A NOVEL HOB DESIGN

FOR PRECISION
INVOLUTE GEARS:

PART I
The following paper outlines the

development of a new precision

gear hob design for machining

involute gears on conventional

gear-hobbing machines.
By Stephen P. Radzevich, Ph.D.

34 GEAR SOLUTIONS APRIL 2007 gearsolutionsonline.com

Abstract
This paper is aimed at the development of a novel design of precision gear hob for the machining of involute gears on a conventional
gear-hobbing machine. The reported research is based on the use of fundamental results obtained in analytical mechanics of gearing.
For solving the problem, both the descriptive-geometr y-based methods (further DGB-methods) together with pure analytical methods have
been employed. The use of DGB-methods is insightful for solving most of the principal problems, which consequently have an analytical
solution. These analytical methods provide an example of the application of the DG/K-method of sur face generation earlier developed
by the author. For interpretation of the results of research, several computer codes in the commercial software MathCAD/Scientific
were composed. Ultimately, a method of computation of parameters of design of a hob with straight-line lateral cutting edges for the
machining of precision involute gears is developed in the paper. The coincidence of the straight-line lateral cutting edges of the hob with
the straight-line characteristics of its generating sur face eliminates the major source of deviations of the hobbed involute gears. The
relationship between major principal design parameters that affect the gear hob per formance are investigated with use of vector algebra,
matrix calculus, and elements of differential geometr y. Gear hobs of the proposed design yield elimination of the principal and major
source of deviation of the desired hob tooth profile from the actual hob tooth profile. The reported results of research are ready to put in
practice. Part I is presented here, with the conclusion to appear in the May issue of the magazine.

Nomenclature
C g / h = center distance do.h = outside diameter of the involute hob
Dg = pitch diameter of the gear ht. g = gear tooth whole depth
Do.g = outside diameter of the gear
m = gear modulus
G = gear tooth surface being machining p b.h = base pitch of the involute hob
N g = number of gear teeth
tc = normal tooth thickness
Nh = number of starts of the involute hob
O g = gear axis of rotation Greek Symbols
Oh = hob axis of rotation = cross-axis angle

Px.h = axial pitch of the involute hob h = hob-setting angle

R = auxiliary phantom rack of the involute hob b.h = involute hob base lead angle (b.h =90degg.h )
Sh = involute hob feed-rate
n = normal pressure angle
T = the generating surface of the involute hob
b.h = involute hob base helix angle
U = idle distance in gear hobbing operation
g = gear pitch helix angle
WR = pitch plane of the auxiliary phantom rack R
h = involute hob pitch helix angle
a g = gear tooth addendum
R = auxiliary rack pitch helix angle
aR = the auxiliary rack tooth addendum
g = gear rotation
bg = gear tooth dedendum
h = involute hob rotation
bR = the auxiliary rack tooth dedendum

