Abstract: A method for the precision machining of flanks of gear-wheel-shaped workpieces, in particular those with convex teeth, using an internally toothed tool with crossed axes, in which simultaneous relative movements take place not only in three mutually perpendicular axes but also around an axis perpendicular to the cross-axes angle such that not only the tooth flanks of the tool and the workpiece have tangential contact with one another but also the base body of the tool and of the workpiece touch one another at a point of contact IV of which the position changes continuously, and a straight line g orthogonally penetrating the base body of the tool and the base body of the workpiece at the point of contact not only intersects the axis C.sub.1 of the workpiece or of its base body and the axis C.sub.2 of the tool or its base body (points III, II), but also passes through the center I of an ideal sphere K.sub.1 which adapts itself to the base body of the workpiece at the point of contact IV.

Abstract: A method of determining backlash wherein one member of a gearset is rotated in a first direction and rotary positions are recorded at predetermined increments. The rotary positions of the other member of the gearset are recorded simultaneously with those of the one member. The direction of rotation of the one member is reversed and rotary positions are recorded at the same increments while simultaneously recording the rotary positions of the other member. The difference in recorded positions for the other member are calculated thus representing the amount of gearset backlash.

Abstract: A method of determining a contact pattern representative of the contact patterns on successive gear teeth. The method comprises providing a first digital image comprising actual drive side or coast side tooth surfaces comprising contact patterns of a plurality of successive gear teeth, and, providing a second digital image comprising one of respective drive side or coast side theoretically correct tooth surfaces of the same successive gear teeth. Each theoretically correct tooth surface is represented by a matrix grid comprising a plurality of grid elements. The theoretically correct tooth surfaces are superimposed on the respective actual tooth surfaces image to congruently match the actual tooth surfaces image to the respective theoretically correct tooth surfaces. The grid elements of each theoretically correct tooth surface which contain at least a portion of a contact pattern image are then identified.

Abstract: Apparatus capable of performing wet and dry machining processes such as a hobbing machine for producing spur and helical gears, shafts, splines, and the like, by wet and dry hobbing methods. The apparatus comprises means to remove metal chips resulting from the wet and dry machining processes from the apparatus via respective independent wet and dry chip outlets. The chip removal means comprises a transfer means located in the machine base with the transfer means being reversible in direction in order to convey metal chips, emanating from the machining process, to the respective wet or dry chip outlet. The chip removal means enables metal chips from wet machining processes to be conveyed to and discharged from an outlet in one side surface and metal chips from dry machining processes to be conveyed to and discharged from an outlet in another side surface.

Abstract: A method of dressing a threaded grinding wheel comprising rotating the grinding wheel and dressing tool about their respective axes and bringing the tool into contact with a point on a flank of the grinding thread. The dressing tool is traversed along the width of the grinding wheel with the dressing tool maintaining contact with the point during the traversing to remove stock material at the point on the flank along the width of the grinding wheel. The method includes controlling the amount of stock material removed by the dressing tool during the traversing at the point whereby different amounts of stock may be removed in different axial sections along the grinding wheel width at the point thus varying the grinding profile at each section at the point of contact. The tool is traversed at successive points along the grinding thread profile to produce a different grinding profile at each section of the grinding wheel. A method of grinding spur and helical gears is also disclosed.

Abstract: A front-loading rotary ring cutter for face milling or face hobbing processes wherein the cutter ring is secured to the cutter head by means which eliminate the need to remove the entire cutter assembly from the spindle of a machine tool when changing cutter rings. Preferably the cutter ring includes a radially inward extending base portion through which mounting screws may pass to engage the cutter head for securing the cutter ring to the cutter head. The cutter assembly may also include an adapter plate for attaching the rotary cutter to a machine spindle.

