpm)
m Factor of Cutting speed
1)Workability of material
•Feed
2)The module of gear
•finish:0.8~2.5mm/rev
3)Cutting depth •rough : 2.5~5mm/rev

4)Gear class
starts feed cycle time
5)Hob’s condition 1 1 1
2 0.8 0.63
6)Hob’s material 3 0.55 0.61
4 0.42 0.59
7)Required cutting cycle time per piece 5 0.35 0.57
6 0.3 0.55
8)Machine rigidity
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▣ Hob life & Cycle Time▣
m Hob Shift
The most serious wear part of a hob is the edge of the hob because the hob start to cut from the edge
of hob addendum.By shifting the hob to axial direction,the wear amount can be distributed.So the tool
can be used efficiently.
STRAIGHT FLUTE SHIFT(mm)= M xπx (Zh) HELICAL FLUTE SHIFT(mm)= M xπx (Zh)xCOS LA
NTxCOS LA NT
(M:MODULE,NT:HOB NT,LA:HOB LEAD ANGLE , Zh:hob STARTS)

m Cycle Time
Increasing RPM for high productivity
T(MIN) = ZxL
RPMxFxZh
(Z:gear teeth, L:HOB moving distance(mm), RPM:HOB revolution, F:feed(mm/rev), Zh:hob starts)

m HOB Life
Shows hob life as cutting length (100M)
L(M) = Zxbxnxi
1000
(Z:gear teeth,b:tooth width(mm), n:cutting amount/1cycle, i:the number of resharpening)

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