db. g = base diameter of a gear

Subscripts
db.h = base diameter of an involute hob g = gear to be machined

d f .g = gear root diameter h = involute hob to be applied

dh = gear hob pitch diameter R = auxiliary phantom rack of the gear hob

gearsolutionsonline.com APRIL 2007 GEAR SOLUTIONS 35

Introduction
Gear hobs are recognized as economical cutting tools for the machin-
ing of spur and helical gears. Almost any external tooth form that is
uniformly spaced about a center can be hobbed. Application of gear
hobs of special design yields machining of internal gears as well. In
order to achieve high accuracy of hobbed gears, lateral cutting edges of
an involute gear hob are required to be located on the surface of invo-
lute worm. It is also required that this worm is in proper mesh with the
involute gear to be machined. Usually this worm is referred to as the
generating (machining) surface of an involute hob [1]. Lateral cutting
edges of the hob teeth align with the line of intersection of the gener-
ating surface of a gear hob by rake face of the hob tooth. These lines
are curved lines. For the manufacturing purposes, the required curved
lateral cutting edges of the involute hob teeth usually are approximated
with the straight-line lateral cutting edges. Approximation of that kind
results in deviations of the actual lateral cutting edges of the involute
hob from the generating surface of the hob. The deviations of that kind
are the major source of the gear tooth deviations, and are unavoidable
for gear hobs of conventional design.
Analysis of known designs of involute hobs [2], [3] and others
reveals that no design of a hob with straight-line lateral cutting edges
are developed yet for he machining of precision involute gears.
Formulating the problem at hand: To develop a method for compu-
tation of parameters of a novel design of gear hob with straight-line
lateral cutting edges for the machining of precision involute gears.
The method of computation of parameters of design of a hob with
straight-line lateral cutting edges for machining of precision involute
gears is reported in the paper.
Outline: The paper is organized in the following way. In Section 2
generation and geometry of the generating (machining) surface on
the involute hob is investigated. For this purpose, equation of the
gear screw involute tooth surface is utilized. Ultimately the generating
surface of the involute hob is determined in both ways; say, using the
DGB-approach, and analytically as well. Use of the DGB-approach is
insightful for derivation of equations for computation of major design
parameters of the gear hob. The concept of design of the precision
involute gear hob with straight-line lateral cutting edges, as well as
computation of principal parameters of its design, is considered
in Section 3. A practical example of computation of parameters of
design of the precision involute hob of proposed design is consid-
ered. In Section 4 a possible enhancement of the developed theory
to the area of hobbing of involute gear with modified tooth profile
is reported. This consideration is based largely on application of
the DG/K-approach1 of surface generation earlier developed by the
author. Part II ends with Conclusions and Acknowledgement.
2: The Generation Surface T on an Involute Hob
Determination of the generation surface of a cutting tool is the start
point for designing the tool. We refer to the generation (i.e. to the
machining) surface of a cutting tool as to a surface that is conjugate
to the surface being machined [1], [6]. Concerning a gear hobbing
operation, the generating surface T of an involute hob is represented
by a screw involute surface that is conjugate to the gear tooth sur-
face being machined. Parameters of shape of the surface T can be
expressed in terms of (a) parameters of shape of the gear tooth sur-
face G, and (b) parameters of relative motion of the hob with respect
to the gear.
Several methods for generation of the surface T of a cutting tool
36 GEAR SOLUTIONS APRIL 2007 gearsolutionsonline.com
are known [1]. Following common practice, for generation of the sur-
face T of an involute gear hob the single-parametric method can be
used [1]. This method is based on the first method of generation of
enveloping surfaces proposed by Olivier2 [7].
The generating surface T of a gear hob could be generated in three
steps. For this purpose it is required (a) to specify the gear tooth
surface to be machined, (b) to generate an auxiliary phantom rack R,
and, finally (c) to generate the surface T itself. Below, the generating
surface T of an involute gear hob is determined following the above
listed routine.
2.1.
Gear tooth surface. Gear tooth surface G is a screw involute sur-
face. In the left-handed Cartesian coordinate system XgYgZg it can be
described analytically in terms of curvilinear (Gaussian) parameters
Ug and Vg [8]
rb.g sin V g U g cos b.g cos V g
rb.g cos V g + U g cos b.g sin V g .
G : r g (U g , V g ) = (1)
pV g U g sin b.g
1
Here, in Eq. (1) is designated
rb.g = the gear base radius (rb.g = 0.5db.g=, and db.g is the gear base diameter)
g.b
= base lead angle
p = screw parameter of the gear tooth surface G
The interested reader may wish to go to [1], [8] for details on Eq. (1).
Equation (1) of the gear tooth surface G is of critical importance for
the analysis following below. Mostly, this is because it is helpful for
derivation of equation of the auxiliary phantom rack R, and of the
generating surface T of the involute hob.
2.2.
The auxiliary phantom rack R . The auxiliary phantom rack R of an
involute gear hob can be generated as an enveloping surface to con-
secutive positions of the gear tooth surface G in its motion relative
to the coordinate system XR YR ZR associated with the rack R. For
generation of the auxiliary rack R, the left-handed Cartesian coordi-
nate system XRYR ZR has been employed. Generation of the auxiliary
rack R is illustrated in Fig. 1.
Dg Gear being machining
g Og
A
VR
Eg
B
R WR R g FR Fg
FIG. 1. THE AUXILIARY PHANTOM RACK R OF AN INVOLUTE HOB.
 The gear being machined is rotating about it axis Og with a certain translation along YR axis at a distance 0.5Dg, and (c) the operator
angular velocity g. A pitch plane WR of the rack R is moving straight- Tr(l,XR ) of translation along XR axis at a distance l . The considered
forward. Velocity of this translational motion is designated as VR. operators of the elementary coordinate system transformations yield
The rotation g and the translation VR are synchronized in a timely equation for Rs(g0 R1)
manner. This results in that the pitch plane WR is rolling without slid-
Rs ( g0 R 1 ) = Tr (l , XR ) Tr (0.5 Dg , YR ) Rt ( , Z g )
ing over the pitch cylinder of diameter Dg of the gear. Without going
into details, one can come up with the conclusion that the lateral The interested reader may wish to go to [1] [9] for details of coor-
surfaces of the auxiliary rack R teeth are the planes. Face-width FR dinate system transformations.
of the rack R is identical to the face-width Fg of the gear ( g R ). Angle can be computed from equation = gt, and length
Pitch helix angle R is identical to the pitch helix angle g of the gear l=|V |t, where t designates time. Therefore, the gear tooth surface
(Fg FR ). The auxiliary rack R makes contact with the gear tooth sur- Gt in its current location in the coordinate system XRYR ZR could be
face G along straight-line segment AB, which is often referred to as analytically described by equation
the characteristic Eg.
Gt : rg .t = Rs ( g 0 R 1 ) rg
The intuitive understanding of the shape of the lateral tooth sur-
faces of the rack R is helpful but not sufficient. For further consider- Equation (3) for Gt can be cast into the form rg.t (Ug,Vg,t), which is
ation, equation of the rack R tooth surface is required to be derived. expressed in term of the parameter t of relative motion. This imme-
The major coordinate systems to be used in this research are the diately yields analytical representation for the lateral tooth surface of
following: (a) the coordinate system XgYgZg embedded to the gear, (b) the auxiliary rack R
the coordinate system XRYR ZR associated with the auxiliary rack R
(Fig. 2), and ultimately XhYhZh connected to the involute hob. A few
rg .t = rg (U g , Vg , t )
more intermediate coordinate systems were used as well. R rg .t
The auxiliary rack tooth surface R could be represented as an (U g , Vg , t ) = 0
t
enveloping surface to consecutive positions of the gear tooth surface
G, while the pitch plane WR is rolling without sliding over the pitch Exploding Eq. (4) and eliminating the enveloping parameter t, one
cylinder of diameter Dg. This concept can be used for derivation of can come up with an equation of the lateral tooth surface of the aux-
equation of the surface R. iliary rack R in matrix representation
In order to derive equation of the surface R, it is necessary to
represent (a) the gear tooth surface G, (b) the pitch plane WR, and rR = [ X (UR , VR ) Y (UR , VR ) Z (UR , VR ) 1] T
(c) their relative motion in a common coordi-
nate system XRYR ZR. Therefore, the operator
Rs(g0 R 1) of the resultant coordinate system
transformations is required to be composed.
The resultant coordinate system transfor-
mation could be analytically represented as a
superposition of several elementary coordinate
system transformations (Fig. 2). The elemen-
tary coordinate system transformations could
be analytically described by (a) the operator
Rt( ,Zg) of rotation about Zg axis through an
angle , (b) the operator Tr(0.5Dg,YR ) of