Abstract: A lapping compound mixing and supply system wherein lapping compound is recirculated to the mixing vessel when not supplied to the lapping chamber of a machine tool such as a gear lapping machine. Lapping compound is pumped at about a first range of pump speeds to the lapping chamber, however, when no lapping is being performed, lapping compound is pumped at about a second, decreased range of pump speeds through a recirculating conduit and introduced into the mixing vessel along the conical bottom surface of the vessel. The introduction of lapping compound in this manner, along with the action of an rotating impeller in the vessel, provides improved mixing of the lapping compound and homogenizes the temperature thereof.

Abstract: A method of sharpening face-sharpened cutting blades for gears and the like comprising engaging a rotating grinding wheel and the cutting blade in a manner whereby the grinding wheel traverses across the cutting face along a grinding path wherein at least a portion of the grinding path is defined by a feed vector directed generally toward the cutting edge, with respect to the axis of rotation of the grinding wheel. The feed vector comprises components of (1) a first axis located in the sharpening plane and extending substantially perpendicular to the top of the cutting face, and, (2) a second axis located in the sharpening plane with the second axis being substantially perpendicular to the first axis. Preferably, the feed vector is directed perpendicular to the cutting edge.

Abstract: A method of sharpening cutting blades of the type made from bar stock type material, the method comprising producing relief surfaces on the cutting profile surface. The method comprises forming first and second relief surfaces on the cutting profile surface. The first relief surface extends from a location inward of the cutting edge to the back face and is oriented at a first relief angle with respect to a side surface. The second relief surface extends from the cutting edge to the first relief surface and is oriented at a second relief angle with respect to the side surface with the second relief angle being smaller than the first relief angle. The cutting blades may comprise a uniform cross-section and the cutting profile may include a protuberant portion adjacent the top surface of the cutting blades.

Abstract: A universal cutting blade blank and cutting blades formed therefrom. The front face of the blank and blade comprises a pair of mounting surfaces with a front rake surface and connecting surface located therebetween. The cutting blade formed from the blade blank is more stable in a cutter head during cutting operations such as in the production of gears and related toothed articles. A single cutting blade blank can be used for forming inside and outside cutting blades regardless of the direction of cutter rotation.

Abstract: Disclosed herein is a method of truing and angling the blades of a form-relieved face mill cutter during the blade sharpening process thus eliminating a separate time-consuming procedure for truing and angling. The position of the cutting edge of each blade is determined and a reference blade is selected. The sharpening plane of each remaining cutting blade is repositioned, if needed, such that after removing stock material from the blades in accordance with the newly repositioned sharpening plane, the cutting edge of each blade will follow essentially the same path when the cutter is rotated about its axis.

Abstract: Disclosed herein is a process for feeding a tool relative to a workpiece in a machining process such as a process for forming bevel and hypoid gears. The method comprises feeding the tool from an initial contact position with the workpiece to a full depth position in the workpiece along a feedpath at least a portion of which is defined by a feed vector having at least two feed vector components lying in an axial plane. The first feed vector component being substantially in the direction of the axis of a theoretical generating gear and the second feed vector component being substantially in a direction perpendicular to the generating gear axis. The feed vector may include a third feed vector component lying in a normal plane. With this feedpath undesirable tool shifting and workpiece spiral angle changes are significantly reduced.

Abstract: A method of sharpening cutting blades of the type made from bar stock type material, the method comprising producing relief surfaces on the cutting profile surface. The method comprises forming first and second relief surfaces on the cutting profile surface. The first relief surface extends from a location inward of the cutting edge to the back face and is oriented at a first relief angle with respect to a side surface. The second relief surface extends from the cutting edge to the first relief surface and is oriented at a second relief angle with respect to the side surface with the second relief angle being smaller than the first relief angle.

