Gleason Nastroje Komplet - AJ PDF

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O ver vie w
Welcome to Gleason Cutting Tools!

Gleason Cutting Tools Corporation is devoted exclusively to developing and manufacturing the industrys most
complete line of bevel and cylindrical gear making tools, from manufacturing sites in the U.S., Europe, India
and China.
Products produced today include hobs, shaper cutters, shaving cutters, milling cutters, carbide stick blades for
bevel gear cutting, CBN and diamond plated precision grinding wheels and master dressing gears, DIN AA quality
shaper cutters, and new aluminum chromium nitride PVD coatings (AlCroNite). Tool services are provided
with in-house chemical stripping, re-sharpening, re-plating, re-coatings, heat treatments, and tool management.
Unprecedented investments in equipment, facilities, and people continue to raise cutting tool quality to the
highest level while simultaneously reducing tool cost and lead times with the application of lean GBP principles
(Gleason Business Philosophy). Gleason Cutting Tools Corporation is registered to ISO 9001:2000 Quality and
ISO 14001:2004 Environmental International Standards.
C on t en t s
Standard Gear Milling Cutters.......................................................................................................................... 23

Special Gear Milling Cutters............................................................................................................................ 25
Roughing Gear Milling Cutters........................................................................................................................ 26
Thread Milling Cutters..................................................................................................................................... 28
Saw Milling Cutters.......................................................................................................................................... 29
Opti-Cut Products............................................................................................................................................30
Plated Diamond and CBN Wheel Products........................................................................................38

Worldclass Manufacturing Capabilities............................................................................................................ 39

Advanced Plating Technologies....................................................................................................................... 40
Guaranteeing Consistent Quality, Optimum Performance............................................................................... 41
Gleason Cutting Tools: Leading in Technology, Capabilities, Selection......................................................... 42
Plated Wheel RFQ............................................................................................................................................ 43
PLATED DIAMOND AND

CBN WHEEL PRODUCTS
Improved Large Gear Cutting Efficiencies....................................................................................................... 31

Inserts............................................................................................................................................................... 32
Complete System.............................................................................................................................................. 33
Opti-Cut RFQ................................................................................................................................................. 34
OPTI-CUT PRODUCTS
MILLING CUTTERS
Milling Cutters......................................................................................................................................................22
SHAPER CUTTERS
Shaper Cutters.....................................................................................................................................................16
Shaping Process................................................................................................................................................ 17
Isoform Shaper Cutters................................................................................................................................... 18
Shaper Cutter RFQ........................................................................................................................................... 20
HOBBS
Hobs..............................................................................................................................................................................4
Hobbing Process................................................................................................................................................. 5
Multiple Thread Hobs......................................................................................................................................... 6
OptiGash Concept and Analysis Program........................................................................................................ 6
E-Z Cut Roughing Hobs..................................................................................................................................... 7
Carbide Hobs...................................................................................................................................................... 8
Worm Gear Hobs................................................................................................................................................ 9
Fine Pitch Gear Hobs........................................................................................................................................ 10
Effects of Hob Mounting Errors....................................................................................................................... 11
Hob Sharpening Problems................................................................................................................................ 13
Hobs RFQ......................................................................................................................................................... 14
www.gleason.com/services gctc@gleason.com
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HOBBS
H obs Ove r v i ew
Hobs
SHAPER CUTTERS
Gleason hobs are designed to signicantly improve the productivity of the pre-nishing and nishing of gears in
the green, pre-hardened state.
We use premium high speed steels, advanced new carbide materials and the latest thin hard-lm coatings to help
deliver signicant reductions in the machining signicant reductions in the machining cost per part.
In addition, Gleason offers a complete range of hobs to improve hobbing efciency in virtually any application
wet or completely dry, very large sizes to ne pitch, rough cutting or highly accurate nishing.
PLATED DIAMOND AND

CBN WHEEL PRODUCTS
OPTI-CUT PRODUCTS
MILLING CUTTERS
Hobs are custom made to your application. To get the process started, please submit the Hobs RFQ or e-mail us
at gctc@gleason.com.
Hob b i n g P r oces s
HOBBS
Hobbing Process
A basic description of the gear hobbing process:
MILLING CUTTERS
As the hob and gear rotate in the timed relationship the hob also feeds along the axis of the gear, removing
material from the spaces and generating to involute curvedtooth form.
SHAPER CUTTERS
Gear hobbing a generating process in that the form of the gear space is not a one to one reproduction of the
hob tooth form. The generating process requires an accurate timed relationship between the rotation of the part
being cut and the hob rotation, based on the number of hob threads. For example if a 40 tooth gear is being
cut by a single thread hob, for each revolution of the hob, the part must rotate to advance one tooth angle. For
a two thread hob, the part would rotate twice as fast. The generating process also means that the hob teeth are
advancing into the gear space in a sequence. Each sequential cut of the straight edge of the hob tooth begins to
generate a curved surface of the involute form of the gear. The spacing of the sequential cuts is dependant on the
number of gashes (rows of teeth), and number of threads in the hob, and the number of teeth being cut.
OPTI-CUT PRODUCTS
PLATED DIAMOND AND
CBN WHEEL PRODUCTS
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HOBBS
Mult iple Threa d Hob s
Multiple Thread Hobs
Cut Time =
Part # Teeth x Length of Cut

Feed Rate x Hob RPM x # Threads
Other factors also need to be considered when changing an application from single thread to multiple threads.
The ratio of part # of teeth to hob number of threads, for example should be a prime number, if possible, to
minimize the impact of any thread errors in the hob causing index errors in the gear. If an even ratio, the thread
errors may be repeated in the part, but with a prime ratio each thread enters every part space, minimizing
the impact of the hob thread to thread accuracy. Of course, highly accurate class AA and AAA hob grinding
technology has also helped to minimize thread to thread errors in the tool.
Using multiple thread hobs is just one of the design factors involved with the overall process of optimizing
the hobbing application. Smaller hob diameters, longer shiftable length hobs, increased number of threads,
premium materials and coatings have all helped the OptiGash hobbing concept reduce your total cost per part
by attacking the machining cost.
PLATED DIAMOND AND

CBN WHEEL PRODUCTS
MILLING CUTTERS
The cutting time calculation above shows the number of hob threads in the denominator of the equation,
therefore if the number of thread is doubled the calculated time can theoretically be cut in half. Of course, to
accommodate the increased chip load on the multi-thread tool, you may need to reduce the feed rate. But the
overall cycle time will still be greatly improved.
OPTI-CUT PRODUCTS
SHAPER CUTTERS
The use of multiple thread hobs can make an enormous improvement in the productivity of the gear cutting
process. The advantage afforded by the multi-thread hob comes from the increased indexing speed of the work
piece. With a single thread hob, the part rotation advances one space for each revolution of the hob. With a two
thread hob, the part rotation advances two spaces for each hob revolution.
E-Z C u t Rou g h i n g Hob
All the advantages of the E-Z Cut hob geometry are quite compatible with the universal use one expects from
standard conventional hobs. An E-Z Cut hob with normal diametral pitch and pressure angle can cut any range
of teeth in pinions or gears with like pitch and pressure angle.
PLATED DIAMOND AND

CBN WHEEL PRODUCTS
The sharpening of the E-Z Cut hob is relatively easy, even though there are different depths of gash. The method
used for sharpening is to index sharpen all teeth to the shallowest depth. Next, set up for the deeper teeth, index
sharpening them by blending in the sharpening with the previously sharpened shallow depth of gash.
OPTI-CUT PRODUCTS
Many large coarse pitch gears with high numbers of teeth require two (and sometimes three or more sharpenings
of a conventional hob before the roughing operation is completed This situation seldom occurs wit E-Z Cut
hobs. The easy cutting action extends time between sharpenings, saving sharpening time and costs.
MILLING CUTTERS
Besides adding extra cutting edges in the tip area, E-Z Cut hobs have a slight modification from the true involute
form to control chip size for easy removal. Dual pressure angles on the hob generate a slightly barrel-shaped
gear tooth form with relief on the flank and at the tip of the tooth. This gear tooth form is conducive to accurate
finishing of the gear.
SHAPER CUTTERS
The primary objective of the E-Z Cut roughing hob is the swift removal of metal to permit accurate and economical
finishing of the gear tooth profile in a secondary operation. Conventional generating hobs use less than one third
of their tooth depth for about two thirds of the metal removal work. E-Z Cut hobs add extra cutting edges by
adding specialized flutes. The additional flutes equalize cutting effort and eliminate the problem of overworked
tip. Since there is a practical limit to the chip load a tooth can carry, it stands to reason that a hob with more
flutes (in a given diameter) can feed faster through the work.
HOBBS
E-Z Cut Roughing Hob
As with any conventional hub, the E-Z Cut may be furnished as single or multiple thread. In either design,
cutting efficiencies are improved, thus releasing more productive machine time for the finishing operation.
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HOBBS
Carbide H ob s
Carbide Hobs
PLATED DIAMOND AND

