NACHI - Precision Tools

Precision Tools
Precision Tools
Gear Cutting Tools & Broaches
Pursuing advanced high-speed technology that is both user and environmentally friendly
Since developing Japan's first broaching machine in the late 1920s, Fujikoshi has developed a variety of tools and machine tools to handle advancements in production systems. Fujikoshi continues to lead the way by developing machining systems that integrate tools and machines.
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Gear Cutting Tools
Guidance
Materials and Coating of Gear Cutting Tools 5 Gear Cutting Comparison and Types NACHI Accuracy of Gear Shaper Cutters Cutting Condition and Regrinding Disk Type Shaper Cutters Type1Standard Dimensions 25 26 27 28 30 31
Technical Introduction
Hard Hobbing High Speed Dry Hobbing High Performance Shaving Cutter Dual Forming Rack 6 7 9
Disk Type Shaper Cutters Type2Standard Dimensions Disk Type Shaper Cutters Type2Standard Dimensions Helical Gear Shaper Cutters Disk Type Shaper Cutters Type3Standard Dimensions Clutch Keyway Dimensions Deep Counterbore Type Shaper Cutters Standard Dimensions 10 Sproket Shaper Cutters Standard Dimensions
32
33 34
Hobs
Hob Cutting Action and Nomenclature Inclination Angle of Hob and Hobbing Methods Multi-thread Hob and Short Pitched Hob Design Tooth Profiles of Hob and Sign NACHI Accuracy of Gear Hobs Standard Keyways for Hobs Cutting Condition and Regrinding Solid Gear Hobs Standard Dimensions Fine Pitch Gear Hobs Standard Dimensions Involute Spline Hobs Tooth Profile Parallel Side Spline Hobs Standard Dimensions Roller Chain Sproket Hobs Standard Dimensions 11 12 13 14 15 17 18 19 20 21 22 23
Shaving Cutters
Feature and Nomenclature of Shaving Cutters Shaving Methods and Features Shaving Mechanism and Cycle Diagram NACHI Accuracy of Shaving Cutters Standard Number of Cutter Teeth and Simple Calculation for Cutter Width 35 36 37 38 39
Forming Racks
Feature and Rolling Principles Example Type of Racks and Basic Dimensions 40 41 42
Other Types of Gear Cutting Tools Gear Shaper Cutters

Feature and Nomenclature of Gear Shaper Cutters 24 Gear Chamfering Tools Reverse Lead Taper Tooth Forming Tool 43 44
Hard Broaches Broach for MQL Off-normal Gullet Helical Broach Micro Module Broaching 45 46 47 48
Basic Design and Cutting Method Calculation of Pulling Load Face Angle and Relief Angle Finished Size of Broaches
61 62 63 64
Guidance
Terms of Internal Broaches Terms of Surface Broaches Nomenclature of Broaching Machine Cycle of Broaching 49 50 51 52
Pull End
66
Retrievr End
70
GPA
Internal Broaches
Work Piece Samples of Internal Broaches Involute Spline Broaches Push Broaches Helical Broaches 53 54 55 56
71
Surface Broaches
Work Piece Samples of Surface Broaches Connecting Rod Broaches Fir Tree Type Broaches Steering Rack Broaches 57 58 59 60
Broaches
Essential Points and Notice for Broaching Process
65
Gear Cutting Tools
Broaches
Design of Broach
Guidance
Gear Cutting Tools
Materials and Coating of Gear Cutting Tools

Gear Cutting Tool Material
Tool Material HSS HSD SKH51 SKH55 FM34D FM29A FM23A Power HSS FAX31 FAX38 Nitride TiN Dual Heat Resistance Wear Resistance Hobs Gear Shaper Cutters Shaving Cutters Forming Racks Features Toughness Up Toughness Up Standard Crater Wear Resistance Wear Resistance Wear Resistance
Guidance
FAX55 Carbide Surface Treatment
Coating Technology
Hardened Steels 50HRC
TiAIN Multilayered Coating AG Coat TiC TiNTiC TiCN Multilayered TiCN Multilayered Coating Coating Platina Coat UG Coat SG Coat Hybrid Surface Modification + Rigid Film CBN TiAIN Multifunctional Multilayer Composite Film Aqua Coat Dual Coat GS Hard Coat Surface Modification + Multi-element & Multilayer Film
Hybrid
Hardened Steels 40HRC
Carbon Steels Cast Irons
TiCN
TiN G Coat
Generation
'80
'85
'90
'95
'00 Hybrid
'05
Coating Technology Creation
Compound Multilayer Increase of Film
VBWear
NACHIs coating technology developed from research on physical vapor deposition (PVD) ion plating. By using the peculiarities of ionization acceleration technology, surfaces can be coated with multiple layers of TiN, TiC and TiCN. The tool life of coated products are extended to five times those of uncoated products because the coatings have very good wear resistance and solvent resistance. It makes high speed and high performance possible and greatly reduces total costs.
Performance of Dual Coat Hob

(mm) 0.3 0.2 Dual Coat 0.1 TiN Coat
1000
2000 3000 Number of Gears
4000
Hob 95L150 31.75, 3Thread, RH, 12Number of Teeth, FM34D Workpieces m1.75PA17.5 30T30RH, Tooth Width18mm, SCr420, 150HB Cutting ConditionCutting Speed V150m/min, Feed F2.0mm/rev, Cutting Face Non Coat, Dry Hobbing
Hard Hobbing
Suitable for high accuracy gear hobbing of the shaft and small module which was difficult in grinding Realized high accuracy by hob and spindle one body tooth profiles grinding Achieved longer tool life by Hyper Dual coat and herd metal of new development
Carbide Hob Technical Introduction After Carbide Hob with shank
Work Piece
Before
Accuracy
Before Hard Hobbing After Hard Hobbing Before Hard Hobbing After Hard Hobbing
Profils Error
Lead Error
Performance
Comparison of Tool life
Cutting face Hard Hob Non Coat Competitor Coat
Number of Gears
1500 1000 500 0
NACHI Hard Hob
Competitor
KE250 (Kashifuji)
Workpiece Module Number of Teeth Pressure Angle Tooth Width Material 2 6 20 28mm SCM420(60HRC) Hob Specifications Outside Dia. Overall Length Threads Flutes 50mm 100 1 12 Cutting Conditions Cutting Speed Feed Cutting Method Coolant 2.5mm/rev 2.5mm/rev Climb Cutting
Hard Hobbing
Gear Cutting Tools
Hobbing of hardened gear is possible
Gear Cutting Tools
Realize High Speed Dry Hobbing of 250m/min
High Speed Dry Hobbing

Both and hobbing are perfomed by one hob. A long tool life is ensured even in high speed dry hobbing. Dual coat improves in wear resistance and the heat-resistant oxidation. Coherence and tenacity, anti-welding improve, too. New steel class is good in heat-resistant shock and chipping resistance, wear resistance.
Dual Cut Hob Technical Introduction High Speed Dry Hobbing
Dry Hobbing
Performance
Comparison of tool life
Method Cutting Speed (Pcs/Reg) 1200 Number of Gears 1000 High Speed Dry Hobbing 150m/min Method Cutting speed Wet 120m/min High Speed Dry Hobbing 160m/min
Comparison of Tool Life
1.5 times the tool life of competitors

800 530
1.8 times the tool life of conventional products

2.0 1.8 2.0
500
1.0
1.0
Hob
Dual Cut Hob
Competitor A
Competitor B
Hob
Conventional
Dual Cut Hob
Workpiece Module 2.5
Hob Specifications Outside Dia. 85 Overall Length 200 Threads Flutes 4THD 16
Cutting Conditions Feed Rate 2.5mm/rev
Workpiece Module 2.8
Hob Specifications Outside Dia. 105 Overall Length 150 Threads 3THD 14
Cutting Conditions Feed Rate 2.2mm/rev
Number of Teeth 65 Tooth Width Material 30mm SCR420
Cutting Method Climb Cutting
Number of Teeth 48 Tooth Width Material SCR420H
Cutting Method Climb Cutting Cutting Length 210m
Flutes
As for the Hyper Dual coating, high speed dry processing more than 200m/min is possible, too.
(mm/revn) 4
HSS (wet)
HSS dry (Dry)
Hyper Dual (Dry)
Hyper Dual Cut Hob
Cabide (Dry)
100
200 Hobbing speed
300
Performance
0.3 0.25 0.2 Wear 0.15 0.1 0.05 0 0 40 80 120 Cutting Length 160 200(m) (mm)
Convention Hyper Dual
More than 5 times the tool life of conventional hobs
Convention
Hyper Dual Hobs
40m Cutting Length
40m Cutting Length
200m Cutting Length
Workpiece Module Pressure Angle Tooth Width Material 2.87 15 50mm SCM420(180HB)
Hob Specifications Outside Dia. Threads Flutes 90mm 3 12
Cutting Conditions Cutting Speed Feed Cutting Method Coolant 250m/min 2.2mm/rev Climb Cutting
High Speed Dry Hobbing
400 (m/min)
Feed
Cabide (Wet)
Gear Cutting Tools
Hyper Dual Cut Hob Features
Gear Cutting Tools
Realize High-speed Shaving
High Performance Shaving Cutter