Abstract: A multi-purpose probe module 82, comprising both a touch-trigger type contact probe 84 and a non-contact type probe 86, is used in method and apparatus for monitoring and adjusting the accuracy of a computer-controlled machine for manufacturing precision bevel and hypoid gears. The probe module is mounted on the machine's tool support and is used in conjunction with locating points positioned on the machine's work support to monitor and recalibrate the relative positions of the tool and work supports. The probe module is also used to monitor the flanks of the gear-shaped workpieces (a) for initial stock division, (b) for pre-machining accuracy, (c) for first-piece testing, (d) for in-process accuracy, and (e) for post-machining accuracy. The same probe module is used in combination with a sacrificial test wafer mounted on the work support for adjusting the position of the machine's cup-shaped grinding wheel following each dressing of the latter's working surfaces.

Abstract: A face mill type cutter, preferably a rotary ring cutter, having coolant passages located within the cutter to supply coolant to discharge outlets located between and/or in the stock removing surfaces located on the cutter. Coolant is supplied to the face mill cutter either by a coolant shroud arranged about at least a portion of the periphery of the cutter, or, by at least one coolant delivery passage arranged in the spindle of a machine tool.

Abstract: A method of dressing a threaded grinding wheel for grinding crown gears. The method comprises providing a dressing tool in the form of a pinion member with the dressing tool having the same pitch as a mating pinion member of the crown gear. Rotating the dressing tool and the grinding wheel at respective velocities whereby the dressing tool and grinding wheel may run in mesh with one another. Moving the dressing tool across the width of the grinding wheel simultaneously with the dressing tool and grinding wheel rotating in mesh, with the dressing tool moving completely along the width of the grinding wheel. The path that the dressing tool moves along being defined as an arcuate path about a point on the grinding wheel corresponding to a center point of the mating pinion.

Abstract: A grinding process and wheel are disclosed wherein any or all surfaces of a cutting blade may be generated in a continuous grinding operation utilizing a single grinding wheel having a simple profile. A grinding wheel having a grinding profile comprising an inner conical surface and an adjacent outer narrow substantially flat surface is provided. The inner conical surface rough grinds to generate a roughed blade surface and the adjacent outer narrow substantially flat surface finish grinds the roughed surface to generate a finished blade surface. Computer numerical control (CNC) is utilized to control the relative movement of the grinding wheel and cutting blade along or about a plurality of axes. Inner and outer arcuate grinding surfaces may also be provided for rough grinding.

Abstract: Disclosed herein is a hobbing machine particularly for the production of spur and helical gears. The hobbing machine is characterized in that a separate mechanism for hob shifting is not required. The hob shifting, as well as other machine motions, is carried out by linear movement of the tool and workpiece relative to one another in up to three mutually perpendicular directions. The machine also includes tool support means to which the hobbing tool is mounted and which is rotatably adjustable for controlling the angular orientation of the hobbing tool. A control system including a computer controls the linear movements, angularly adjustable tool support movements, as well as the necessary timed rotations of the tool and workpiece.

Abstract: Disclosed herein is a rotary cutter for cutting gears, couplings and the like. The rotary cutter comprises a cutter head having an axis of rotation, a centering disc located adjacent to a side of the cutter head and concentric with the axis and a cutter ring, centered by the centering disc, on the cutter head. The centering disc has a tapered outer edge surface that abuts against and is complementary with the tapered surface of the bore of the cutter ring. The cutter ring is centered once the surfaces are complementary. Once centered, the cutter ring is secured to the cutter head. The rotary cutter of the present invention enables the cutter ring to rotate true about the axis of a machine tool.

Abstract: Disclosed herein is a rotary cutter for cutting gears and the like. The rotary cutter has an axis of rotation and comprises a disc-shaped cutter head having a circumferential edge surface. The cutter head further includes an inner wall surface located radially inwardly with respect to the edge surface and being concentric about and extending parallel to the axis of rotation. The rotary cutter further includes a cutter ring located on the cutter head. The cutter ring has at least one stock removing surface located on a base portion with the base portion having an inside ring surface, an outside ring surface, and a base surface with the outside ring surface being perpendicular to the base surface. The cutter ring is in a radially expanded condition whereby the outside ring surface is seated against the inner wall surface of the cutter head and the base surface is seated against the first surface of the cutter head.