CBN WHEEL PRODUCTS
OPTI-CUT PRODUCTS
MILLING CUTTERS
SHAPER CUTTERS
Since the right choice for optimizing your application isnt always evident, let Gleason Cutting Tools
Corporation help determine whether you should hob wet or dry, with HSS or carbide tools, with single or
multilayer coatings.
Our experience with carbide cutting tools dates back to 1966. Improvements in carbide materials since that time
have dramatically improved its performance for hobbing applications.
Gleason Cutting Tools Corporation can provide carbide hobs in either ISO K or P grades. ISO K grades of
carbide are a simple two-phase composition consisting of tungsten carbide (WC) and cobalt (Co). A K-Grade
carbide is suited to cutting soft (160-200Hb) or hard hobbing (40-55Rc) fine module parts from solid, or for
skive hobbing materials (52-64 Rc), with a fully coated tool. For reconditioning, the K-Grades of carbide can be
stripped of coatings, resharpened and must be recoated with a fully coated face.
ISO P grades of carbide are threephase alloyed compositions consisting of tungsten carbide (WC), cobalt
(Co) and cubic carbides. The cubic carbide binders can be titanium carbide (TiC), tantalum carbide (TaC) and
niobium carbide (NbC).
A P grade carbide is for soft cutting applications up to 370 Hb, where recoating is not desired. For reconditioning,
only resharpening of the worn cutting face is required. P-grades cannot be stripped of coatings.
Wor m Gear Hob s
HOBBS
Worm Gear Hobs

Gleason Cutting Tools Corporation makes HSS hobs for cutting worm gears which mate with non-enveloping
worms. They can be single or multiple-thread, bore type or shank type, topping or non-topping, radial or
tangential feed type of tools. Depending on finished gear accuracy specifications, worm gear hobs may be
supplied either unground or ground, for roughing or finishing.
A radial feed worm gear hob is the most common. The

hob feeds radially to depth and the part rotated enough
times to complete the cutting of all teeth. This method
can be used for all cutting gear to thread ratios.
PLATED DIAMOND AND

CBN WHEEL PRODUCTS
A radial-tangential type feed hob. The hob is fed

radially to depth and then fed tangentially to achieve a
smooth profile. The worm gear hob is designed slightly
larger than the worm, providing a contact pattern near
the center of the gear face width. As the hob is sharpened
back until it is the same size as the worm, the bearing
contact pattern gets wider across the gear face width.
OPTI-CUT PRODUCTS
A tangential feed hob process feeds the hob axially,

parallel with the hob axis on a line tangent to the outside
diameter of the worm gear. The hob moves at a slow
feed rate. This method can be used primarily on ratios
where gear teeth to worm threads are 6:1 or less to
produce an extremely smooth gear profile.
MILLING CUTTERS
The Worm Gears are cut on a hobbing machine using one of the four types of hobbing processes and respective
hob designs. Most commonly, the direction of hob feed can be radial, or in a tangential direction, but the hob
does not feed axially across the worm gear face width.
SHAPER CUTTERS
The manufacturing of worm gears, like any hobbing process, has many variables that must be evaluated,
monitored, and controlled to achieve the desired quality part. The worm gear design is strictly tied to the
design of the mating worm and its manufacturing process. The worm gear hob design likewise must take into
consideration the worm manufacturing process and accuracy.
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PLATED DIAMOND AND

CBN WHEEL PRODUCTS
OPTI-CUT PRODUCTS
MILLING CUTTERS
SHAPER CUTTERS
HOBBS
Fine Pit c h G ea r Hob s
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Fine Pitch Gear Hobs

According to the American Standards Association and the American Gear Manufacturers Association, gears 20
diametral pitch and finer are fine-pitch gears. Types of fine-pitch hobs available include finishing and semifinishing, topping and non-topping, ground and unground, standard and special, multiple thread and carbide.
These hobs can be made to ANSI tolerance classes AA through C. Equivalent classes from other tolerancing
standards may be applied if requested.
One of the primary differences between fine-pitch and coarse-pitch hobs is the provision for a greater
percentage of clearance in the fine-pitch series. Prior to the adoption of the fine-pitch system, clearance at the
root of the gear tooth was insufficient and caused unsatisfactory gear operations in some cases. The clearance
was increased to eliminate possible interference with the mating part.
Interference can sometimes be caused by normal hob wear. When the corners of the hob tooth become slightly
worn, the hob may not cut the correct form to the required depth, causing interference at this point. Although
this type of wear occurs on all hobs, it is not proportionately as great on coarse-pitch hobs as on the finer
pitches. Clearance is added by increasing the hob addendum. The standard practice is to increase the height
above the pitch line. Thus, even if the corners of the tooth become slightly worn, the correct gear tooth form
extends beyond the working depth of the tooth, eliminating interference with the outside corners of the
mating tooth.
Hob M ou n t i n g Er r or s
HOBBS
Hob Lead
A theoretically perfect hob, manufactured error free, can produce profile errors if mounted incorrectly on the
hobbing machine arbor. A hob that is mounted incorrectly can exhibit a condition known as runout. Traditional
runout is in phase. An out of phase runout condition is known as wobble. Runout introduced through poor hob
mounting can destroy the hobs accuracy.
SHAPER CUTTERS
MILLING CUTTERS
OPTI-CUT PRODUCTS
PLATED DIAMOND AND
CBN WHEEL PRODUCTS
To eliminate runout, hobs are designed with hubs to provide a qualifying surface. Hubs are used to true up the
hob on the arbor. Since hubs are held in relation to the form on the hob teeth, truing the hubs makes the hob
rotate about the proper axis. Hub runout causes errors in the part tooth form since the hob teeth are not in the
proper position relative to the generating pitch line.
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SHAPER CUTTERS
HOBBS
H ob Mount ing Er r or s
Hob Lead
The figures below illustrate the effects three types of hob runout have on the gear tooth form. These are most
often created by:
Failure to true up the hob arbor
Failure to true up the hob on the arbor by indicating the hubs on the ends of the hob
Bent hob arbor
Oversize hob bore or undersize hob arbor
Non-parallel hob clamping spacers
Misaligned or worn outboard support bearing for hob arbor
OPTI-CUT PRODUCTS
Effect of uniform runout

over entire hob.
Runout on each side of hob

180 degrees apart.
PLATED DIAMOND AND

CBN WHEEL PRODUCTS
MILLING CUTTERS
Hob runout error due either to careless mounting or improper sharpening is the greatest contributor to poor
hobbed involute profiles.
Runout on one side of hob only.
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Hob M ou n t i n g Er r or s
Rake Angle Error

The hob cutting face is designed to lie in a specified plane and any variations of the actual hob from that plane is
considered flute cutting face error. This error is measured from the outside diameter to the cutting depth.
Negative rake error results in cutting drag and a gear tooth that is thin at the top and thick at the bottom. The
effect of negative rake is an involute chart that leans in the positive direction.
SHARPENING ERROR Cutting face ground with negative rake when it should be radial.
MILLING CUTTERS
Negative rake error occurs when too much stock is removed from the upper portion of the tooth face. Incorrect
negative rake decreases the depth and increases the pressure angle on the hob tooth.
SHAPER CUTTERS
A perfectly accurate hob, with a proper setup, on an accurate machine with good tooling can cut a bad gear if
the hob is improperly sharpened. Sharpening errors that affect hob and gear accuracy are as follows:
Rake angle error
Index error
Flute lead error
HOBBS
Hob Sharpening Errors
Effect of negative rake resharpening error on profile.