Realize high speed, high feed shaving by improvement of serration and high rigidity design of a shaving cutter. Longer tool life by adoption of shaving cutter materials of new development. Adopt serration form to leave both end land in plunge cut shaving.
High Performance Shaving Cutter Technical Introduction
Performance
Gear
Workpiece m2.89, PA2312T, SPUR , Cutter 225 Type, 12 Conventional RH, Workpiece m2.25, PA2027T, SPUR , Cutter 225 Type, 15 Conventional RH, Competitor HSS NACHI SKH51 NACHI 1650 3500 2800 5000 2500 4200
Tool Life (pcs)

2500 3700
High Performance Shaving Cutter
Workpiece m2.25, PA17.579T LH , 28 Cutter 200 Type, 15.5 Plunge Cut RH, Workpiece m1.75, PA17.546T, 36 , LH Cutter 200 Type, 21 Plunge Cut RH,
Competitor HSS NACHI
SKH51 NACHI
Serration Form to Leave Both End Land
Finished Accuracy
Profile Error Lead Error
Chip
Workpiece Module 2
Cutter Specifications Outside Dia. 225 Type Number of Teeth 113 Helix Angle 13 LH
Shaving Conditions Shaving Method Plunge Cut Cutter Rotation Cutter Feed Cycle Time 280min-1 0.45mm/min 32second
Suitable Cutter Design by FEM
Number of Teeth 75 Tooth Width 25mm Helix Angle 28 RH
Dual Forming Rack

Special surface treatment improves in wear resistance and lubrication, and realize MQL roll forming. Longer tool life in both conditions of conventional oil coolant and MQL roll forming.
Dual Forming Rack
MQL Roll Forming
Conventional
Performance
Tool Life Comparison
PFM-610E
Work Spec. m1.058PA30Ng23 Work Rolling Length 20mm SCM440 200HB MQL MQL 12cc/h
Tool Life
100%
Oily
Water Soluble
MQL
MQL Dual Forming Rack
Convention Tool
MQL Roll Forming Example by Use of NC Roll Forming Machine.

Spline DP 24/48PA 30NT26 Rack Type 24in. Machine PFM610E Screw M 22P 1.5 Rack Type 13in. Machine PFM330E
Tool Life Tool Life Spline DP24/48PA30NT26 MQL Roll Forming Conventional Screw M22P1.5
MQL Roll Forming
Conventional
1 0
Dual Forming Rack
Gear Cutting Tools
Clean in MQL Roll Forming
Hobs
Gear Cutting Tools
Features of Gear Cutting Hobs

Hob is the cutting tool which has the rack cutting teeth on its body as the shape of a screw. The basic rack (rack cutting teeth) projects the rotating hob which has teeth in a screw pattern to generate the gear. Work piece is rotated so that it may gear with this basic rack, and feeding a hob in the lead direction generates the gear.
Hob Cutting Action

Hobs
Hob Hob
Basic Rack
Hob Cutting Action and Nomenclature
Gear
Axial Feed
Gear
Generating Chart
Hob Nomenclature
Cam Rise Cutting Face Flute Depth Keyway Flute Pitch Circle Diameter Outside Diameter Thread Helix Top Edge Right Edge Left Edge Hab Hub Face Hub Diameter Lead Angle Length of Teeth Overall Length Hub Length Pressure Angle Whole Depth of Cut Addendum Whole Depth
D ore
ete iam
Tooth
Normal Section of Hob Tooth Profile

Pitch Tooth Thickness Tip Radius Straight Portion
Pitch Line Tip Relief Modification
1 1
Hobs
Gear Hob
Spur Gear
Helical Gear Right Helix

Hob
Left Helix

Right
Gear
Handed
Tooth Lead Angle of Hob

Hob
Reverse Handed
Left
Gear
Reverse Handed
Handed Inclination Angle of Hob and Hobbing Methods
Helix Angle of Gear Tooth Lead Angle of Hob
Hobbing Methods and Comparison

Conventional Hobbing Climb Hobbing
Feed Hob Gear
Feed
Hob
Gear
Hobbing Elements Flank Wear of Hob Surface Roughness Chip Removal Bite of Chip Spur
Comventional Helical Spur
Climb Helical
Common Design
In case of the gears with the same module and pressure angle, it can be used with a common designed hob, even if a number of teeth and helix angle are differ. However, the amount of the chamfer changes depending on the number of teeth a semi-topping hob has. Chamfer of Gear
Large Number of Teeth Chamfer 70 40 25 20 0 Shift Coefficient Hob Chamfer Gear
Semi-topping Tooth Profile
Small
1 2
Hobs
Gear Cutting Tools
Inclination Angle of Hob
Hobs
Gear Cutting Tools
Gear Generation Line Chart of Multi-thread Gear Hob

Single Thread Hob 3threads Hob 5threads Hob
Hobs
Features of Multi-thread Gear Hob

Merits
Processing Efficiency Improves Because chip thickens, Tooth profile error is large
Demerits
1.Chipping of tooth edge is effective 2.Flank wear is controlled

Multi-thread Hob and Short Pitched Hob Design
Use of high rigidity hobbing machine
Short Pitched Hob Design

Applications of short pitch hobs 1. When the tip radius of hob is too small by the original pressure angle due to narrow space width on root diameter of gear. 2. When the space width on bottom of hob teeth is too narrow for manufacturing hob by the original pressure angle. 3. If change chip flow, and take cutting edge chipping measures.
Mesh with Normal Hob

Pb
20
Outer Diameter Hob Reference Circle Gear
Reference Circle
Base Circle
Base Circle
Mesh with Short Pitched Hob

PbH
15
Outer Diameter Hob Reference Circle Gear Cutting Pitch Circle Base Circle
Reference Circle
Base Circle Cutting Pitch Circle
1 3
Hobs
D+F
D+F
D+F
Semi-topping Finishing Use Pre-shaving Use Pre-grinding Use S-TOP PS PGS
Protuberance PP PGP
Semi-topping and Protuberance PSP PGSP

Hobs
D+F
D+F
D+F
Finishing Use Pre-shaving Use Pre-grinding Use D+F Whole Depth of Cut
TOP
Tooth Profile with Protuberance

Tooth Profile Hobbing Finish Tooth Profile
Hobs
Work Gear
Protuberance
1 4
Tooth Profiles of Hobs and Sign
Modified Tooth Crest
Topping
Topping and Semi-topping
Gear Cutting Tools
Tooth Profiles of Hobs
Hobs
Gear Cutting Tools
NACHI Accuracy of Gear Hobs

Hob Elements Grade 8 0+4 0+6 10 Bore Diameter AA A 13 0+5 0+8 22 22.225 Tolerance Bore Diameter(mm) 27 32 40 25.4 26.988 31.75 38.1 0+9 0+11 50 50.8 60 63.5 76.2 0+13
Unit : m
80
Tolerance Hob Elements Grade 0.1m0.25 Hub Diameter Runout

Hobs
Module 0.25m0.6 5 5 3 5 10 16 10 12 19 25 6 10 4 6 8 12 3 5 16 20 0.6m1 5 5 3 5 12 20 12 16 22 32 8 12 4 8 7 11 5 8 10 16 4 6 16 20
Hub Face Outside Diameter Ajacent Flute Spacing Accumulative Flute Spacing
Flute Radial Alignment of Flutes Lead Over Cutting Face Width()

Adjacent Error 1 Thread 2 Threads In Any One Turn of Helix Lead 4 Threads 5 Threads 1 Thread In Any Three Turn of Helix 2 Threads Single Pitch Error() 2 Threads Adjacent Error 3 Threads 4 Threads 5 Threads 1 Thread 2 Threads Three Pitch Error() 3 Threads 4 Threads 5 Threads Adjacent Error Action Length of Action Tooth Profile Error Profile Tooth Thickness() 3 Threads
Cutting Face
5 AA 5 A 3 AA 5 A 8 AA 12 A 10 AA 12 A 19 AA 25 A 6 AA 10 A Overall Length(mm) Lead Over Cutting Face Width AA A AA A AA A AA A AA A AA A AA A AA A AA 4 A 6 AA A AA A AA A AA A AA 8 A 12 AA A AA A AA A AA A AA A AA A AA 2 A 3 AA 16 A 20
Remarks : Lead Error is applied in pressure angle of less than 35 and tolerance of pressure angle of over 35 1.5 time of table value. , is Profile Error is applied in pressure angle of less than 35 and tolerance of pressure angle of over 35 1.5 time of table value. , is
1 5
Hobs
Unit : m Tolerance Hob Elements D or L30 Outside Diameter & Overall Length 500 Dimension(mm) 30D or L120 800 120D or L400 1200 Unit : m Tolerance Module 1m1.6 5 5 3 5 16 25 14 22 26 42 10 16 L35 25 5 8 7 11 8 12 8 12 9 14 9 14 12 20 12 18 5 8 5 8 6 9 6 10 6 10 10 16 11 18 11 18 14 22 14 22 5 11 5 8 20 20