g
X g .1

Dg

Og X g .0
VR
XR .0

Y g .0 Y g .1 XR .1

WR l

YR .0 YR .1

FIG. 2. TO GENERATION OF THE AUXILIARY RACK

R OF AN INVOLUTE HOB.

gearsolutionsonline.com APRIL 2007 GEAR SOLUTIONS 37

 Equation (5) for R could also be derived using equation of con-
tact ng V .g= 0 [1], [4]. Here ng designates the unit normal vector
to the surface G , and V .g designates velocity vector of relative
motion of the surface G and of a coordinate system embedded to
the auxiliary rack R . Unit normal vector ng could be computed from
the equation ng =ug x vg, where ug =Ug |Ug|, vg =Vg |Vg|, and Ug =rg Ug,
Vg =rg Vg. Relative motion of the gear G and of the auxiliary rack R
yields representation in the form of instant rotation about pitch point
P . Therefore,vector V .g could be represented as the vector of linear
velocity of instant rotation about P .
The actual value of the auxiliary rack normal pressure angle R is
equal to the gear normal pressure angle at the pitch point when it
meshes with the rack R . Variation of kinematics of relation motion
results in corresponding variation of normal pressure angle R (see
[10] for details). In a gear hobbing operation, use of hobs with dif-
ferent normal pressure angle causes transition curves of different
parameters (see [10] for details).
configuration (location and orientation) of the plane R , an auxiliary
plane of projections 4 is constructed. The axis 1/4 is orthogonal
to the trace R 1 .
The hob base helix angle b.h is the angle that the lateral rack sur-
face R makes with a plane that (a) is orthogonal to the horizontal
plane of projections 1 , and (b) is orthogonal to the trace R4 . Use
of conventional descriptive geometry rules yields construction of the
hob base helix angle b.h, as well as the hob base lead angle b.h that
complements the angle b.h to 90 (Fig. 3).
The derived solution (Fig. 3) to the sub-problem of determining of
the base helix angle b.h gives an insight to how an expression for
d2
A2 R 2 H2
Q2 a2 g2 g3