OPTI-CUT PRODUCTS
PLATED DIAMOND AND
CBN WHEEL PRODUCTS
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PLATED DIAMOND AND

CBN WHEEL PRODUCTS
OPTI-CUT PRODUCTS
MILLING CUTTERS
SHAPER CUTTERS
HOBBS
H obs RF Q
SaleS engineering DeSign & Quote Sheet
Hobs Request for Quotation

Company Name:
Attention:
Address:
City
Phone No.
Best time to call:
State
Fax No.
E-mail
Zip
Date Requested
1.0 - Part information needed for quoting and to Place an order:

* ONLY NEEDED FOR QUOTING. All information required for orders.
_____________
Customer part number _______________ Customer tool number
_____________
Part material & hardness
_____________
Number of teeth in gear
_____________
N.D.P./mod. Numerator _______________ N.D.P./mod. Denominator
_____________
Circular pitch if not gear or involute spline
_____________
Pressure angle in decimal degrees, theoretical (normal/transverse)
_____________
Pitch diameter theoretical _______________ Base diameter
_____________
Helix angle in decimal degrees (-)=LH (like hand or opposite hand hobbing)
_____________
Is the involute modified? (Y/N)
_____________
Diameter to start of modification
_____________
Diameter to end of modification
Print out, Fill out

and Fax to:
+1 815.282.0271
_____________
Amount of modification as shown on involute chart
_____________
O.D. nominal _______________ + tol _______________ - tol
_____________
Hobbed or shaped R.D. nominal _______________ + tol _______________ - tol
_____________
Grind stock in root
_____________
Addendum _______________ W.D. _______________ Dedendum
_____________
Number of teeth in span
_____________
Max. finish span measurement
_____________
Min. finish span measurement
_____________
Dimension over pins
_____________
Pin size
_____________
Max. amount of undercut (if grinding)
_____________
Min. amount of undercut (if grinding)
_____________
Semi-finish form dia. _______________ Finish form dia. (SAP or TIF dia.)
_____________
Chamfer dia. max. _______________ Chamfer dia. min.
_____________
Chamfer dia. is semifin or finish?
_____________
Chamfer angle from horizontal
_____________
Fillet radius _______________ Top radius (only if topping)
_____________
Shoulder diameter _______________ Clear? (Y or N)
_____________
AGMA gear quality (Q) _______________ DIN quality _______________ Profile Tolerance
_____________
Internal or external part
_____________
Key width if parallel key _______________ + tol _______________ - tol
_____________
Number of keys _______________ straight and parallel diameter
_____________
Max. semi-finish span measurement
_____________
GCT104, 7/10
Page 1 of 3
For any questions, call +1 815.639.4222.

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Gleason Cutting Tools Corporation l 1351 Windsor Road, Loves Park, IL 61111 USA l P: 815.877.8900
E-mail: gctc@gleason.com l Website: www.gleason.com
F: 815.877.0264
Hob s RFQ
Request FoR quotation: Hobs

HOBBS
Hobs Request for Quotation

Company Name:
State
State
Fax No.
Fax No.
E-mail
E-mail
Zip
Zip
Date
Requested
Date
Requested
INFORMATION NEEDED FOR QUOTING AND ORDERING
*Required data for quoting.
MILLING CUTTERS
Your part number:

Your tool number:
*Part material:
*AGMA gear quality (Q):
DIN quality:
*Number of teeth in gear:
*Circular pitch if not gear or involute spline:
*NDP/mod. Numerator:
NDP/mod. Denominator:
*Pressure angle in decimal degrees, theoretical:
Pitch diameter theoretical:
Base diameter:
*Helix angle in decimal degrees (-) = LH:
*Internal or external part:
Internal
External
Is the involute modified?
Yes
No
Diameter to start of modification:
Diameter to end of modification:
Amount of modification as shown on involute chart:
*O.D. nominal:
+tol:
-tol:
*Hobbed or shaped R.D. nominal:
+tol:
-tol:
Grind stock In root:
Addendum:
W.D. :
Dedendum:
Number of teeth in span:
Finish span measurement: Max.:
Min.:
Amount of undercut: Max.:
Min.:
Semi-finish form dia.:
Finish form dia.:
Chamfer dia. max.:
Chamfer dia. min.:
Chamfer dia.:
Finish
Semifinish
*Chamfer angle from horizontal:
Fillet radius:
Top radius (only if topping):
Shoulder diameter:
Clear?
Yes
No
*Key width if parallel key:
+tol:
-tol:
*Number of keys:
Straight & Parallel Diameter:
Semi-finish span measurement:
Max.:
Min.:
OPTI-CUT PRODUCTS
Yes
No
FAX RFQ
Name of drawing, if any, you are faxing:
PLATED DIAMOND AND

CBN WHEEL PRODUCTS
HOB INFORMATION NEEDED TO PLACE AN ORDER

*Material:
*TiNite coating:
*O.D.:
*Length:
*Bore:
*Protuberance:
*Fin/S-Fin./Rough:
SHAPER CUTTERS
Company Name:
Attention:
Attention:
Address:
Address:
City City
Phone
Phone
No. No.
Best
to call:
Best timetime
to call:
*Keyway (Clutch, Std.):

*Number of threads:
*Hand:
*Class (AGMA, DIN):
*Top/N-Top/S-Top:
*Full top radius:
*Lugs:
Fax form and drawing, if any, to:
+1 815.282.0271
Write none, if you are not faxing a drawing.
GCT101, 7/10
Page 1 of 1
For any questions, call

+1 815.639.4222.
www.gleason.com/services
gctc@gleason.com
F: 815.877.0264
15
HOBBS
Shape r Cut t e rs Ov er v i ew
Shaper Cutters
PLATED DIAMOND AND

CBN WHEEL PRODUCTS
OPTI-CUT PRODUCTS
MILLING CUTTERS
SHAPER CUTTERS
Shaping is often the preferred process for the pre-finishing and finishing of nonhardened internal gears and for
producing shoulders and special profiles.
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Gleason Cutting Tools offers a complete range of highly productive and cost-effective shaper cutters all
produced with maximum precision and consistent high quality on new state-of-the-art production equipment.
This is essential, since the quality of the shaper cutter, and variations in pitch and concentricity in particular, are
ultimately reflected in the machined gear.
Our exclusive Isoform generating process rolls the cutter from side to side as the profiled grinding wheel
reciprocates through the tooth space. This method generates both sides simultaneously, resulting in a truer
cutting geometry and higher quality of gears and other shaped forms through the life of the cutter.
Shaper cutters are custom made to your application. To get the process started, please submit the Shaper Cutter
RFQ, or e-mail us at gctc@gleason.com.
Range*:
Disk-type, deep counterbore-type
and shank-type shaper cutters with
grinding of tooth flanks in accordance
with Gleasons high-precision
Isoform process.
Wafer shaper cutters.
Designed specifically to customer
requirements or to a standard.
Large variety of high-performance
PM HSS materials and carbide
as well as modern coatings supplied.
Shaper Cutter Data:
Module range 0.5 12 mm.
Outside diameter 12 250 mm.
Helix angle 0 50.
S h ap i n g P r oces s
For helical gears and additional twisting motion is required to cause a helix angle to be generated onto the gear.
This twisting motion is imparted by either a mechanical helical guide on the machine or by a CNC axis of the
machine.
OPTI-CUT PRODUCTS
Shaping can be used for cam forms, single index cutting of slots, keyways, or ratchet forms. Sector gears can be
cut by the shaping process. A special type of internal shaper cutters called an Enveloping Cutter can be designed
to produce an external gear that is recessed inside of a component. Virtually any form that is spaced around a
circle can be cut by a shaping process. Modern shaping equipment and specially designed shaper cutters have
made high speed shaping a very productive and accurate gear cutting process.
MILLING CUTTERS
The versatility of the shaping process lends it to cutting internal as well as external gear forms. In addition, two
or more cutters can be tandem mounted on the cutter spindle adaptor to cut more than one component on a shaft
or cluster gear.
SHAPER CUTTERS
The gear shaping process is a generating process that involves reciprocating a tool that resembles a mating gear
to the gear being produced. While the tool is being reciprocated up and down, it also rotates in a timed relationship with
gear based on the index ratio of the number of teeth in cutter and the desired number of teeth in the gear. As
the cutter and gear are rotating, the centerdistance is gradually reduced, causing the cutter to engage in cutting
material from the spaces of the gear. As the cutter to part center distance reduces, the cutter reaches full depth of
the gear teeth, and then one full revolution of the part will complete the shaping process.
HOBBS
Shaping Process
PLATED DIAMOND AND

CBN WHEEL PRODUCTS
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HOBBS
I sof orm Shape r C u t t er s
Isoform Shaper Cutters
COMPARING THE DIFFERENCE

The traditional grinding process, which is used to
form the teeth of conventional shaper cutters, rocks
the cutter against one side of a stationary grinding
wheel as shown in Figures 1 & 2 to the right,
imparting the curvature of the wheel into the form.
The grinding wheel remains in a fixed position
midway through the cutter. Teeth are first ground
on one flank all the way around. The cutter is then
removed from the grinder, reversed, then replaced
on the machine to grind the other flank.
With the Gleason grinding process shown in
Figures 1 & 2
Figures 3 & 4 below, the Isoform Shaper Cutter is
rocked from side to side against a grinding wheel which carries the basic rack form. At the same time, the
wheel reciprocates rapidly through the entire length of the cutter, front to back. As a result, both flanks are
generated simultaneously.
PLATED DIAMOND AND

CBN WHEEL PRODUCTS
OPTI-CUT PRODUCTS
MILLING CUTTERS
SHAPER CUTTERS
Gleason Isoform Shaper Cutters produce the original part form accuracy, even after repeated sharpening. The
Gleason Shaper Cutter is through-generated by our Isoform grinding process which produces the correct form
geometry from the front face to the back face of the cutter tooth.
Figures 3 & 4
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I s of or m S h ap er C u t t er s
Through-grinding process maintains correct cutter tooth geometry.