1.6m2.5 5 5 3 5 16 25 16 25 30 48 12 20 35L50 40 5 8 8 12 8 14 10 16 11 18 11 18 12 20 14 22 6 10 6 10 7 11 8 12 8 12 10 16 11 18 11 18 14 22 14 22 5 11 6 10 20 20

2.5m4 5 6 4 5 20 25 16 25 30 48 16 25 50L100 60 6 10 10 16 11 18 12 20 14 22 14 22 16 25 18 28 8 12 8 12 8 14 10 16 10 15 12 20 14 22 14 22 18 28 18 28 6 13 8 12 25 25
4 m6.3 6 8 5 6 25 32 19 30 36 55 20 32 100L150 80 8 12 12 20 14 22 16 25 28 28 20 32 22 36 10 16 10 16 11 18 20 20 16 25 18 28 18 28 36 36 7 16 10 16 25 32
6.3m10 6 10 5 8 32 40 24 38 45 70 25 40 150L200 100 10 16 16 25 18 28 32 25 40 28 45 12 20 12 20 14 22 20 32 36 36 9 20 14 22 32 40
10m16 12 10 50 50 96 50 L200 120 20 32 36 50 56 25 16 25 40 45 22 36 50
16m25 16 12 63 70 130 63 25 40 63 32 50 36 56 63
1 6
Hobs
Gear Cutting Tools
Hobs
Gear Cutting Tools
Standard Keyways for Hobs

r F R1 H
45
C E d
r
Type of Axial Keyways (JIS B 4201-1998)

Unit : mm Height of Keyway E Size 11.5 14.6 17.7 21.1 24.1 29.8 34.8 43.5 53.5 64.2 85.5 0.3 0 0.25 0 3 4 5 6 7 0.23 0.08 1.6 2 1.2 8 10 12 14 18 0.275 0.095 0.19 0.07 Tolerance Width of Keyway F Size Tolerance 0.160 0.060 Corner Radius (ref) r 0.4 0.6 1 Type B Bore Diameter D Size 12.7 15.875 19.05 22.225 26.988 31.75 38.1 50.8 63.5 76.2 Height of Keyway E Size 14.2 17.7 0.31 0.13 0.25 0 6.35 7.92 9.52 12.7 15.87 19.05 0.32 0.14 0.89 0.25 3.18 20.9 24.1 29.4 35.2 42.3 55.8 69.4 82.9 Tolerance Width of Keyway F Size 2.39 Tolerance
Hobs
Type A Bore Diameter D Size 10 13
Unit : mm Corner Radius (ref) r 0.5
Standard Keyways for Hobs
16 19 22 27 32 40 50 60 80
0.8
1.2
1.6
2.4
Type of Clutch Keyways

Unit : mm Bore Diameter d Type A 10 12.7 15.875 19.05 22.225 26.988 31.75 38.1 50.8 63.5 76.2 10.4 12.4 14.4 16.4 18.4 20.5 24.5 0.052 0 8.4 0.043 0 13 16 19 22 27 32 40 50 60 80 Type B Size 6.4 Width of Keyway F Tolerance Depth of Keyway H Size 4.5 5 5.6 6.3 7.0 8.0 9.0 10.0 11.2 14.0 0.180 0 2.0 0.150 0 1.2 7 8 0.8 1.6 9 10 11 12 2.5 15 1.2 1.0 0.040 0.6 Tolerance (H12) 0.12 0 1 Corner Radius(ref) r
R1
Eccentricity (1)
0.5
0.030
0.050
(1) This shows the tolerance between the bore diameter axis and the center line of the clutch keyway.
1 7
Hobs
Cutting Condition Elements Work Material S45C SCM440 Cutting Speed and Axial Feed SCM420 SCr 420 FCD 70 Radial Feed Cutting SpeedNote1 m/min 40 70 100 50 80 100 60 110 140 40 50 Axial Feed (mm/rev)Note2 Threads 12 1.52.5 2.03.0 2.53.5 2.03.0 Threads 35 1.02.0 1.52.5 2.03.0 1.52.5
Please avoid radial feed not to promote the cutter damage. Hob Rotation : Q Q No. of Thread : THWork RotationTH (min-1) Z No. of Teeth : Z By work specification 0.1m0.5mm : Module
Work Rotation
Depth of Cut Shifting
Note1 ; in the case of coating hob. ; in the case of dual coating. Note2Feed is different from a processing aim (finishing, pre-shaving) by necessary surface roughness, accuracy.
Regrinding
Damage to the cutting edge of a hob is generally separated into flank wear and crater wear depending on the location of the wear. The most economical way for regrinding is when the flank wear is approx. 0.2 mm wide or if the crater wear is approx. 0.1 mm deep. We recommend regrinding to a depth of 0.1 mm + existing wear. It is also important to choose a sharp grinding tool and to be careful that the heat from grinding does not dull the teeth and that grinding cracks do not occur. Specifically with high alloy powder high-speed steel, avoid creep feed grinding, use light grinding stock or high-speed feed grinding. Example
Tool Material HSS Wheel Dia. 200mm Powder HSS Abrasive Grain Size Concentration Grade 200mm Wheel CBN (Resinoid) 100 100 R Wheel Rotation 22003000min-1 22003000min-1 Feed 300600mm/min 300600mm/min Depth of Cut Roughing Finishing Roughing Finishing 0.100.15mm 0.020.05mm 0.050.10mm 0.010.02mm Non-water Soluble Oil Cutting Oil
Radial Flank Crator Wear
Cutting Face Flank Wear
Side Flank
Regrinding points A guideline for the economical point for regrinding is when the flank wear is approximately 0.2 mm wide. Be careful of grinding burn with dressing grinding wheel and keeping it very sharp.
1 8
Cutting Condition and Regrinding
Hobs
Gear Cutting Tools
Cutting Condition (In case of m2~2.5)
Hobs
Gear Cutting Tools
Solid Gear Hobs Standard Dimensions

This table shows standard hob dimensions suited for gear cutting. NACHI can also manufacture various sizes of solid hobs.
Unit : mm Module m
Hobs
Diametral Pitch DP 26
Outside Dia. D 50 50 50 50 55 55 55 60 60 65 65 70
Overall Length L 50 50 50 50 55 55 55 60 60 65 65 70 70 75 75 80 85 90 95 100 110 115 130 145 160 175 190 200 210 220 230 250 270 300 320
Bore Diameter (d) Type A 22 27 32 40 50 50.8 38.1 26.988 22.225 Type B
No. of Flutes N 12 10
1 1.25 1.5 1.75
24 22 20 18 16 14 12 11 10 9 8 7 6 5 5 4 4 3 3 2 2 2 2 1 1 1 1
1 3 1 4 2 3 1 1 1 2 1 1 2
Solid Gear Hobs Standard Dimensions
2 2.25 2.5 2.75 3 3.25 3.5 3.75 4 4.5 5 5.5 6 6.5 7 8 9 10 11 12 14 16 18 20 22 25
70 75 80 85 90 95
2
100 105 110 115 120 125 130 140 150 170 170 190 190 210 220 230 250
31.75 9 8
4 2 4
1 9
Hobs
This table shows standard hob dimensions suitable in manufacture of small gears such as watch. There are two types of Non-Topping and Topping.
8 Type Module m 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5 0.55 0.6 0.65 0.7 0.75 0.8 96 72 64 56 48 44 40 36 32 30 28 26 0.9 1 Diametral Pitch DP Outside Dia. D 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 Overall Length L 8 8 8 8 10 10 10 10 10 10 12 12 12 12 12 12 12 12 12 Bore Diameter d
Unit : mm No. of Flutes N 12 8
10 Type Module m 0.2 0.25 0.3 0.35 0.4 0.45 0.5 0.55 0.6 0.65 0.7 0.75 0.8 96 72 64 56 48 44 40 36 32 30 28 26 24 22 20 0.9 1 1.25 1.5 1.75 2 Diametral Pitch DP Outside Dia. D 32 32 32 32 32 32 32 32 32 32 32 32 32 32 32 32 32 40 40 40 40 40 40 Overall Length L 12 12 12 12 15 15 20 20 20 20 20 20 20 20 20 20 20 25 25 25 25 30 30 Bore Diameter d
Unit : mm
Hobs Fine Pitch Gear Hobs Standard Dimensions
No. of Flutes N
10 10 12
13 Type Module m 0.2 0.25 0.3 0.35 0.4 0.45 0.5 0.55 0.6 0.65 0.7 0.75 0.8 96 72 64 56 48 44 40 36 32 30 28 26 24 22 20 0.9 1 1.25 1.5 1.75 2 Diametral Pitch DP Outside Dia. D 32 32 32 32 32 32 32 32 32 32 32 32 32 32 32 32 32 40 40 40 40 40 40 Overall Length L 12 12 12 12 15 15 20 20 20 20 20 20 20 20 20 20 20 25 25 25 25 30 30 Bore Diameter d
Unit : mm No. of Flutes N 10 13 12
2 0
Gear Cutting Tools
Fine Pitch Gear Hobs Standard Dimensions
Hobs
Gear Cutting Tools
Involute Spline Hobs Tooth Profile