2.3.
The generating surface T of an involute hob. The surface T of an 2 3
f2 e2 b2 s2
involute hob can be generated as enveloping surface to consecutive
f1 c2 b1 d 1 1 f3 s3
positions of the auxiliary phantom rack R in its screw motion rela- 1 a1
tive to the hob axis. In order to get a comprehensive understanding c1 e1
4
of the involute hob geometry, it is helpful to consider two different R 4
approaches for determining of the surface T . The first approach is b.h
H2
a descriptive-geometry-based approach to which we refer to as the
DGB-approach3. The second approach is an analytical one. It is usu- Q1
ally referred to as the DG/K-approach4. The DGBapproach gives a a4
A1 R 1 g1
fruitful insight to the development of the DG/K-approach. It could be
considered as a perfect filter for the elimination of rough errors h n
of the analysis. Both the approaches complement one another, and s1
b.h
together they provide the user with profound understanding of the
involute hob geometry and kinematics of the surface T generation
[8], [11], [12]. FIG. 3. DETERMINING OF BASE HELIX ANGLE B.H
OF AN INVOLUTE
HOB.

2.3.1. computation of b.h can be derived. Using the above solution (Fig. 3),
The DGB-approach of the surface T generation. It is convenient to one can come up with the equation [1], [13], [14].
subdivide the problem of generation of the gear hob surface T onto cos b.h = cos n cos h
several sub-problems.
Base helix angle. For solving of the problem of determining of the Equation (6) could also be represented in the form
hob base helix angle, actual values of normal pressure angle n and
the hob-setting angel h are required been known. sin 2 n + tan 2 h
tan b.h =
The solution to the problem under consideration is represented cos n
in the system of three planes of projections. They are 1, 2 and 3
respectively. An auxiliary plane of projections 4 is also used. Here is designated
In order to determine the hob base helix angle b.h using DG- n
= normal pressure angle
based method, the lateral tooth surface of the auxiliary rack R is h
= hob-setting angle
required been constructed. Lets start from an arbitrary plane A that Base lead angle b.h can be computed from the equation b.h
=90 b.h
.
is orthogonal to the axis of projections 1 2 (Fig. 3). The plane A
is specified by the traces A1 and A2 . After being turned about the Base diameter of an involute hob. The generating surface T of a
trace A2 through the hob-setting angle h the plane A occupies the gear hob can be represented as an enveloping surface to consecutive
position of the plane Q . The plane Q is specified by the traces Q1 positions of the plane R that is performing a screw motion around
and Q2 . Then the plane Q is turned about the trace Q1 through the the hob axis of rotation.
normal pressure angle n of the hob tooth. In this final location, the Consider the plane R in a system of planes of projections 123
plane is designated as R , and it is specified by the traces R1 and (Fig. 4). The plane R is performing a translational motion along the
R2 respectively. axis 1/2 with a certain velocity VR . Simultaneously, the plane R is
In order to construct the hob base helix angle b.h in this particular rotating about that same axis 1/2 with an angular velocity R .

38 GEAR SOLUTIONS APRIL 2007 gearsolutionsonline.com

 this purpose, velocity of translational motion
VR is required to be considered together with
linear velocity of rotation R . Those points of
Va.2 Vav.2 Vb.2 Vbv.2 the plane R at which the resultant velocity V
a2 Va.3 Vav.3 b3 Pr h Vb.3
is orthogonal to NR belong to the characteris-
NR b2 a3
.2 E2 E3 tic E . The characteristic E is the straight-line
VR at a distance 0.5 db.h from the hob axis of
Pr v Vb.3 Vb.3
R 2 R2 h R3 rotation that crosses the axis at the base
Va.1 = R R
helix angle b.h of the hob.
Vb.1 = R R 2 3
db.h
a1 Vav.1 The solution to the problem of determining
1 the base diameter db.h is depicted in Fig. 4.
R The developed solution to the sub-problem
NR Va.1
.1 b.h
under consideration is insightful for deriva-
Va.1 R1
tion of the equation
E1 Vbv.1
m N h cos n
R b1
db.h =
1 cos 2 n cos 2 h
1
Vb.1
Vb.1

b.h for computation of the diameter db.h .

Here is designated
FIG. 4. DETERMINING OF THE INVOLUTE HOB BASE DIAMETER dB.H.
m = hob modulus
Nh = number of starts of the hob