Through-grinding generates a smooth profile of correct shape along the full length of the cutter tooth.
Therefore, any involute modifications traditionally prone to radical change as the cutter is sharpened back
remains within tolerance. This provides a much longer usable tooth life.
Generated tip contour.

The generated tip contour in turn generates smooth and consistent gear tooth filets. Gears in existing designs
can be made consistently stronger. New gear designs can be more compact.
EXTENDED LIFE CUTTERS GIVE A LONGER USE ABLE TOOTH LENGTH .

The Gleason grinding process, with its unique reciprocating stroke, allows the production of Isoform to make
shaper cutters with the longest effective tooth length available anywhere. Our Extended Life Cutters have a
longer usable life than standard cutters, which allows for a lower tool cost per part produced. Special cutters
with modified forms or chamfering features benefit the most.
MILLING CUTTERS
Stronger cutter tooth roots.

The through-stroking grinding process also produces tooth roots that are straight and free of excessive
deeps and shallows. The resultant cutter is less prone to breakage.
SHAPER CUTTERS
HOBBS
THE ADVANTAGES TO GLEASON GRINDING PROCESS.

Positive cutter concentricity.
Grinding both flanks of the cutter simultaneously in the same machine setup helps assure symmetry of the
tooth form. Centering errors are eliminated. All teeth are of uniform thickness and spacing.
OPTI-CUT PRODUCTS
PLATED DIAMOND AND
CBN WHEEL PRODUCTS
(Isoform is a registered trademark of Gleason Cutting Tools Corporation)
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PLATED DIAMOND AND

CBN WHEEL PRODUCTS
OPTI-CUT PRODUCTS
MILLING CUTTERS
SHAPER CUTTERS
HOBBS
Shape r Cut t e r s RFQ
Shaper Cutters Request for Quotation

Company Name:
Attention:
Address:
City
Phone No.
Best time to call:
State
Fax No.
E-mail
Zip
Date Requested

_____________
_____________
_____________
_____________
_____________
_____________
_____________
_____________
_____________
_____________
Print out, Fill out

and Fax to:
+1 815.282.0271
_____________
_____________
_____________
_____________
_____________
Grind stock in root
_____________
_____________
_____________
_____________
_____________
Dimension over pins
_____________
Pin size
_____________
_____________
_____________
_____________
_____________
_____________
_____________
_____________
_____________
_____________
_____________
_____________
_____________
_____________
GCT104, 7/10
20
Page 1 of 3

F: 815.877.0264
S h ap er C u t t er s RFQ
Request FoR quotation: shapeR CutteRs

HOBBS
Shaper Cutters Request for Quotation

Company Name:
State
State
Fax No.
Fax No.
E-mail
E-mail
Zip
Zip
Date
Requested
Date
Requested
INFORMATION NEEDED FOR QUOTING AND ORDERING
*Required data for quoting.
MILLING CUTTERS
Your part number:

Your tool number:
*Part material:
*AGMA gear quality (Q):
DIN quality:
*Number of teeth in gear:
*Circular pitch if not gear or involute spline:
*NDP/mod. Numerator:
NDP/mod. Denominator:
*Pressure angle in decimal degrees, theoretical:
Pitch diameter theoretical:
Base diameter:
*Helix angle in decimal degrees (-) = LH:
*Internal or external part:
Internal
External
Is the involute modified?
Yes
No
Diameter to start of modification:
Diameter to end of modification:
Amount of modification as shown on involute chart:
*O.D. nominal:
+tol:
-tol:
*Hobbed or shaped R.D. nominal:
+tol:
-tol:
Grind stock In root:
Addendum:
W.D. :
Dedendum:
Number of teeth in span:
Finish span measurement: Max.:
Min.:
Amount of undercut: Max.:
Min.:
Semi-finish form dia.:
Finish form dia.:
Chamfer dia. max.:
Chamfer dia. min.:
Chamfer dia.:
Finish
Semifinish
*Chamfer angle from horizontal:
Fillet radius:
Top radius (only if topping):
Shoulder diameter:
Clear?
Yes
No
*Key width if parallel key:
+tol:
-tol:
*Number of keys:
Straight & Parallel Diameter:
Semi-finish span measurement:
Max.:
Min.:
OPTI-CUT PRODUCTS
FAX RFQ
PLATED DIAMOND AND

CBN WHEEL PRODUCTS
SHAPER CUTTER INFORMATION NEEDED TO PLACE AN ORDER

*Material:
Yes
No
*TiNite coating:
*No. of teeth:
*Face width:
*Shank dimensions Clutch keyway:
*Full top radius
Yes
No
*Size (- = aligned):
SHAPER CUTTERS
Company Name:
Attention:
Attention:
Address:
Address:
City City
Phone
Phone
No. No.
Best
to call:
Best timetime
to call:
*Machine lead of guide:

*Pitch diameter:
*Top/N-Top/S-Top:
*Fin/Pre-G/Pre-S/Rgh:
*Bore size Disc Deep CBore/:
*or Shank Type:
*Protuberance:
+1 815.282.0271
GCT102, 7/10
Page 1 of 1

+1 815.639.4222.
gctc@gleason.com
F: 815.877.0264
21
HOBBS
Milling Cut t e rs Ov er v i ew
Milling Cutters
PLATED DIAMOND AND

CBN WHEEL PRODUCTS
OPTI-CUT PRODUCTS
MILLING CUTTERS
SHAPER CUTTERS
Gleason Cutting Tools offers all types of gear milling cutters, from standard convex and concave radius designs,
to the most complex impeller rotor form cutter.
22
Standard gear milling cutters can be designed with either a ground or unground form to produce spur or helical
gear teeth, bevel and miter gear teeth, rack teeth and special gear forms.
Special gear milling cutters also can be designed to produce a true involute form on the gear teeth. This type of
cutter is required if the gear is to roll with a gear hobbed with a standard gear hob. Gear cutters for any pressure
angle can be made with the true involute form.
Designs include:
Ground and unground forms
Straight helical or angular flutes
Radial, positive or negative rake tooth faces
Gang sections butted together or interlocked

Staggered or intermittent cutting teeth
Radial, axial and undercut clearances
Milling cutters are custom made to your application. To get the process started, please e-mail us at gctc@gleason.com.
S t an d ar d Gear M i l l i n g C u t t er s
HOBBS
Standard Gear Milling Cutters

Standard gear milling cutters can be designed with either a ground or unground form to produce spur or helical
gear teeth, bevel and mitre gear teeth, rack teeth and special gear tooth forms.
Figure 1
Tooth proportions of
the basic rack for a
standard 1 DP 14 1/2
P.A. gear cutter
SHAPER CUTTERS
The tooth form of a standard gear milling cutter is a composite of the involute and cycloidal forms. The basic
rack shown in Figure 1 is the form that will be produced by a standard gear milling cutter, and all standard
Gleason Cutting Tools gear cutters are based on this form.
MILLING CUTTERS
Figure 2
Comparison of the tooth
forms on No. 1 and
No. 8 gear cutters
PLATED DIAMOND AND

CBN WHEEL PRODUCTS
Gears from 12 teeth to infinity (a rack) are covered by 8 designs for each pitch, designated by range numbers 1
through 8. The form of the cutter is made correct for the lowest number of teeth in that particular range. Thus,
all teeth within the range are provided with sufficient tip relief.
OPTI-CUT PRODUCTS
Unlike gear generating tools, gear milling cutters are not usable for all numbers of teeth. Instead, a standard gear
milling cutter is designed for cutting varying numbers of teeth within a certain range. Hence, the term range
cutter is commonly applied to these cutters.
23
HOBBS
Standard G ear Mill i n g C u t t er s
Standard Gear Milling Cutters
PLATED DIAMOND AND

CBN WHEEL PRODUCTS
OPTI-CUT PRODUCTS
MILLING CUTTERS
SHAPER CUTTERS
Gear cutters have been classified into eight different groups according
to the number of teeth to be cut. The number of teeth in spur gears
covered by each range is shown in the following table. They can be
provided with either a 141/2 or 20 pressure angle.
24
These cutters are usually considered as sufficiently accurate for most

work. However, the special half-size cutters listed to the right may be
used when a more accurate tooth form is required.
Helical gears can be cut by these same cutters. However, the range
number may not be the same as for a spur gear with the same number
of teeth. The number of helical teeth must be translated into an
equivalent number of spur teeth. The formula for determining the
equivalent number of spur teeth is:
Equivalent number of spur teeth =
N
Cos3
Where N = number of teeth in helical gear and = helix angle of gear.