This table shows Hob Tooth Profile of involute spline and serration.
Involute Spline Hob Tooth Profile

t S he r Flat Root Hobs hk
S r
hk
Fillet Root
Involute Serration Hob Tooth Profile

t S r hk he

Unit : mm Standard D2001-1959 Flat Root m 20 1.0m 1.2m 0.3m m t/2 0.75m 1.25m 0.2m m t/2 B1603-1995 ANSIB92.2M-1980 (Metric) Flat Root m 30 0.9m 1.4m 0.4m 1.35/DPS 2.35/DPS 0.075/DPS Fillet Root ANSIB92.2-1980 (Inch) Flat Root Fillet Root DP16 DP/DPS 30 2.0/DPS 3.0/DPS 0.36/DPS 25.4/DP t/2 1.8/DPS 2.8/DPS 0.46/DPS DP12 DIN 5480-1964 Flat Root m 30 0.6m 1.2m 0.16m m t/2
Elements Module/DP Pressure Angle () Addendum (hk) Whole Depth of Cut Tip Radius (r) Normal Pitch (t) Tooth Thickness (s)
Involute Serration Hob Tooth Profile

Unit : mm Standard Elements Module/DP Pressure Angle () Addendum (hk) Whole Depth of Cut Tip Radius (r) Normal Pitch (t) Tooth Thickness (s) 1.0m 0.4476m m 1.3708m 1.15m 0.3m m t/2 t/2 1.0m 0.25m 2.53/DPS 0.4/DP 25.4/DP 1.3708/DP 2.1/DPS 0.327/DP D1602-1960 m 45 0.5m 37.5 0.7m B1603-1995 ANSIB92.2M (Metric) m 45 0.6m 37.5 1.53/DPS ANSIB92.2-1980 (Inch) DP/DPS 45 1.1/DPS
2 1
he
Hobs
This table shows standard hob dimensions to manufacture parallel side spline.
Parallel Side Spline

B
Generating Curve
d Parallel Side Spline Hobs Standard Dimensions
Unit : mm Hob Dimensions Bore Dia. D No. of Type A Type B Spline N Minor Dia. d 6 6 7 8 8 10 12 14 14 16 18 20 22 6 7 8 9 10 10 12 12 12 14 16 18 26 30 32 36 40 46 50 58 62 68 78 88 98 36 40 46 50 58 62 68 78 88 98 108 120 23 26 28 32 36 42 46 52 56 62 72 82 92 32 36 42 46 52 56 62 72 82 92 102 112 60 60 22 22.225 Spline Dimensions (JIS B 1601-1996 J Type) Type 1 Major Dia. D Width B Chamfer f No. of Spline N Minor Dia. d 11 13 16 18 21 23 26 28 32 36 42 46 52 56 62 72 82 92 32 36 42 46 52 56 62 72 82 92 102 112 Type 2 Major Dia. D 14 16 20 22 25 28 32 34 38 42 48 54 60 65 72 82 92 102 38 42 48 54 60 65 72 82 92 102 112 125 Width B 3 3.5 4 5 5 6 6 7 8 8 10 12 14 14 16 18 20 22 6 7 8 9 10 10 12 12 12 14 16 18 Chamfer f
Size
Outside Dia. D
OAL L
11 13 16 18 21 23 26 28 32 36 42 46 52 56 62 72 82 92 32 36 42 46 52 56 62 72 82 92 102 112
0.3
75
75
27
26.988
0.3 6
0.4
95 115 135 145 75
90 115 175 190 75
32 32 40
31.75 31.75 38.1
0.5
0.4
27
26.988 8
0.4
95
90
32
31.75
0.5 10
0.5
115
115
32
31.75
10
With Semi-topping
With Lugs
With Full Radius
Hob
Hob
Hob
2 2
Hobs
Gear Cutting Tools
Parallel Side Spline Hobs Standard Dimensions
Hobs
Gear Cutting Tools
Roller Chain Sproket Hobs Standard Dimensions

This hob is used to manufacture sproket wheels according to ANSI B29.1, ASA B29.1, DIN 8196, JIS B 1802, BS 228, and this table shows standard hob dimensions.
Hobs
Basic Rack Tooth Profile (JIS B 1802 S Type)

CP CP 2 Q W CP 2 Tip
90
Ds 2
R
Roller Chain Sproket Hobs Standard Dimensions
.5 35
Ds
17
F Pich Line E Root
Unit : mm Hob Dimensions Chain Pitch (CP) Roller Dia. (RD) Outside Dia. D 60 75 85 90 110 120 130 160 170 190 210 240 75 27 32 40 50 50.8 38.1 9 31.75 90 105 125 140 170 190 210 240 260 310 65 Overall Length L Type A 12.7 15.875 19.05 25.4 31.75 38.1 44.45 50.8 57.15 63.5 76.2 6.35 9.525 3.3 5.08 6.35 7.77 7.94 10.16 11.91 15.875 19.05 22.225 25.4 28.575 35.72 39.688 47.625 60 26.988 10 65 22 22.225 12 Bore Dia. d Type B No. of Flutes N
Ds
DIN 8196 24 BS 228 25
JIS B 1802 Type S ASA B29.1 Type 2 ANSI B29.1
JIS B 1802 Type U ASA B29.1 Type 1
2 3
Gear Shaper Cutters
Gear shaper cutter is the gear cutting tool for generating the gear teeth. The both gear and cutter are mounted on the gear shaper machine. Then a symmetrical motion of rotation and reciprocating generates the gear teeth. 1. Generating internal gears and shoulder gears 2. Generating omitted teeth, combined one or variable tooth thickness.
Gear Shaper Cutters Gear Shaper Cutters Feature and Nomenclature of Gear Shaper Cutters
Gear Shaper Cutter
Gear
Virtual Gear
Gear Shaper Cutters Nomenclature
Addendum Dedendum Tooth Space
Whole Depth
Pitch Circle Tip Chamfer
Datum Face Side Relief Angle Radial Relief Angle
Chamfer
Tooth Flank
re Di am et er
OAL
Right Tooth Flank
Inner Face Rake Angle Web Thickness Counter Bore Diameter Counter Bore Depth Pitch Circle Diameter Outside Diameter Cutting Face
Left Tooth Flank
Bo
Face Angle Downhill Side Uphill Side Helix Angle Helical Gear Shaper Cutter Sharpening Angle
2 4
Gear Cutting Tools
Gear Shaper Cutters
Gear Shaper Cutters
Gear Cutting Comparison of Gear Shaper Cutter and Hob