The base diameter db.h of the involute hob tic E it is required to select those points of
is equal to the shortest distance of approach the plane R at which the resultant speed 2.3.2.
between the characteristic E and the axis of the plane points is perpendicular to the The DG/K-approach of generation of the surface
1/2. In order to determine the characteris- normal vector NR to the plane R itself. For T of an involute hob. Equation of the generating

gearsolutionsonline.com APRIL 2007 GEAR SOLUTIONS 39

surface T of an involute gear hob can be derived using elements of theory
of enveloping surfaces, which is a part of DG/K-approach of surface
generating.
In order to derive equation of the surface T , it is convenient to consider
the relative motion that the auxiliary rack R is performing with respect to
the coordinate system XhYhZh embedded to the hob. The coordinate sys-
tem XhYhZh is the left-handed Cartesian coordinate system (Fig. 5).
Similarly to Eq. (2), the operator Rs(R T) of the resultant coordinate
system transformation could be composed
Rs (R T ) = Rt ( , Z h ) Tr (0.5d h , Y h ) Tr (l , X h )
In Eq. (9), the hob angle of rotation is equal to =| h | t , and transla-
tion of the auxiliary rack R can be computed from the equation l =|VR | t.
The hob pitch diameter is designated as dh .
The derived Eq. (5) together with Eq. (9) could be employed for analyti-
cal description of the auxiliary rack R that is performing a screw motion
with respect to the hob axis of rotation Oh . Corresponding equation for the
auxiliary rack Rt in its arbitrary position is as follows.
Gear
d w.g
For computation of the hob base diameter db.h and the hob base helix
angl b.h Eq. (6) and Eq. (8) can be employed.
Equation (12) is of critical importance for the development of a novel
design or gear hob for hobbing of precision involute gears. Important fea-
tures of geometry of the surface T are the major reasons for this. It is easy
to verify that for a specific value of Vh , Eq. (12) describes a straight-line
on T , the so-called the characteristic line Et . Further, the lateral cutting
edge of the involute hob will be aligned with the straight-line characteristic
Et . Therefore, the straight-line characteristic Et will serve as a vital link
between the geometry of the generating surface T of the involute hob and
the principal features of its design. Again, this intermediate result is of
critical importance for the analysis that follows.
Equation (12) for the surface T could also be derived using equation
of contact nR V .R =0 [1], [4]. Here nR designates the unit normal vector
to the surface R , and V .R designates velocity vector of relative motion
of the surface R and of the coordinate system XhYhZh embedded to the
hob. The unit normal vector nR could be computed from equation nR =uR
vR , where uR =UR /|UR |, vR =VR /|VR |, and UR = rR / UR , VR = rR
/VR. It is convenient to decompose V .R onto V .R =V(n) R
+VR(t) . Motion with
V(n)
R
is directed perpendicular to the auxiliary rack R . This motion results
in enveloping surface T . Motion with VR(t) is directed along the auxiliary
rack R. This motion results in sliding of the auxiliary rack surface R over
itself. It doesnt affect the shape of the surface T and, therefore, it is out
of our current interest. Ultimately, the decomposition of V .R yields elimina-
tion of VR(t) , and simplifies further analysis.

Og Xg 3: Principal Parameters of Design of the Involute Gear Hob

Yg XR The above consideration (see sub-section 2.3) yields a conclusion, which
g is significant for further development of an involute gear hob of the novel
YR design. The concept of the novel design of an involute hob is based on
VR R
the following considerations: (a) lateral cutting edges of one side of an
involute hob tooth belong to the corresponding screw involute surface; (b)
P
lateral cutting edges of the opposite side of the involute hob tooth belong
Yh to the opposite screw involute surface; (c) the screw involute surfaces of
Oh Zh
the opposite sides of the involute hob tooth intersect each other, and the
line of intersection is a helix; (d) two characteristics El and Er are pass-
d w.h
ing through every point of the helix; (e) the two characteristics El and Er
through the common point of the helix intersect one another at that point
and, thus they specify a plane; (f) that plane is used as a rake-face of the
h T involute hob teeth.
FIG. 5. CYLINDRICAL GENERATING SURFACE T OF AN INVOLUTE HOB. The above listed steps yield determination of orientation of the rake-
face of the involute hob teeth.
R t : rR .t = Rs (R T ) rR = rR .t (UR , VR , t )

The generating surface T of the involute gear hob can be analytically 3.1.
described by the set of two equations The DGB-approach of determining of orientation of the rake-face. The DGB-
solution to the problem of determining of orientation of the rake-face of the
rR .t = rR .t (UR ,VR , t ) involute hob teeth is depicted in Fig. 6.
T rR .t For solving of the problem of determining of orientation of the hob tooth
(UR ,VR , t ) = 0
t rake-face, the following parameters of design of the hob are required to be
known: the hob tooth modulus m , normal pressure angle n , the hob-set-
After substituting of Eq. (4), the Eq. (11) casts into ting angel h , number of starts of the hob Nh , the hob outside diameter
Do.h , and the hob base diameter db.h.
0.5 db.h sin Vh U h sin b.h cos Vh The solution to the problem under consideration is represented in the
0.5 db.h cos Vh + U h sin b.h sin Vh system of three planes of projections 1, 2 and 3 respectively. Two auxil-
T : r h (U h , Vh ) = iary planes of projections, say 4 and 5, are also used. The auxiliary axis
p hVh U h cos s b.h
of projections 1/4 makes the hob-setting angle h with the axis of projec-
1 tions 1/2. The axis of projections 1/5 is parallel to the axis 1/4. Use