The number of the cutter should be selected according to the equivalent number of spur teeth.
Whole depth (WD) marked on finishing gear cutters refers to the depth of cut as measured from the theoretical
outside diameter of the gear. At this depth of cut, the cutter will produce a tooth thickness which will be one half
of the circular pitch. To provide for backlash between mating gears, one or both gears must be cut to a depth
greater than the whole depth marked on the cutter.
Gears of 12 or more teeth milled with standard finishing milling cutters of the proper range numbers will
operate together.
Gears cut by a standard finishing gear cutter will mesh properly with a gear produced by a hob with composite
form. They will not, however, mesh properly with a gear generated by a tool having a standard involute tooth
form.
S p eci al Gear M i l l i n g C u t t er s
SHAPER CUTTERS
Gear milling cutters also can be designed to produce a true involute form on the gear teeth. This type of cutter
is required if the gear is to roll with a gear hobbed with a standard gear hob. Gear cutters for any pressure angle
can be made with the true involute form. Some form modifications may be required for cutters designed for
gears with a small number of teeth and small pressure angle to assure satisfactory performance. The number of
the cutter for a range of gear teeth is the same as for the standard range cutters. For non-standard gears, such
as enlarged pinions, the cutter is made single purpose and does not follow the number designation.
HOBBS
Special Gear Milling Cutters
MILLING CUTTERS
OPTI-CUT PRODUCTS
PLATED DIAMOND AND
CBN WHEEL PRODUCTS
25
HOBBS
Roughing Ge ar Mill i n g C u t t er s
Roughing Gear Milling Cutters
PLATED DIAMOND AND

CBN WHEEL PRODUCTS
OPTI-CUT PRODUCTS
MILLING CUTTERS
SHAPER CUTTERS
Roughing gear cutters are designed for rapid removal of metal. Such use requires various types of chip breakers,
depending mainly upon the amount of metal to be removed. The amount of stock left for finishing is nominally
.200/DP. The five different styles of standard roughing cutters are shown below.
STYLE A
Style A has steps on both sides of all teeth and leaves steps on the sides of the gear teeth. Style A cutters are
used primarily on gears of 4 DP or coarser.
STYLE B
Style B has chip breakers on only one side of each tooth, each succeeding tooth having steps on the alternate
side. This style of cutter leaves a smooth cut since the plain side of the teeth cleans up the grooves left by the
chip breakers. Style B cutters are normally used to cut gears from 4 DP TO 10 DP.
STYLE C
Style C has teeth which are smooth on both sides, and the teeth are not staggered. It is most commonly used
on gears of 10 DP or finer. Style C is also used for the roughing cuts on bevel gears and gears where the cutter
tooth must be very narrow at the tip.
26
Rou g h i n g Gear M i l l i n g C u t t er s
HOBBS
Roughing Gear Milling Cutters

STYLE D
MILLING CUTTERS
STYLE A1
SHAPER CUTTERS
Style D has teeth with chip breakers on both sides, three on one side and two on the other, alternating on every
other tooth. They are spaced so that there are no steps produced on the gear tooth profile.
OPTI-CUT PRODUCTS
Style A1 has proven to be very efficient in cutting coarse-pitch gears. It is similar to style A in appearance,
but has side clearance on both sides and a 5positive radial rake. The above drawing shows the cutter form in
relation to the various finished gear profiles.
PLATED DIAMOND AND

CBN WHEEL PRODUCTS
27
HOBBS
Thre ad Milling C u t t er s
Thread Milling Cutters
PLATED DIAMOND AND

CBN WHEEL PRODUCTS
OPTI-CUT PRODUCTS
MILLING CUTTERS
SHAPER CUTTERS
A thread milling cutter is a rotary cutter with one or more convolutions or rows of teeth around the periphery of
the cutter. They are used for milling threads or thread dies of almost any form. They can be designed to mill any
of the standard thread forms, and can also be designed to mill virtually any type of special thread form.
28
In the operation of thread milling, the lead is imparted into the work by the axial advance between the cutter
and the work during the cut. Thread milling cutters can be made as single, duplex or multiple thread. Single
milling cutters are usually set to the lead angle of the thread and centered on the axis of swivel. They cut one
thread space at a time. For cutting more than one thread on a part, an accurate method of indexing from thread
to thread must be available. Duplex cutters cut two thread spaces at one time. They are also, in most cases, set to
the lead angle of the thread with the tooth space centered on the axis of swivel. They will finish a double thread
in one cut.
Multiple thread milling cutters are set parallel to the work axis, and cut the complete thread on the work in one
revolution of the work with the cutter at full depth. The length of the multiple thread milling cutter must be at
least equal to the length of the threaded portion of the work. The high production rate possible with multiple
thread milling cutters favors their use over single and duplex cutters for most applications. However, there are
length limitations for cutters. Therefore, for long screws, single and duplex cutters are used.
Thread milling cutters are form relieved, can be made with either a ground or unground tooth form and can
be provided with either straight or helical gashes. Multiple thread milling cutters can be manufactured to four
different classifications. These classes are:

AT Precision Ground
BT Commercial Ground
CT Accurate Unground
DT Commercial
For m Rel i ev ed S a w M i l l i n g C u t t er s
MILLING CUTTERS
The alternate cutting of every other flute of the cutter creates the sharp point on the saw blade tooth. Since all
saw blade teeth must be the same height so that each tooth will cut its share of the load, it is critical that the
cutter produce consistent cross-over point heights. The relative axial and radial positions of the milling cutter
tooth cross-over points are held accurately from flute to flute. In addition, the cutter axial and radial runout is
accurately maintained. Accurate resharpening of the cutter will insure that the point-height accuracy of the blade
will be milled consistently throughout the life of the cutter.
SHAPER CUTTERS
Form relieved milling cutters for milling saw blades have special design features which improve the quality of
saw blade point accuracy, and reduce production costs. Gleason Cutting Tools Corp can provide milling cutters
for hack saw, band saw, reciprocating, or circular saw blades. Cutters can be made with straight or helical flutes,
and with radial, positive, or negative rake offset sharpening. Tapered O.D. cutters can be furnished for saw
blades that require a positive hook angle on the blade teeth. Interlocking gangs of cutters can be developed to
cut long lengths of hack saw blade.
HOBBS
Form Relieved Saw Milling Cutters
OPTI-CUT PRODUCTS
PLATED DIAMOND AND
CBN WHEEL PRODUCTS
29
HOBBS
O pt i- Cut O ver v i ew
Opti-Cut: Advanced Indexable Insert Technology
PLATED DIAMOND AND

CBN WHEEL PRODUCTS
OPTI-CUT PRODUCTS
MILLING CUTTERS
SHAPER CUTTERS
Introducing Opti-Cut: A new family of gear gashing, shaping and hobbing cutters that employ the latest in
replaceable, indexable insert technology to improve cutting efficiencies for production of large spur and helical
gears as large.
30
Op t i -C u t Ad van ced Tech n ol og y
HOBBS
Improving Large Gear Cutting Efficiencies with Indexable Insert Technology

Introducing Opti-Cut: A new family of gear gashing, shaping and hobbing cutters that employ the latest in
replaceable, indexable insert technology to improve cutting efficiencies for production of large spur and helical
gears as large.
MILLING CUTTERS
OPTI-CUT PRODUCTS
Features and benefits include:

Now all the benefits of the latest replaceable, indexable insert technology are yours with the new
Opti-Cut Series of cutting tools from Gleason. With Opti-Cut, manufacturers of large cylindrical gears
found in windpower, truck, tractor, power generation and many other applications have an alternative to
solid, resharpenable tools.
SHAPER CUTTERS
Advantages of the new Opti-Cut tools include:

The use of indexable inserts with advanced carbide substrates and coatings provide consistent tool life,
surface finishes and accuracy, while at the same time eliminating the time and expense required for solid
cutter grinding/re-sharpening.
Feedrates can be optimized, and machine power consumption reduced, with Opti-Cuts unique cutting
geometry.
By combining the latest carbide materials, coatings and cutting geometries, cutting dry at higher feeds and
speeds is possible, ultimately helping reduce total cost per workpiece.
The use of indexable insert technology means that a smaller inventory of cutters can do the work of what
normally would require a much larger inventory and investment in conventional tooling.
A full product range is available, designed to run on your existing machinery.
PLATED DIAMOND AND