Gear Cutting Tools Work Gear Tooth Width Type Accuracy Thin thing Suitable for cutting of internal gear and Shoulder gear Pitch Error Tooth Profile Error Surface Roughness Large Small Small Gear Shaper Cutters Thick thing Cutting of internal gear and Shoulder gear is not possible Pitch Error Tooth Profile Error Surface Roughness Small Large Large Hobs
After Gear Shaper Cutting
Feed per Stroke After Hobbing Must hold down a gach spacing error in regrinding Heavy cutting is easy In one hob, can do gear processing of various helix angle Pitch of a processing gear is related to a master warm of hobbing machine
Others Gear Shaper Cutters
Regrinding is easy Heavy cutting is not made Cutters are different, and need a helical guide by helix angle of gear
Types of Gear Shaper Cutters
Gear Cutting Comparison and Types
Disk Type for Shoulder Gears
Deep Counterbore Type with Recessed Nut
Shank Type for Small Diameter Internal Gear
2 5
Gear Shaper Cutters
Unit : m
Tolerance Cutter Elements AA d18 Bore Diameter d 18d30 30d50 50d80 80d120 Shank Runout Outside Diameter Runout Datum Face Runout Inner Face Runout Cutting Face Runout Face Angle(min.) Side Relief Angle(min.) Radial Relief Angle(min.) 03 04 04 05 06 2 7 5 5 10 5 5 5 Unit : m Tolerance Cutter Elements Under Type 38 and m1.5 Outside Diameter 200400 Module 1.5m5 400 m5 500 Grade A 05 06 07 08 010 3 10 5 5 16 14
Unit : m Tolerance Cutter Elements Grade Type 0.5m1 Module 1m1.6 1.6m2.5 2.5m4 15 19 16 20 16 20 18 23 19 25 20 26 3 4 4 5 6 7 12 13 15 19 22 25 6 9 13 21 11 14 12 15 13 17 17 22 18 23 19 25 4 4 5 6 6 7 13 14 16 21 23 26 7 10 17 27 11 14 13 17 14 18 16 20 18 23 20 26 4 4 5 6 7 8 14 15 17 23 25 28 9 13 21 33 4m6 14 18 15 19 20 26 22 28 5 6 8 8 17 19 28 32 11 16 27 43 6m10 17 22 18 23 24 31 26 34 6 7 9 10 20 22 34 37 15 22 33 53 10m16 32 41 13 46 22 53
Tooth Space Runout
Adjacent Pitch Error
Accumulative Pitch Error
Profile Error Tooth Thickness()
AA A AA A AA A AA A AA A
25 38 50 75 100 25 38 50 75 100 25 38 50 75 100 25 38 50 75 100 125150175 25 38 50 75 100 125150175 25 38 50 75 100 125150175 125150175 125150175 125150175
15 19 16 20 19 25 19 25 3 4 5 6 11 12 18 21 6 8 13 21
Remarks : Value in ( ) is applied to the pressure angle of less than 15 degrees.
2 6
NACHI Accuracy of Gear Shaper Cutters
Gear Shaper Cutters
Gear Cutting Tools
NACHI Accuracy of Gear Shaper Cutters
Gear Shaper Cutters
Gear Cutting Tools
Cutting Condition (In the case of coated shaper cutter)

Elements Cutting SpeedNote1 Rotary Feed Radial Feed Back Off Offset Depth of Cut Blister Steel S45C FCD70 Cutting ConditionNote2 4080m/min 3050m/min 2040m/min 0.23.0mm/Stroke 0.0020.01mm/Stroke 0.20.8mm By Direction of Revolution and Gear Spec. By Gear Spec.
Note1.Cutting speed is calculated on cutting length and numbers of cutter stroke. b Work width mm Wc b6 Wc Numbers of stroke str/min V= 1000 V Cutting speed m/min Note2.Please note that cutting speed should be selected based upon gear shaper machine.
Gear Shaper Cutters
Regrinding
Regrinding with disc type and hub type gear shaper cutters is done with a rotary surface grinder. When grinding is done, the cutter is placed in the center of the table and attached with magnetic clamps (or inserted into taper shank cutter holders if its a shank type). Next, the proper rake angle (generally 5) is set on the magnetic chuck and regrinding is done as shown in the diagram. Regrinding Method
Abrasive Wheel 5 6mm Installation Plug
Cutting Condition and Regrinding
The position of grinding wheel is determined based on the depth of tooth space.
Example
Tool Material HSS Wheel Dia. 305mm Wheel Rotation 1500min-1 Wheel Speed 1500m/min Depth of Cut Roughing Finishing Roughing Finishing 0.020.05mm 0.02mm 0.02mm 0.010.02mm Cutting Oil Noritake NK55 Soluble Oil
Power HSS
305mm
1500min-1
1500m/min
Wheel Abrasive Grain Size Structure Grade C 220 9 H
Regrinding points
A guideline for the most economical points for regrinding is when the flank wear is approx. 0.2 mm wide. Be careful of grinding burn with dressing grinding wheel and keeping it very sharp.
2 7
Gear Shaper Cutters
d L2
This type of cutter is used in cutting spur gears or splines, and this table shows standard dimensions.
B Pitch Circle Diameter
Unit : mm Module m
0.3 0.35 0.4 60 40 36 32 30 28 26 25 24 22 20 18 16 14 12 11 10 9 8 7 6
1 2
L2
L2
80
0.45 0.5 0.55 0.6 0.65 0.7 0.75 0.8 0.9 1.0 1.25 1.5 1.75 2 2.25 2.5 2.75 3 3.25 3.5 3.75 4 4.5 5 5.5 6 6.5 7 8
164 164 142 126 120 110 100 90 84 80 76 72 72 66 64 64 60 56 56 52 50 50 48 44 40 40 36 34 32 28 28 25 24 23 22 20 20 19 18 17 16 16 15 14 14 13
8 150 136 126 120 116 108 108 100 96 94 90 84 84 78 76 76 72 66 60 60 54 50 48 44 42 38 36 34 33 30 30 28 27 25 24 23 22 21 20 19 18 17 17 16
10
14
16 100 100 96 88 80 80 72 66 64 56 56 50 48 44 44 40 40 36 36 33 32 30 28 28 26 25 24 22 22 20 20 19 18 17 16 16 15 14 13 18
12
6.5
19.05
28
14
18
20
31.742
50
16 8
20
10 22 31.742 or 44.450 65
18
22
10
5 5
24
4 1 2

28
12
Next Page
2 8
Disk Type Shaper Cutters TypeStandard Dimensions
Gear Shaper Cutters
Diametral Pitch No. of Teeth DP
Type 50 OAL L Bore Web Thickness Dia. d L2 B (Ref.) No. of Teeth OAL L
Type 75
Web Thickness
Type 100 Bore Dia. d B No. of (Ref.) Teeth OAL L

Web Thickness
Bore Dia. d
B (Ref.)
Gear Cutting Tools
Disk Type Shaper Cutters Type Standard Dimensions
Gear Shaper Cutters
Gear Cutting Tools
Unit : mm Module m 1 25 24 22 1.25 20 18 1.5 16 1.75 14 2 12 2.25 11 2.5 10 2.75 9 3 8 3.25 3.5 7 3.75 4 6 4.5 5 5
1 2
Gear Shaper Cutters
Diametral Pitch No. of Teeth DP 126 126 120 110 100 100 90 84 80 72 70 64 60 56 54 50 50 46 45 42 40 38 36 35 34 32 30 28 28 25 25 23 22 21 20 20 19 18 17
Type 125 OAL L Bore Web Thickness Dia. d L2 B (Ref.) No. of Teeth 150 150 142 130 120 120 106 100 94 86 82 75 70 66 64 60 60 54 54 50 48 46 44 42 40 38 36 34 33 30 30 28 27 25 24 23 22 21 19 18 17 15 OAL L
Type 150
Web Thickness
Type 175 Bore Dia. d B (Ref.) No. of Teeth OAL L

Web Thickness
L2
L2
Bore Dia. d
B (Ref.)
20
22 116 110 100 96 88 82 78 76 70 68 64 62 58 56 54 50 48 47 44 42 39 38 35 34 32 30 29 28 27 25 24 22 21 19 18 17 16 15
Disk Type Shaper Cutters TypeStandard Dimensions
22 10
5.5 6 6.5 7 8 9 10 11 12
24
26
12
24 44.450 85
26 44.450 95
28
14 30
44.450 or 58.735
110
26 12
28
5 4
1 2
14
4 3

30
32
34
3 2
1 2
36
16
2 9
Gear Shaper Cutters

This type of cutter is used in cutting helical gears, and this table shows standard dimensions.
d L2
B Pitch Circle Diameter
Unit : mm Module m 0.3 0.35 0.4 60 40 36 32 30 28 26 25 24 22 20 18 16 14 12 11 10 9 8 7 6 5

1
L1
L2
L1
L2
80 12 8
0.45 0.5 0.55 0.6 0.65 0.7 0.75 0.8 0.9 1.0 1.25 1.5 1.75 2 2.25 2.5 2.75 3 3.25 3.5 3.75 4 4.5 5 5.5 6 6.5 7 8
6.5 16 12
20
16
19.050
28
24 22 18 8
18
18
14
31.742
50
26
20
20
16 8
24
20
10 28 22 31.742 or 44.450 65
22
18 26 22 10 30 24
5 4
1 2
34 28 12
4 3