40 GEAR SOLUTIONS APRIL 2007 gearsolutionsonline.com

of the plane of projections 5 yields considerable size reduction of Fig. 6. A2 A3
d2 e2
In the system of three planes of projections 1, 2 and 3 , the axis of e3 d3
l2 n2 n3 l3
the hob rotation O is oriented parallel to the axis 1/2 (Fig. 6).
Normal plane section of the auxiliary rack R tooth is shown in the
plane of projections 4 .
R d f .h dh do.h T3 P3
Consideration of images of the hob elements in the planes of projec-
tions 4 and 3 (that are connected to one another through the planes of Er El
Base Cylinder
projections 1 and 2) yields determination of location of the point A within 1 3

3 . Two straight lines through A3 that are tangent from the opposite sides db.h
O2 f 2 g2 f3 g3
to the hob base cylinder of diameter db.h represent straight lines which the
b2 a2 b3 O3 a3
lateral cutting edges of the hob align to. The rake-plane of the hob tooth 1
is the plane through these two straight lines. Conventional methods of f1 2 e1 T1
descriptive geometry are used for the construction of all others projections b1 O1
1 1
P1 l1 A n1 a1
of these two straight lines that initially are constructed in 3 . 1
5
h
d1 1 g1
Angle that the rake-plane makes with the hob axis of rotation O is 4
constructed in the plane of projections 1. b4 a4 O4
db.h
g4
The hob tooth profile in the rake-plane is shown in the plane of f4
projections 5 .
K4 n n M4 r r

3.2. do.h dh d f .h

b ht
The DG/K-approach of determining of orientation of the rake-face. Figure R
6 provides a clear understanding of the geometry of the precision involute
n5 l5
gear hob with straight-line lateral cutting edges. Understanding features l4 n4
of the hob geometry (see sub-section 3.1) is very helpful for derivation d 4 e4 tr
A4 tc Sc a
of equations for computation of major parameters of the gear hob of the
developed design. Pn

FIG. 6. DETERMINING OF THE ORIENTATION OF THE RAKE-FACE

3.2.1. OF AN INVOLUTE HOB TEETH.
An auxiliary parameter R . Lateral tooth surfaces of the auxiliary rack R
intersect each other along a straight line through the point A (Fig. 7). This
straight line is at a distance R from the hob axis. For the distance R Fig. trf The rake face
8 yields
Yh
R = 0.5 ( d h + tc cot n ) (13) A th
A

3.2.2.
The angle r between the lateral cutting edges of the hob tooth. Prior to
D
deriving the equation for computation of the angle r that make the lateral R C h
cutting edges of the gear hob tooth, it is convenient to derive an equation
for computation of projection of the angle r onto the coordinate plane n Er
B
XhYh.
The projections of the lateral cutting edges of the involute tooth onto the r Zh
coordinate plane XhYh make an angle . g
El
For computation of the actual value of the angle , the following expres-
D
sion can be used

tan =
db.h E
4 R 2
db2.h db.h
f

Then, consider three unity vectors A, B, and C. These vectors yield the
Xh
following analytical representation
A = [cos h 0 sin h 1] T

B = [sin n sin h cos n sin n cos h 1] T FIG. 7. ORIENTATION OF RAKE-FACE OF THE PRECISION GEAR HOB.

C = [ cos r tan cos r sin r cos 1] T

gearsolutionsonline.com APRIL 2007 GEAR SOLUTIONS 41

 tr
The idea of the hob-setting angle can be traced back to the publication
Yh A by Buckingham (1963) [11].
A As the vectors A , B , and C are located within the common lateral
surface of the auxiliary rack R , therefore the following identity AB C 0
Prxy C
observes. The last expression yields a determinant
El Er R
R Yh cos h 0 sin h
D r 0.5 d h
El Er
db.h
sin n sin h cos n sin n cos h = 0

g Xh cos r tan cos r sin r cos
f
Oh Prxz E f Prxy C Pr A g

db.h L

db.h cot
0.5 do.h
~ 0.6
Zh
0.5 d h

0.5 d h
h
n E A
tc A Xh d b.h
Er
Prxy C tr d w.h
A r
B A
do.h
db.h
El

FIG. 8. THE EMPLOYED CHARACTERISTIC VECTORS.

Fig. 8. The employed characteristic vectors.