CBN WHEEL PRODUCTS
31
PLATED DIAMOND AND

CBN WHEEL PRODUCTS
OPTI-CUT PRODUCTS
MILLING CUTTERS
SHAPER CUTTERS
HOBBS
O pt i- Cut Ins er t s
Opti-Cut Inserts
Line Type
LINE type negative geometry for maximum strength on root cutting positions
4 indexable positions
Special root form or application tailored edge preparation is possible
Root cutting inserts are normally supported by replaceable cutter hardware
Precision ground periphery provides repeatability.
DPM Type
DPM type positive geometry for maximum efficiency on flank cutting positions
4 indexable positions
Normally a standard 0.8-1.66 mm corner radius used
One insert design has both RH and LH indexes so it can be used on both sides of
cutter form
Precision ground periphery provides repeatability
ID or OD Rough Gashing
Multi-edged straight-edged inserts contour a best fit involute form, leaving stock for
finish operations
Half-effective side insert design takes advantage of chip thinning to reduce
operation costs.
Inserts can be manufactured to suit special root radii or protuberance forms.
ID or OD Finish Gashing
Close tolerance involute form ground inserts
Extra long inserts eliminate insert side mismatch on finished product
Secondary root cutting inserts allow for higher feedrates
Shaping
Rough shaping of gear teeth
Increased cutting speed compared to HSS
Significantly improved tool life
Increased chip thickness capability compared to HSS
Insert indexing with tool body remaining on machine tool
Hobbing
Indexable Hobs for diameters greater than 125mm
Angular screw hole allows simple indexing without cutter disassembly or special drivers
Increased cutting speeds compared to HSS
Modular cutter assembly reduces cutter body repair costs
32
Op t i -C u t C om p l et e S y s t em
OPTI-CUT PRODUCTS
Tooling and Workholding

Gleason is the worlds leading source for advanced new tooling and
Quick Change workholding systems to meet the latest requirements
for accuracy, speed, and tool life. Only Gleason provides the
complete range of gear cutting and finishing tools for cylindrical
and bevel gears, including hobs, shaper cutters, shaving and honing
tooling, bevel blades and heads, replatable CBN and diamond
grinding and dressing wheels and plated diamond rolls.
MILLING CUTTERS
Global Service and Support

With a manufacturing presence worldwide, and fast-growing
sales and service representation in over 30 countries, Gleason is
truly a global company. Our broad-based infrastructure and strong
worldwide presence place us in a unique position to respond to
customer requirements anywhere, anytime.
SHAPER CUTTERS
At every stage of the gear production process, Gleason offers

advanced new technology that takes significant production time and
cost out of the operation. For the production of spur and helical gears,
for example, Gleason offers a full range of vertical and horizontal
hobbing machines, gear shapers (electronic- and mechanicalguide),
shaving and honing machines, and advanced threaded wheel and
profile grinding machines. Together with world metrology leader
Gleason-M&M Precision Systems Corporation, Gleasons ability to
manufacture and completely inspect all types of gears is unmatched.
HOBBS
Complete System
PLATED DIAMOND AND

CBN WHEEL PRODUCTS
33
PLATED DIAMOND AND

CBN WHEEL PRODUCTS
OPTI-CUT PRODUCTS
MILLING CUTTERS
SHAPER CUTTERS
HOBBS
Opt i- Cut R FQ
Opti-Cut Request for Quotation

Company Name:
Attention:
Address:
City
Phone No.
Best time to call:
State
Fax No.
E-mail
Zip
Date Requested

_____________
_____________
_____________
_____________
_____________
_____________
_____________
_____________
_____________
_____________
Print out, Fill out

and Fax to:
+1 815.282.0271
_____________
_____________
_____________
_____________
_____________
Grind stock in root
_____________
_____________
_____________
_____________
_____________
Dimension over pins
_____________
Pin size
_____________
_____________
_____________
_____________
_____________
_____________
_____________
_____________
_____________
_____________
_____________
_____________
_____________
_____________
GCT104, 7/10
34
Page 1 of 3

F: 815.877.0264
Op t i -C u t RFQ
Request FoR quotation: opti-Cut
Opti-Cut Request for Quotation
HOBBS
Company Name:
State
State
Fax No.
Fax No.
E-mail
E-mail
Zip
Zip
Date
Requested
Date
Requested
SHAPER CUTTERS
Company Name:
Attention:
Attention:
Address:
Address:
City City
Phone
Phone
No. No.
Best
to call:
Best timetime
to call:
information needed for quoting and to place an order:

Type of tool required:
Rough Gasher (Straight sided) __________________________
Finisher _____________ Rougher_____________
Indexable Hob:
Finisher _____________ Pre-Finish _____________ Rougher _____________
Shaper Cutter:
Rougher Only _____________
MILLING CUTTERS
Involute Form:
Normal Diametral Pitch _____________ or Normal Module _____________

Normal Pressure Angle: Degree: _____________ Min: _____________ Sec: _____________
Part Print or the following:
Part Number: __________________________
_____________
Helix Angle:
_____________
Face Width:
_____________
True Involute Form Diameter:
_____________
Minimum Fillet Radius:
_____________
Normal Circular Tooth Thickness:
_____________
Stock amount per side for Finishing:
_____________
Material and BHN Hardness:
_____________
External Gear
Internal Gear
Outside Diameter / Major Diameter:
_____________
_____________
Root Diameter / Internal Diameter:
_____________
_____________
_____________
_____________
Pin/ Ball size:
_____________
_____________
Dimension over Pins/Balls:
_____________
_____________
Dimension between Pins / Balls:
_____________
_____________
Span or Mic Readings ____ Teeth:
_____________
PLATED DIAMOND AND

CBN WHEEL PRODUCTS
Whole Depth (with one of the above given):
OPTI-CUT PRODUCTS
Number of Teeth:
Comments: ____________________________________________________________________________
Machine Information and Cutting Conditions:
Model Name and Number: __________________________
Machine Power:
Horse power _____________ or kW _____________
Cutting with:
Coolant _____________ or Dry _____________
Maximum Cutter Diameter:
_____________
Number of passes to cut to depth:
One _____ or Two _______
Comments: ____________________________________________________________________________
Page 1 of 2
GCT106, 7/10
Page 1 of 2

+1 815.639.4222.
gctc@gleason.com
F: 815.877.0264
35
O pt i- Cut RFQ
HOBBS
Request FoR quotation: opti-Cut

information needed for quoting and to place an order:
Cutting Tool:
Bore Diameter:
_____________
or Axial Keyway in Bore: _____________
Maximum Cutter Outside Diameter:
_____________
Cutter Hub Diameter (if specified):
_____________
Cutter Overall Width (if specified):
_____________
Under cut required in the gear form:
Yes ___ No ___
Point Width (if Gasher):
_____________
Maximum Tooth Depth (if specified):
_____________
Air Holes Required:
Yes ___ No ___
Other Required Data (Must be given to obtain a quote):

Tools will be use for Commercial or Military Use:
Commercial ___ Military ___
The final installation location of the machine/tools:
USA ___ or Specified Country __________________________
Final part application (i.e. what the part will be assembled in to):
_______________________________________________________________________________________
PLATED DIAMOND AND

CBN WHEEL PRODUCTS
OPTI-CUT PRODUCTS
MILLING CUTTERS
SHAPER CUTTERS
Clutch keyway: _____________
faX rfq
name of drawing, if any, you are faxing:
fax form and drawing, if any, to:
+1 815.282.0271
Page 2 of 2
GCT106, 7/10
Page 2 of 2

36
F: 815.877.0264
Op t i -C u t
HOBBS
SHAPER CUTTERS
MILLING CUTTERS
OPTI-CUT PRODUCTS
PLATED DIAMOND AND
CBN WHEEL PRODUCTS
37
HOBBS
Plated Diamond & CBN Technology Overview
Plated Diamond & CBN Technology
PLATED DIAMOND AND

CBN WHEEL PRODUCTS
OPTI-CUT PRODUCTS
MILLING CUTTERS
SHAPER CUTTERS
Gleason Cutting Tools is one of the worlds leading sources for plated CBN profile grinding wheels, diamond
plated gears and diamond plated dressing rolls used in the hard finishing and grinding of bevel and cylindrical
gears and other profiles.
38
Gleason plated wheels are made to the most precise quality standards. They feature a hardened steel body with
ground mounting surfaces and precision ground profiles plated with a single layer of CBN or diamond abrasive.
Profile accuracy and surface quality are guaranteed to meet customer requirements for accuracy, faster metal
removal rates, and predictable tool life in all types of tool and cutter grinding applications.
OPTI-CUT PRODUCTS
Precise CNC processing

Precise grinding processes after heat treatment
ensure the product, prior to plating, conforms to
equidistance and profile accuracy requirements.
Compute-driven Coordinate Measuring Machine
(CMM) measures profiles and provides error
corrections for totally integrated quality assurance.
MILLING CUTTERS
Our products are manufactured using computerized

techniques from concept to final inspection. Our
established experience in machining gear tooth
shapes is a major advantage to many of our
customers.
SHAPER CUTTERS
Hardened and ground blank production

Hardened and ground blanks plated with CBN and
diamond abrasives must be manufactured with a high
degree of precision from the beginning. At Gleason,
an extensive array of modern CNC equipment for
blanking, turning, heat treating and grinding offers
a variety of solutions and capacities up to 500 mm
O.D. Manufacturing in accordance with ISO 9001
International Quality Standards is the basis for
achieving and guaranteeing accuracy of profiles to
exactly match customer requirements, even at plus or
minus 2 micron tolerances.
HOBBS
World-Class Manufacturing Capabilities
PLATED DIAMOND AND