3 0
14
10
16
14
6.5
Gear Shaper Cutters
Diametral Pitch DP
Type 50 OAL L Tooth Bore Web Width Thickness Dia. d L1 L2 B (Ref.) OAL L Tooth Width
Type 75
Web Thickness
Type 100 Bore Dia. d B (Ref.) OAL L Tooth Web Width Thickness Bore Dia. d B (Ref.)
Gear Cutting Tools
L1
Gear Shaper Cutters
Gear Cutting Tools
Helical Gear Shaper Cutters Dimensions

This type of cutter is used to cut helical gear. The No. of cutter Teeth is determined by module and helix angle of gear and the helical guide. When ordering the helical shaper cutter, please specify the guide lead on addition to the cutter and work dimensions. Shared calculation is necessary. NC guide gear shaping machine does not need a helical guide.
Helical Gear Gear Shaper Cutter
Unit : mm Module
Gear Shaper Cutters
Diametral Pitch DP 25 24 22 20 18 16 14 12 11 10 9 8 7 6 5 5 4 4
1 2 1 2
Type 125 OAL L Bore Tooth Web Width Thickness Dia. d L1 L2 B (Ref.) OAL L
Type 150 Tooth Web Width Thickness L1 L2 Bore Dia. d B (Ref.) OAL L
Type 175 Tooth Web Width Thickness L1 L2 Bore Dia. d B (Ref.)
m 1
26
20
28
22
1.25 1.5
12
Disk Type Shaper Cutters Type Standard Dimensions Helical Gear Shaper Cutters
1.75 2 2.25 2.5 2.75 3 3.25 3.5 3.75 4 4.5 5 5.5 6 6.5 7 8 9 10 11 12
28
22 10
30
24
26
36
30
24 44.450
85
34
26
28
14 44.450 95
36 32 26 12
28 14 40 30
44.450 or 58.735
110
36 3 3 2
1 2
30
80 40 32 44 34
48
36
16
100
Helical Guide
Lead of Guide Lead of Cutter=Lead of Guide
Cutter Pitch Dia.
Lead of Cutter
m Zc c L
Cutter Helix Angle at Pitch Dia.=Work Helix Angle
: Normal Module : No. of Cutter Teeth : Helix Angle of Cutter : Lead Of Guide m Zc L= sinc
3 1
Gear Shaper Cutters
d L2
This type cutter is used in cutting larger module gears, and this table shows standard dimentions.
Pitch Circle Diameter
Unit : mm Module m 8 3 9 10 12 14 16 2 2
1
Diametral Pitch DP
Type 200 No. of Teeth 25 24 23 21 20 17 OAL L Tooth Width L1 Web Thickness L2 Bore Dia. d B (Ref.) No. of Teeth OAL L
Type 250 Web Thickness L2 Tooth Width L1 Bore Dia. d B (Ref.)
40
24
18
58.735 or 76.200
135
Clutch Keyway Dimensions
Unit : mm W For Positioning Size 5.0 6.5 8.0 9.5 12.5 16.0 Tolerance +0.015 0 +0.025 0 Size 5.0 6.5 8.0 9.5 12.5 16.0 For Stopper Tolerance Size 1.6 +0.1 0 3.2 +0.4 0 H Tolerance
3 2
Disk Type Shaper Cutters Type Standard Dimensions Clutch Keyway Dimensions
25 25 21 20 18 16
50
30
20
76.200 or 101.600
170
Gear Shaper Cutters
Gear Cutting Tools

L1
Gear Shaper Cutters
Gear Cutting Tools
L1 Pitch Circle Diameter
Deep Counterbore Type Shaper Cutters Standard Dimensions

This type of cutter is used in cutting internal gears or shoulder gears, and this table shows standard dimentions.
d L2 L
Unit : mm Type 50 Type 75 Type 100 Type 125 Module Diametral Pitch No. of OAL Tooth Web Bore No. of OAL Tooth Web Bore No. of OAL Tooth Web Bore No. of OAL Tooth Web Bore Teeth Width Thickness Dia. Teeth Width Thickness Dia. Teeth Width Thickness Dia. Teeth Width Thickness Dia. L L L L L1 L2 L2 L2 L2 d L1 d L1 d L1 d m DP
0.3 0.35 0.4 0.45 0.5 0.55 0.6 0.65 0.7 0.75 0.8 0.9 1.0 80 60 164 164 142 126 120 110 100 90 84 80 76 72 72 66 64 64 60 56 56 52 50 50 48 44 40 40 36 34 32 28 28 26 25 24 24 23 23 22 22 20 19 19 18 17 16 16
Gear Shaper Cutters
22
Deep Counterbore Type Shaper Cutters Standard Dimensions
40 36 32 30 28 26 25 24 22 20 18 16 14 12 11 10 9 8 7 6 51 2 5 4 4 31 2
1 2
24
10
30
12
19.05
1.25 1.5 1.75 2 2.25 2.5 2.75 3 3.25 3.5 3.75 4 4.5 5 5.5 6 6.5 7 8
32
14
34
16
38
18
150 136 126 120 116 108 108 100 96 94 90 84 84 78 76 76 72 66 60 60 54 50 48 44 42 38 36 34 32 30 30 28 27 26 25 24 23 22 21 20 19 18 18 17
32
14
34
16
8 36 18
38
20
42
22
10
100 100 96 88 80 80 72 66 31.742 64 56 56 50 48 44 44 40 40 36 36 34 32 30 28 28 27 25 24 23 22 21 21 20 20 19 18 17 16 16 15
38
18
40
20
42
22
10
44
24
50
28
12
126 126 120 110 100 100 90 84 80 72 70 64 60 56 54 50 50 46 45 31.742 42 or 40 44.450 38 36 35 34 32 30 28 28 25 25 23 22 21 20 20 19 18 17
40
20
42
22 10
44
24
44.450
48
26 12
50
30
3 3
Gear Shaper Cutters
d L2
This cutter is used to manufacture sproket wheels, and this table shows standard dimensions.
Unit : mm
Type 75 Chain Pitch CP No. of Teeth OAL L Web Thickness L2 Bore Dia. d No. of Teeth Type 100 OAL L Web Thickness L2 Bore Dia. d No. of Teeth Type 125 Gear Shaper Cutters Sproket Shaper Cutters Standard Dimensions OAL L Web Thickness L2 Bore Dia. d
6.35 9.525 12.7 15.875 19.05 25.4 31.75
36 24 18 14 12 18 8 31.742
48 32 24 20 16 12 22 10 31.742 or 44.450
60 40 30 24 20 15 12 12 24 10 44.450
3 4
Gear Cutting Tools
Sproket Shaper Cutters Standard Dimensions
Shaving Cutters
Gear Cutting Tools
Shaving Cutters
Shaving cutter is the gear cutting tool that have many serrated grooves at the tooth flanks. The both gear and the cutter is mounted on the shaving machine with intersecting angle. Then it makes sliding action on these flanks by rotating shaving cutter to finish the flanks of the gear teeth. Features of shaving 1. Short finishing tact time 2. Easy to modify the gear profile and lead form such as crowning form
Feature and Nomenclature of Shaving Cutters
Shaving Cutters
Before Shaving
After Shaving
Shaving Cutter Nomenclature

Full Width Body Width Full Width Body Width Key Way
Marking 165 (135) 145 (115)

ia.
Outside Diameter
Bo
D re
Top Land Serration
Tooth Flank
Helix Angle Serration Depth
Land
Cutting Edge Pitch Cincle Clearance
Slot
3 5
Shaving Cutters
Shaving Methods
Features This is most common shaving method and the tooth of gear is very finely finished. In this shaving, work gear is fed along a path parallel to its axis, with the center of the tool passing from one edge of the gear face to the opposite edge. Crowned gear teeth are produced by rocking the table during the shaving cycle. This process is particularly adaptable to shaving wide-faced gears.
Figure
Cutter Work
Conventional Shaving
Cutter Work
Direction of Table Traverse
Table Traverse
Diagonal Shaving
Work
Cutter
Cutter Work Cutter Work
Underpass Shaving
Of the four methods, this method has the shortest shaving time and produces high quality finished tooth profile, making it most suitable for high production. The work gear is fed in the gear's radius direction. The cutter is wider than the work gear, and is provided with specially designed differential serration. Tooth-crowning is produced by a reverse-crowned cutter in this process. Plunge cut Shaving
Work
Cutter In Feed Work Cutter
Serration
Non Serration Lead Having Serration Lead
Normal Serration
For Conventional Shaving For Diagonal Shaving
Differential Serration
For Underpass Shaving For Plunge cut Shaving
3 6
Shaving Methods and Features
This is used mainly for shaving shoulder gears. The work gear is reciprocated across the cutter at an angle of 90 the work gear axis. The direction of rotation to is reversed at each end to the stroke. The cutter is wider than the work gear and is provided with a differential serration. Tooth-crowning is produced by a reversecrowned cutter in this process.
Shaving Cutters
This method is used in finishing of automobile gears. In this shaving, work gear is reciprocated across the cutter in a path between zero to 90 the work gear axis. to Normaly this angle is from 15 35 to . The direction of rotation is reversed at each end to the stroke. Tooth-crowning is produced by a reverse-crowned cutter in this process.The cutter may be narrower than the work gear. The cutting time is shorter than the Conventinal Shaving.
Cutter Work
Gear Cutting Tools
Shaving Methods and Features
Shaving Cutters
Shaving Mechanism and Cycle Diagram
Gear Cutting Tools Traverse Type Conventional Plunge Cut Type
Cutter
Cutter
Shaving Mechanism
Work Work
Shaving Cutters
Serration
Normal Serration (Parallel)
Differential Serration
Infeed
Time (Second)
Shaving Mechanism and Cycle Diagram
Infeed
Cycle Diagram
Rev Back Movement T1 Rough T2 Finish T3
Width of Work Traverse
Plunge Cut Shaving Cutter