Here h designates the hob-setting angle of the involute hob. The angle
h
is measured in the auxiliary rack R pitch plane. It is the angle that FIG. 10. THE INVOLUTE GEAR HOB AFTER BEEN REGROUND.
makes a perpendicular to the rack R tooth and axis of rotation of the hob
(Fig. 9) [8],[14] After exploding of the determinant, and after the necessary formulae
Required for further computations, the hob-setting angle h can be cho- transformations are performed, one can come up with the equation of two
sen by a designer of the gear hob. Usually it is recommended to assign unknowns, namely of r and .
the actual value of the hob-setting angle h equal to the pitch helix angle
of the hob. As it is proven in our earlier work [14], in order to satisfy the
3.2.3.
h
equality h= h (this condition is the best possible) the actual value of the
hob-setting angle is required to be computed from the equation. The angle of intersection of the rake-face and of the hob axis of rotation.
Rake-face of the involute hob is inclined to the hob axis at a certain angle
m Nh
tan h = . In order to determine the required value of the angle , the following
(d o.h 2 1.25 m do.h ) 2 m 2 N h2 three unity vectors C, D, and E were used. For the vectors D and E Fig. 8
yields
Here do.h designates reduction of the hob outside diameter do.h due to
D = [0 1 0 1] T
re-sharpening of the worn gear hob (Fig. 10). Figure 10 yields very simple
formula for computation of do.h = (do(new)
.h
(worn)
do.h ). E = [sin 0 cos 1] T
R
Og Face As of the vectors C, D, and E are located within the rake-face of the hob
0
Oh Oh tooth, therefore the following identity CD E 0 observes. This yields a
determinant
R + + h
Oh
FR
C cos r tan cos r sin r cos
0 1 0 =0
sin 0 cos

R Face WR h After exploding of the determinant, and after the necessary formula
transformations are performed, one can come up with the one more equa-
FIG. 9. HOB-SETTING ANGLE OF AN INVOLUTE HOB.
tion of two unknowns, namely of r and .
h

42 GEAR SOLUTIONS APRIL 2007 gearsolutionsonline.com

 Further, consider the set of two equations, say of Eq. (19) and Eq. (22)
of the two unknowns r and . Solution to the set of the above equations
can be represented in the form
cos h tan
tan =
tan n + sin h tan
tan
tan r =
sin
The hob-setting angle h specifies inclination of the gear hob axis of
rotation Oh with respect to the auxiliary rack R . It is necessary to point
out here that the angle h is a parameter of the gear hob design, and is
not a parameter of gear hobbing operation. Figure 9 reveals that it could
be either positive ( + h > 0 ), or negative ( h < 0 ), as well as it could
be of zero value ( h = 0 ). Under special conditions, the hob-setting angle
could be equal to the gear hob pitch helix angle R (i.e. the equality h = R
could be observed).
The design of gear hob with the computed parameters (Table 1) satis-
fies all the necessary and sufficient conditions of proper surface generat-
ing on machine tool [1], [4], [6] and, what is especially of importance,
gearsolutionsonline.com
The above Eq. (23) and Eq. (24) are necessary for computation of the
required values of the angles r and . These angles are necessary been
indicated in the involute hob blueprint.
The involute hob of novel design [15] with the angle computed from
the Eq. (23), and the angle r computed from the Eq. (24) (a) has straight-
line lateral cutting edges, and (b) it is free of the major source of the tooth
profile deviations. Two more modifications of the gear hob design [16],
[17] are developed as well.
Example of computation. The above derived equations yield computa-
tion of parameters of the novel hob design for machining of precision invo-
lute gears. Such computations can be done, for example, for the single-
start FETTE gear hob (DIN 8002A, Cat.-No 2022, Ident. No 1202055) of
module m =10 mm , outside diameter do.h = 180mm, and pressure angle
n
= 20 [18].
Results of computation are collected in the Table 1 below.
it satisfies the fifth necessary condition of proper surface generating
[10]. The conclusion of this article will appear in the May issue of Gear
Solutions magazine. CONTINUED ON PAGE 50 >
APRIL 2007 GEAR SOLUTIONS 43
 < CONTINUED FROM PAGE 43