CBN WHEEL PRODUCTS
39
PLATED DIAMOND AND

CBN WHEEL PRODUCTS
OPTI-CUT PRODUCTS
MILLING CUTTERS
SHAPER CUTTERS
HOBBS
Advanced Plating Technologies

Computerized, ultrasonic cleaning
Vigilant preparation is a key quality element that
precedes the plating process. Preplating core preparation
processes include the computerized, ultrasonic cleaning
of blanks for contaminant free surfaces, as well as the
use of engineered precision masking fixtures to protect
non-plated surfaces.
Highly developed galvanic process
Gleason Cutting Tools ultra-modern, advanced
electroplating facility specializes in the manufacture
of precision super-abrasive products. Uniformity of
the abrasive layer is achieved using developed plating
techniques and processes to ensure quality and optimum
performance. Gleasons proprietary electroplating
chemistry is monitored and controlled to the highest
standards. Computerized documentation and process
control are maintained through stringent quality control
measures implemented as part of ISO-9001/14001
registration.
Precise quality steps
Several precise quality steps are required to guarantee
the consistent quality and optimum performance of all
Gleason plated products. These steps include:
Precise sieving of abrasive
Using advanced plating techniques
Microscopically verifying particle distribution
Intricate conditioning of the plated profile
Full-profile grinding of a coupon, and
Final CMM inspection of the profiled coupon.
Computer generated documents of the verified wheel
profile and expected K-chart results are produced for all
wheels, including re-plated wheels to original customer
specifications.
40
SHAPER CUTTERS
The electroplating and electroless plating processes provide a matrix which binds the abrasive particle
firmly to the wheel body. Consistent quality and optimum performance of Gleason plated products are the
result of thoroughly cleaning the CBN and diamond crystals and precisely controlling their size and shape.
Only electroformed sieves and ASTM sieving standards are used to provide the highest quality of crystal
classification.
HOBBS
Guaranteeing Consistent Quality, Optimum Performance
MILLING CUTTERS
OPTI-CUT PRODUCTS
Highest quality abrasive classifications
PLATED DIAMOND AND

CBN WHEEL PRODUCTS
41
HOBBS
Gleason Cutting Tools: Leading In Technology, Capabilities, Selection
PLATED DIAMOND AND

CBN WHEEL PRODUCTS
OPTI-CUT PRODUCTS
MILLING CUTTERS
SHAPER CUTTERS
Gleason Cutting Tools is one of the worlds leading sources

for plated CBN profile grinding wheels, diamond plated gears
and diamond plated dressing rolls used in the hard finishing
and grinding of bevel and cylindrical gears and other profiles.
42
Gleason plated wheels are made to the most precise quality

standards. They feature a hardened steel body with ground
mounting surfaces and precision ground profiles plated with
a single layer of CBN or diamond abrasive. The profile
accuracy and surface quality of these new and re-plated
products are guaranteed to meet customer requirements for
accuracy, faster metal removal rates, and predictable tool life
in all types of tool and cutter grinding applications.
In addition, only the highest quality natural and synthetic
diamond and CBN abrasives are used, in conjunction with inhouse precision sieving and sorting of crystal sizes.
All of the manufacturing and plating operations for these products take place at the ultra-modern, ISO 9001 and
ISO 14001 registered facilities of Gleason Cutting Tools, Loves Park, IL.
Plated Diamond & CBN RFQ
State
Fax No.
E-mail
Zip
SHAPER CUTTERS
Company Name:
Attention:
Address:
City
Phone No.
Best time to call:
Date Requested

_____________
_____________
_____________
_____________
_____________
_____________
_____________
_____________
_____________
_____________
Print out, Fill out

and Fax to:
+1 815.282.0271

_____________
_____________
_____________
Grind stock in root
_____________
_____________
_____________
_____________
Dimension over pins

Pin size
_____________
_____________
_____________
_____________
PLATED DIAMOND AND

CBN WHEEL PRODUCTS
_____________
_____________
_____________
_____________
_____________
_____________
_____________
_____________
_____________
_____________
_____________
_____________
GCT104, 7/10
Page 1 of 3
OPTI-CUT PRODUCTS
_____________
_____________
MILLING CUTTERS
*
*
HOBBS

Plated Diamond & CBN RFQ Request for Quotation
F: 815.877.0264
43
SHAPER CUTTERS
HOBBS
CBN GriNdiNG Wheel - iNterNal Gears
CBN Grinding Wheel - Internal and External Gears

Company Name:
Company Name:
Attention:
Attention:
Address:
Address:
City City
Phone
Phone
No. No.
Best
to call:
Best timetime
to call:
State
State
Fax No.
Fax No.
E-mail
E-mail
Zip
Zip
Date
Requested
Date
Requested
DIRECTIONS FOR COMPLETING THESE FORMS:

CBN Profile Grinding Wheels are designed and manufactured according to theoretical gear data. Consequently, the customer is able to specify
the desired tooth form. To define the grinding wheel, we request your completion of the forms below. Please cross out the data that does
PLATED DIAMOND AND

CBN WHEEL PRODUCTS
OPTI-CUT PRODUCTS
MILLING CUTTERS
not apply. Data to be determined by the manufacturer should be marked xx.

Machine Type (Model):
____________________________________________________
Machine Number (Serial Number):
____________________________________________________
Type of grinding Arm/Spindle:
____________________________________________________
Grinding Wheel Diameter:
____________________________________________________
Designation of Workpiece:
____________________________________________________
Workpiece Number:
____________________________________________________
Customer Tool Number (Code):
____________________________________________________
Type of Operation (Check One):
Finishing
Semi-Finishing
Roughing
GEAR DATA UNITS ( INCH / MM ):

Spur Gear
Number of Teeth
Helical Gear
Normal Diametral Pitch
DPn
Normal Module
Mn
Normal Pressure Angle
an
Helix Angle
n
max.
Mdk
Measurement Over Balls / Pins
Mdr
min.
Ball / Pin Diameter
Dm
Span Measurement Over (k= _____ ) Teeth
Wk
Remarks:
GCT109, 7/10
Page 1 of 5

44
F: 815.877.0264

HOBBS
CBN Grinding Wheel - Internal and External Gears

GEAR QUALITy:
Gear Quality:
____________________________________________________
Quality:
____________________________________________________
Gear Material:
____________________________________________________
Hardness:
____________________________________________________
SHAPER CUTTERS
Norm:
Surface Finish:
____________________________________________________
Rz:
____________________________________________________
Ra:
____________________________________________________
CLA:
____________________________________________________
RMS:
____________________________________________________
Profile Form:
With Modification
Show profile modification in chart below:
Modification to be nominal through the tolerance band.
Without Modification
OPTI-CUT PRODUCTS
1/div. = Modification Axis
Modification to be tangent to 0 reference line within the tolerance band.
MILLING CUTTERS
Rt:
Angle of roll = _____________________________
Length of roll = _____________________________
Angle of roll = _____________________________
Length of roll = _____________________________
Angle of roll = _____________________________
Length of roll = _____________________________
Angle of roll = _____________________________
Length of roll = _____________________________
Angle of roll = _____________________________
PLATED DIAMOND AND

CBN WHEEL PRODUCTS
Length of roll = _____________________________
Modification is defined to have smooth gentle curve from the start to the end of active profile.
Modification is defined to have sharp breaks at specified points.
GCT109, 7/10
Page 2 of 5
F: 815.877.0264
45
HOBBS

CBN Grinding Wheel - Internal Gears (Skip to pages 49-51 for External Gears)
CONFIGURATION OF ROOT FILLET:
Please fill in data for one of the corresponding figures on page 3 or 4.
MILLING CUTTERS
SHAPER CUTTERS
1. Ground Root Fillet:

1.1 One full fillet radius hf
1.2 Two fillet radii with flat root hf
Caution: Smallest root radius possible

hf = 0.012 (0.3mm)
Give dimensions in transverse plane.
Root diameter
df
max.
max.
df
min.
min.
Form diameter
dnf
max.
max.
Root fillet radius
hf
max.
max.
hf
min.
min.
PLATED DIAMOND AND

CBN WHEEL PRODUCTS
OPTI-CUT PRODUCTS
2. Root Not Ground (with step):

2.1 Full radius hf on grinding wheel
2.2 Two radii hf on grinding wheel

hf = 0.012 (0.3mm)
Theoretical ground
Root diameter
df
(value must be defined)
Form diameter
Root fillet radius
dnf
max.
max.
hf
max.
max.
hf
min.
min.
NOTE: Premachining data to be completed in section Premachining on page 5.
GCT109, 7/10
Page 3 of 5