Reading accuracy improvent of lead Strength improvement of end land Recommend in less than gear width 32mm
Conventional
Leave Both End Land
Tentative Line
Tooth Width
Actual Tooth Width Tentative Line
Tooth Width=Actual Tooth Width End Lamd Actual Lead Error Actual Hollow Amount
Tentative Hollow Amount
Tentative Lead Error
3 7
Shaving Cutters
Unit : m
Tolerance Cutter Elements Type Grade Module 0.8m1.2 1.2m1.6 1.6m2.5 2.5m4
A Outside Diameter B 300 300 100 0 25 50 0 30 15 20 5 Under 250 300, 325 Tooth Space Runout 400 Under 250 300, 325 400 Under 250 300, 325 Adjacent Pitch Error 400 Under 250 300, 325 400 Under 250 300, 325 Accumulative Pitch Error 400 Under 250 300, 325 400 Lead Lead Error Symmetricity A B A B A B 2 B A B A B A 13 48 4 8 68 15 50 4 8 71 15 52 4 18 74 5/25.4mm 15/25.4mm 5 3 4 5 6 17/25.4mm 15 57 4 20 81 16 63 5 23 90 16 18 81 5 5 25 28 115 18 20 5 5 28 30 7/25.4mm 22 25 400 600 300 0 40 50
4m6.3
6.3m10 10m16 16m20

600 700 300 0 60
A Tooth Thickness B A B
Outside Diameter Runout
Face Runout
6 35
Profile Error (*)
Remarks 1 : Grade A are applied to Ground cutters. Grade B is applied to Semi-ground cutters. Remarks 2 : Indicades tolerance on tooth thickness corresponding to the outside diameter.
Warranty Specitications of Cutter

Cutter Warranty Semi-ground Cutter (Grinding on Bore and Keyway) Cutter Warranty (Without Trial Test) Work Warranty (With Trial Test) New Cutter Regrinding Cutter
3 8
NACHI Accuracy of Shaving Cutters
Shaving Cutters
Gear Cutting Tools
NACHI Accuracy of Shaving Cutters
Shaving Cutters
Standard Number of Cutter Teeth

Gear Cutting Tools
Type
Module m 0.8 1.0 1.25 1.5 1.75 2.0 2.25 2.5 2.75 3.0 3.25 3.5 3.75 4.0 1.0 1.25 1.5 1.75 2.0 2.25 2.5 2.75
No. of Teeth 214 173 137 113 97 89 79 67 61 59 53 47 47 43 197 151 137 113 97 89 79 73 67 61 59 53 47 43 41 37 33
Type
Module m 1.25 1.5 1.75 2.0 2.25 2.5 2.75 3.0 3.25 3.5 3.75 4.0 4.5 5.0 5.5 6.0 4.0 4.5 5.0 5.5 6.0 6.5 7.0 8.0 9.0 10.0 11.0 12.0
No. of Teeth 173 151 121 113 97 89 79 73 67 61 59 53 47 43 41 30 73 67 59 53 47 43 43 37 31 29 27 25
175
225
Standard Number of Cutter Teeth and Simple Calculation for Cutter Width
Shaving Cutters
200
3.0 3.25 3.5 3.75 4.0 4.5 5.0 5.5 6.0
300
: Less than pressure angle 17.5 are not applied
Simple Calculation for Cutter Width

Lc T=Lc T
m :Module b :Gear Width :Crossed Axis Angle 1. Plunge Cut shaving Lcbcos3msin5
8 +0.09 0 67.5 +0.3 0

.00 0 5
2. Under Pass shaving Lc b cos 3msin2
63
.5
+0
3. Diagonal shaving (Travel Angle ) btan Lc3msin4 sincostan 4. Conventional shaving Module6:Lc25.4mm Module6:Lc31.75/32.0mm
Cutter widthT (A Standard Example)

inch Metric 19.05 20.0 25.4 25.4 31.75 32.0 38.1 38.0 44.45 44.0 50.8 50.0
3 9
Forming Racks
Forming Racks are used in pairs to roll the teeth into the workpiece, and have next features. Rolling is generally completed in a few seconds and is a far more efficient than hobbing. This method can achieve better accuracy than cylindrical dies rolling.
Vertical Rolling Machine

Hydraulic Cylinder or Ball Screw
Left Slide
Synchronizing Mechanism
Forming Racks
Headstock
Tailstock
Workpiece
Right Slide
Pinion Gear
Rolling Process
(1)
(2)
(3)
4 0
Feature and Rolling Principles
Rack
Forming Racks
Rolling Principles
Gear Cutting Tools
Forming Racks
Forming Racks
Gear Cutting Tools
Example of automotive parts
Yoke
Input Shaft Steering Shaft
Forming Racks
Drive Pinion Axle Shaft
Drive Axle
Example
Drive Shaft
Main Shaft
Example Workpieces
Forming Rack is for large volume production of parts with involute spline, involute serration, thread, worm and others.
Spline Thread
Worm Screw
Oil Groove (Helix Angle 0)
Number of The Small Teeth Gear
Oil Groove (Helix Angle 30) Spline
Worm
4 1
Forming Racks
Overall Length Teeth Length Width Relief Teeth Finishing Teeth Plate Type
Roughing Teeth Wedge Type
Height Double Wedge Type
Applicable Machine
Plate Type Vertical or Horizontal Rolling Machine
Wedge Type Vertical Rolling Machine
Double Wedge Type Horizontal Rolling Machine
ATC Type Vertical Rolling Machine with ATC Unit : mm
Types & Dimensions Type Plate Type Teeth Length 7 9 11 13 16 20 24 28 32 36 42 48 178 229 280 331 407 508 610 712 813 915 1067 1220 Overall Length 210 261 312 362 439 540 642 744 845 947 1099 1252 Wedge Type Teeth Length 178 229 280 331 407 508 610 712 813 915 Overall Length 195 245 295 346 422 523 623 725 826 928 Double Wedge Type Teeth Length 178 229 280 331 407 508 610 712 813 915 1067 1219 Overall Length 202 253 304 355 431 532 634 736 837 939 1091 1243 ATC Type Teeth Length 178 229 280 331 407 508 610 712 813 915 Overall Length 178 229 280 331 407 508 610 712 813 915
Type of Racks and Basic Dimensions
Tool life & Regrinding

The hardness of work and the pressure angle have the largest influence on life. Hardness of less than 200HB is recommended. (see table 1) On other hand, a larger pressure angle increases life. (see table 2) The tools are reground by removing the worn metal, and regrinding may be allowed for 34 times. But the life become lower as a result of regrinding.
Prectical Handness
Pressure Angle 30 37.5 45 Practical Hardness 285HB less 310HB less 330HB less Maximum Hardness 300HB 330HB 350HB Amount to be Removed Tooth Depth Damage Crack Metal Fatigue
Tool Life of S35CS45C Steel

Hardness Pressure Angle 30 45 200HB 100,000 150,000 260HB 55,000 62,000 320HB 12,000 30,000 340HB 25,000 Rack Height After Regrind
4 2
Forming Racks
Gear Cutting Tools
Type of Racks and Basic Dimensions
Other Types of Gear Cutting Tools
Gear Cutting Tools
Gear Chamfering Tools

Deburring Cutters
This tool is used to create chamfer on the gear hobbed or shaped There are two types of tool. One type chamfers two corners of the tooth, while the other chamfers all four corners. Special type of Deburring Cutter includes the follows(see sketch at right) qChamfer includes the root corner wChamfer parallel to the taper face eChamfer a taper from the tooth tip to root This tool is made up of two gears, and can be adjusted.
Gear Chamfering Tools
Chamfer Gear
2 Corner Chamfer
All Corner Chamfer
C Spur Gear C C Helical Gear C C C C C
C C
Electro-Deposited Burnishing Tools