REFERENCES:
[1] Radzevich, S.P., Fundamentals of Surface Generation. Monograph, Kiev, Rastan, 2001, 592p. Copy
of the monograph is available from The Library of Congress.
[2] Bregi, B.F., Erxleben, R.F., Tersch, R.W., et al, Modern Methods of Gear Manufacture, 4th Edition,
National Broach & Machine Division/Lear Siegler, Inc., 5600 St. Jean Ave., Detroit, MI 48213, 1972,
160p.
[3] Townsend, D.P., Dudleys Gear Handbook. The Design, Manufacture, and Application of Gears, 2nd
Edition, McGraw Hill, Inc., New York, 1991.
[4] Radzevich, S.P., Sculptured Surface Machining on Multi-Axis NC Machine, Monograph, Kiev, Vishcha
Shkola Publishing House, 1991, 192p. Copy of the monograph is available from The Library of
Congress.
[5] Radzevich, S.P., Diagonal Shaving of an Involute Pinion: Optimization of Parameters of the Pinion
Finishing Operation, The International Journal of Advanced Manufacturing Technology. (In press).
[6] Radzevich, S.P., Conditions of Proper Sculptured Surface Machining, Computer-Aided Design,
Vol.34, No 10, September 2002, pp.727-740.
[7] Olivier, T., Theorie Geometrique des Engrenages, Paris, 1842.
[8] Radzevich, S.P., About Hob Idle Distance in Gear Hobbing Operation, ASME J. of Mechanical Design,
December, 2002, Vol. 124, Issue 4, pp.772-786.
[9] Radzevich, S.P., Design of Shaving Cutter for Plunge Shaving a Topologically Modified Involute Pinion,
ASME J. of Mechanical Design, September 2003, Vol. 125, Issue 3, pp.632-639.
[10] Radzevich, S.P., A Novel Approach for Computation of Constraints on Parameters of Modification
of the Tooth Addendum of Precision Involute Hob, ASME J. of Mechanical Design, July 2006, Vol.
128, Issue 6, pp.000-000.
[11] Buckingham, E., Analytical Mechanics of Gears, Dover Publications, Inc., New York, 1963, 546p.
[12] Radzevich, S.P., A Descriptive-Geometry-Based-Solution to a Geometrical Problem in Rotary
Shaving of Shoulder Pinion, ASME J. of Manufacturing Science and Engineering, November, 2005,
Vol. 127, Issue 4, pp. 893-900.
[13] Radzevich, S.P., Design and Investigation of Skiving Hobs for Finishing Hardened Gears, Ph.D. Thesis,
Kiev Polytechnic Institute, 1982, 286p.
[14] Radzevich, S.P., Cutting Tools for Machining Hardened Gears, Moscow, VNIITEMR, 1992, 60p.
[15] Pat. No. 990.445 (USSR), A Precision Involute Hob./S.P. Radzevich, Filed: October 08, 1981, Int.
Cl. B23F 21/16.
[16] Pat. No. 1.114.505 (USSR), A Precision Involute Hob./S.P. Radzevich, Filed: October 18, 1982, Int.
Cl. B23F 21/16.
[17] Pat. No. 2.040.376 (Russia), A Precision Involute Hob./S.P. Radzevich et al, Filed: January 03, 1992,
Int. Cl. B23F 21/16.
[18] FETTE. Gear Cutting Tools: Hobbing, Gear Milling, Leitz Metalworking Technology Group, 196p.

FOOTNOTES:
1) The DG/K-approach is based on fundamental results obtained in differential geometry of surfaces, and
in kinematics of multi-parametric motion of a rigid body in E3 space (For details see (i) Radzevich, S.P.,
Sculptured Surface Machining on Multi-Axis NC Machine. Monograph, Kiev, Vishcha Shkola Publishers,
1991, 192p Copy of the monograph is available from The Library of Congress [4]; and (ii) Radzevich,
S.P., Fundamentals of Surface Generation. Monograph, Kiev, Rastan, 2001, 592p Copy of the mono-
graph is available from The Library of Congress [1]). A perfect example of application of the DG/K-
approach is disclosed in the paper: Radzevich, S.P., Diagonal Shaving of an Involute Pinion: Optimization
of Parameters of the Pinion Finishing Operation, The International Journal of Advanced Manufacturing
Technology. (In press) [5].

2) Olivier, T. disclosed two principal methods of generation of enveloping surfaces in his work published
as early as in

3) The DGB-approach proved to be useful for solving variety of gear related problems (see, for example, the
monograph by Buckingham [11], as well as more recent publications [8] [12]).

4) The DG/K-approach is based on fundamental results obtained in differential geometry of surfaces, and
in kinematics of multi-parametric motion of a rigid body in E3 space. The method is disclosed in two
monographs [1], [4] by the author. Both the monographs are available form the Library of Congress.

ABOUT THE AUTHOR:

Stephen P. Radzevich, Ph.D., is with the Innovation Center in the Eaton Corporations
automotive business segment. He can be reached at (248) 226-6831 or stephen-
pradzevich@eaton.com. Go online to [www.eaton.com]. This article appears courtesy
of the American Society of Mechanical Engineers (ASME).

50 GEAR SOLUTIONS APRIL 2007 gearsolutionsonline.com