46
F: 815.877.0264

HOBBS
Please fill in data below the application sketch.
3. No grinding of root fillet
SHAPER CUTTERS
3.1 Premachined with Protuberance
MILLING CUTTERS
Theoretical ground root diameter
df
Form diameter
dnf
Premachined root diameter
dfv
Root fillet radius
dfv
OPTI-CUT PRODUCTS
Undercut
CAUTION: Smallest radius on grinding wheel hf = 0.012 (0.3mm)
PLATED DIAMOND AND

CBN WHEEL PRODUCTS
GCT109, 7/10
Page 4 of 5
F: 815.877.0264
47
HOBBS

CONFIGURATION OF TIP:
SHAPER CUTTERS
1. Without tip chamfer:

Caution:
Tip diameter
da
max.
da
min.
da
max.
da
min.
MILLING CUTTERS
2. With tip chamfer:

Caution:
Minimum radius possible
Rk = 0.03 (0.8 mm)
PLATED DIAMOND AND

CBN WHEEL PRODUCTS
OPTI-CUT PRODUCTS
Tip diameter
Form diameter at tip
dnas
Tip radius
da
Tip break relief angle
da
Premachining Data (Index v):

Measurement over
Mdkv
Mdrv
max.
balls / pins
Mdkv
Mdrv
min.
Ball / Pin diameter
Dm
Span measurement over
Wkv
max.
k teeth
Wkv
min.
Root diameter
dfv
max.
dfv
min.
hfv
max.
hfv
min.
Fillet radius
FAX FORM
+1 815.282.0271

GCT109, 7/10
Page 5 of 5

48
F: 815.877.0264
CBN GriNdiNG Wheel - exterNal Gears

HOBBS
CBN Grinding Wheel - External Gears

1. Ground Root Fillet:
1.2 Two fillet radii with flat root hf

hf = 0.012 (0.3mm)
max.
max.
min.
min.
Form diameter
dnf
max.
max.
Root fillet radius
hf
max.
max.
hf
min.
min.
MILLING CUTTERS
df
df
Root diameter
SHAPER CUTTERS
1.1 One full fillet radius hf
2. Root Not Ground (with step):

2.2 Two radii hf on grinding wheel

hf = 0.012 (0.3mm)
df
PLATED DIAMOND AND

CBN WHEEL PRODUCTS
Theoretical ground
Root diameter
Form diameter
dnf
max.
max.
Root fillet radius
hf
max.
max.
hf
min.
min.
OPTI-CUT PRODUCTS
2.1 Full radius hf on grinding wheel
GCT108, 7/10
Page 3 of 5
F: 815.877.0264
49
HOBBS

Please fill in data below the application sketch.
3.1 Premachined with Protuberance
MILLING CUTTERS
SHAPER CUTTERS
3. No grinding of root fillet
OPTI-CUT PRODUCTS
Theoretical ground root diameter
df

Form diameter
dnf
Premachined root diameter
dfv
Root fillet radius
dfv
Undercut
CAUTION: Smallest radius on grinding wheel hf = 0.012 (0.3mm)
PLATED DIAMOND AND

CBN WHEEL PRODUCTS
GCT108, 7/10
Page 4 of 5

50
F: 815.877.0264

HOBBS

CONFIGURATION OF TIP:
1. Without tip chamfer:
SHAPER CUTTERS
Caution:
Tip diameter
da
max.
da
min.
da
max.
da
min.
2. With tip chamfer:
MILLING CUTTERS
Caution:
Minimum radius possible
Rk = 0.03 (0.8 mm)
Tip diameter
dnas
Tip radius
da
Tip break relief angle
da
OPTI-CUT PRODUCTS
Form diameter at tip
Premachining Data (Index v):

Mdkv
Mdrv
max.
balls / pins
Mdkv
Mdrv
min.
Ball / Pin diameter
Dm
Span measurement over
Wkv
max.
k teeth
Wkv
min.
Root diameter
dfv
max.
dfv
min.
hfv
max.
hfv
min.
Fillet radius
FAX FORM
PLATED DIAMOND AND

CBN WHEEL PRODUCTS
Measurement over
+1 815.282.0271

GCT108, 7/10
Page 5 of 5
F: 815.877.0264
51
Worldwide
At every stage of the gear production

process, Gleason offers advanced
new technology to significantly
reduce production time and cost.
Gleason offers a full range of vertical
and horizontal hobbing machines,
gear shapers (with electronic and
mechanical helical guides), deburring,
shaving and honing machines,
and advanced profile and threaded
wheel grinding machines for the
manufacture of spur and helical gears.
A complete range of bevel gear
cutting, grinding, lapping and testing
machines is available from Gleason.
The cutting tools, grinding wheels,
workholding, support services
and software are offered for all
gear manufacturing processes and
machines. Gleasons ability to
manufacture and completely inspect
all types of gears is unmatched.
1000 University Avenue

P.O. Box 22970
Rochester, NY 14692-2970 USA
+1-585-473-1000
sales@gleason.com
At Gleason, we recognize that service

is as important to our customers as
the technology that makes Gleason
machines the most productive in the
world. Our customers enjoy a lasting
personal partnership that ensures your
gear production needs are satisfied.
Gleason Global Services (GGS)
maximizes your uptime. You can
rely on our 250 service professionals
serving over 50 countries throughout
the Americas, Europe, and Asia to work
around the clock to support your needs.
1000 University Avenue

P.O. Box 22970
Rochester, NY 14692-2970 USA
+1-585-473-1000
sales@gleason.com
With a manufacturing presence

worldwide, as well as Global Service
support in over 20 countries, Gleason is
truly a global company.
Our broad-based infrastructure and
strong worldwide presence place us in a
unique position to respond to customer
requirements anywhere, anytime.
In addition Gleason also offers
application engineering services,
development programs, hands-on
seminars, gage certification and repair
programs.
C O R P O R AT I O N
1351 Windsor Road

Loves Park, IL 61111 USA
+1-815-877-8900
gctc@gleason.com
www.gleason.com sales@gleason.com
Visit www.gleason.com for Worldwide Sales Locations and Additional Information.
52
MSB 2620 July, 2011

Printed in U.S.A.

Gleason Nastroje Komplet - AJ PDF

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1

Welcome to Gleason Cutting Tools!

Standard Gear Milling Cutters.......................................................................................................................... 23

Plated Diamond and CBN Wheel Products........................................................................................38

Worldclass Manufacturing Capabilities............................................................................................................ 39

PLATED DIAMOND AND

Improved Large Gear Cutting Efficiencies....................................................................................................... 31

PLATED DIAMOND AND

Mult iple Threa d Hob s

Multiple Thread Hobs

Part # Teeth x Length of Cut

PLATED DIAMOND AND

E-Z C u t Rou g h i n g Hob

PLATED DIAMOND AND

E-Z Cut Roughing Hob

PLATED DIAMOND AND

Wor m Gear Hob s

Worm Gear Hobs

A radial feed worm gear hob is the most common. The

PLATED DIAMOND AND

A radial-tangential type feed hob. The hob is fed

A tangential feed hob process feeds the hob axially,

PLATED DIAMOND AND

Fine Pit c h G ea r Hob s

Fine Pitch Gear Hobs

Effect of uniform runout

Runout on each side of hob

PLATED DIAMOND AND

Runout on one side of hob only.

Rake Angle Error

Hob Sharpening Errors

Effect of negative rake resharpening error on profile.

PLATED DIAMOND AND

SaleS engineering DeSign & Quote Sheet

Hobs Request for Quotation

1.0 - Part information needed for quoting and to Place an order:

Customer part number _______________ Customer tool number

Part material & hardness

Number of teeth in gear

N.D.P./mod. Numerator _______________ N.D.P./mod. Denominator

Circular pitch if not gear or involute spline

Pressure angle in decimal degrees, theoretical (normal/transverse)

Pitch diameter theoretical _______________ Base diameter

Is the involute modified? (Y/N)

Diameter to start of modification

Diameter to end of modification

Print out, Fill out

Amount of modification as shown on involute chart

O.D. nominal _______________ + tol _______________ - tol

Hobbed or shaped R.D. nominal _______________ + tol _______________ - tol

Grind stock in root

Addendum _______________ W.D. _______________ Dedendum

Number of teeth in span

Max. finish span measurement

Min. finish span measurement

Dimension over pins

Max. amount of undercut (if grinding)

Min. amount of undercut (if grinding)

Chamfer dia. max. _______________ Chamfer dia. min.

Chamfer dia. is semifin or finish?

Chamfer angle from horizontal

Fillet radius _______________ Top radius (only if topping)

O.D. nominal _ + tol _ - tol

Hobbed or shaped R.D. nominal _ + tol _ - tol

Addendum _ W.D. _ Dedendum

Key width if parallel key _ + tol _ - tol

O.D. nominal _ + tol _ - tol

Hobbed or shaped R.D. nominal _ + tol _ - tol

Addendum _ W.D. _ Dedendum

Key width if parallel key _ + tol _ - tol