This is an electro-deposited diamond tool used for removing burrs or hit marks from heat treated gear corners.
Gear
Chamfer
4 3
This tool efficiently forms a reverse lead taper on synchronizer sleeve of transmission. This process is done after broaching or shaping of the part.
Rolling Tool
This tool forms a reverse lead taper by pushing into the radial direction of work while rolling. The Accuracy of the taper angle is within 15' The burrs after rolled are so big as to be removed by Broaches or other tools
Rolling Tool Other Types of Gear Cutting Tools Work Piece Portion Formed
4 4
Reverse Lead Taper Tooth Forming Tool
Gear Cutting Tools
Reverse Lead Taper Tooth Forming Tool
Realize finishing of 50-60 HRC herdend material Fruit broaching time is high efficiency for one second.
Hard Broaches
Highly precise broaching of the high hardness materials(50-60HRC). Sectional carbide broach and hard broaching machine are used, and a high speed broaching in cutting speed 60m/min. True cutting time is less than for one second. Environment-Friendly with MQL system. No need for work piece washing out and dealing with waste fluid.
Broaches
Hard Broach
Applications
Involute spline hole (gear part for autos), CVT ball groove, various variant holes
Sample
Features
Comparison of finished teeth
Before After Work No.of teeth : 24 Normal Module : 1 Normal Pressure Angle : 45 Pitch Dia. : 24.000 Dia. : 16.971 Major Dia. : 25.46 Minor Dia. : 23.76 HW-5008
Hard Broaches
Squareness
Appearance
Between pin Dia.
Between pin Dia
The variation of between pin dia is small
Profile
0.05
Before heat-treatment
Heattreatment
After Hard Broaching
Lead
The Surface of Broaching Between Pin Dia
4 5
Realize MQL broaching for the first time in the world
Broach for MQL

MQL broach cuts down the running cost by 15% comparing with coolant oil used. Reduce a washing operation after broaching and improve the working efficiency.
Applications
Broaches Oil + Conventional Broach Semi-dry + MQL Broach MQL Broaching Realize a small amont of coolant broaching by turning cutting oil into mist. 54 Cutting length (m) 81 m S45C(200HB) Broach for MQL m2xPA30xNT16 Broaching speed Cutting depth 5m/min 0.06mm/Dia Conventional Too much quantity of oil is required. MQL Broach NBM-5008
Involute Spline, Involute Serratrion
Features
mm 0.10 0.08 0.06 0.04 0.02 0.00 Conventional MQL
Wear
27
Work piece Broach Cutting conditions
What' MQL
MQL = Minimum Quantity Lubrication = Mist Machining = Semi Dry Machining Use a very small quantity of oil of 13cc per one hour, make oil mist of 12m and machining while jetting in cutting edge.
4 6
Realize balance and excellent accuracy
Off-normal Gullet Helical Broach

Off-normal Gullet" Helical Broach is the best broach to ensure accuracy of internal helical gears. The angular design of gullet provides the best balanced cutting. Improve accuracy of workpiece and tool life.
PAT.
Broaches
Assembly type
Solid type
Applications
Off-normal Gullet Helical Broach
Internal Helical gears of Automatic Transmission

Internal helical gear
Features
Comparison of Lead Error
Gullet Comparison of Lead Error
Right
The lead error is improved by locating finishing teeth on spiral gash. (off-normal gullet) PAT.
Conventional Gullet
Left
Off-normal Gullet
Right
Left
4 7
Realize Broaching of Module 0.245
Micro Module Broaching

Best for highly accuracy broaching of a micro module Apply to a standard gear of whole depth 2.25m
Applications
Compactification of planetary gear
0.14mm
T=0.49mm
1.0mm
NT=93 22.5mm 23.65mm 23.65mm
0.18mm
Micro Module Broaching
Technical Introduction NBV-3-6 MNC
Broaches
Profile error Left Right Left
Lead error Right
0.01mm
0.01mm
Cutting conditions Machine Work Cutting speed Vertical Machine NBM 5008 SCM 435 3m/min Cutting Oil Broach Length Pulling Load Mist
900mm (Length of Cutting Teeth 290 mm) 8.8KN (0.9Ton)
4 8
Guidance
Terms
Internal Broaches
Shank Diameter Front Pilot Pull End
First Cutting Teeth
Semi- Finishing Teeth
Finishing Teeth Rear Pilot Retriever End
Roughing Teeth Broaches Front Shank Length Length of Cutting Teeth Overall Length Rear Shank Length
Types of Pull Ends

(1) Cotter Type (3) Threaded Type
Types of Retriever Ends

(1) RoundNeck Type
(2) Jaw/ Claw Type Guidance
(4) Pin Type
(2) Jaw/ Claw Type
(3) Trapezoid Type (Flat Type)
Roughing teeth Semi-finishing teeth
The cutting teeth to conduct main cutting. The cutting teeth having small cutting amount to be arranged before the finishing teeth.
Finishing teeth
The cutting teeth to finishing the workpiece to the specific dimensions . These are constituted usually with several cutting teeth of the same dimensions. Further, the cutting teeth after second one are called also as preparatory teeth.
4 9
Guidance
Keyway Broach
Semi-Finishing Teeth Overall Length Shank Length Front Pilot Length of Cutting Teeth Roughing Teeth Finishing Teeth
Height of Finishing Teeth Pull End Tooth Width
Bottom Face
Broach Width Tooth Cross Section
Slab Broach
Overall Length Length of Cutting Teeth Roughing Teeth SemiFinishing Teeth Finishing Teeth Tooth Width
Bottom Face
Height of Finishing Teeth Broach Width
Gullet
Land Width
Pitch Relief Angle
Depth of Gullet Tooth Radius
Face Angle
5 0
Guidance
Helix Angle
Broaches
Guidance
Internal broaching machine
Lifter
Retrieving head
Broach
Work
Broaches
Work Bolster
Pull head
Surface broaching machine

Guidance Ram
Broach holder
Broach
Work
Work support
Work support of keyway broaching

Work Broach horn Bolster
broach horn
liner
Keyway broach
5 1
Guidance
Broaching
Vertical internal broaching machine
Broach transfer type
(1)
Loading
(2)
Initial positioning
(3)
Broaching
(4)
Unloading
(5)
Setting Retrieving head
(6)
Returning cycle
Broach Retrieving head Broaches
Work piece
Pull head Guidance
Work transfer type
(1)
Loading
(2)
Initial positioning (setting pull head)
(3)
Broaching
(4)
Unloading
(5)
Returning cycle
Broach
Table
Work piece
Bolster
Pull head
5 2
Internal Broaches
Internal Broaching
As for the internal broach, shape of indispensability can finish the inside of the cover crops. A lower hole is opened to the cover crops beforehand and usually machines it through an internal broach in this hole.
Internal Broaching Process
Internal Broaches
Work
Broaches
Work piece sample
Round Broach
Special Spline Broach
Square Broach Internal Broaches
Serration Broach
Parallel Side Spline Broach
Work Piece Samples of Internal Broaches
Special Shape Broach
5 3
Internal Broaches
Round Broaches
Round broaches are finishing broaches used for highly precise round holes. There is burnishing broach to improve surface finish.
Involute Spline Broaches

Involute Spline Broaches are used in automotive massproduction. There are three types of broaches with round teeth at the front, round teeth at the end and alternating spline and round teeth to decrease the eccentricity on the minor and major diameter of a spline.
Round teeth at the front
Round teeth at the end
Alternating spline and round teeth
Parallel Side Spline Broaches

In track part or machine part production, Parallel Side Broaches are mainly used, There are broaches with round teeth as well as Involute Spline Broaches.
Round teeth at the end
5 4
Involute Spline Broaches
Internal Broaches
Broaches
Internal Broaches
Push Broaches
Broaching is generally done by pulling, but in cases where the cutting stock is small. Push Broaches will be used.
Broaches
Complicated Formed Spline Broaches

Various complicated formed broaches can be manufactured such as Outer Rotor Spline Broach and others.
Internal Broaches
Built-up Broaches
This broach is assembled of some broaches and used instead of solid broach to obtain more tool life and more accuracy of workpiece.
Push Broaches
Large Diameter Broaches

NACHI can manufacture broaches with an outside diameter of 300mm and a weight of 500kg, and precise shell-type broaches for internal gears.
5 5
Internal Broaches
Helical Broaches
All of internal helical gears of automotive AT are fabricated by this helical broaches. This assembly broach design has a front roughing section and a removable floating shell-type finishing section with full involute teeth in rear section.
Assembly type Broaches Solid type Cutting Method Internal Broaches Roughing teeth Finishing teeth Helical Broaches
5 6
Surface Broaches
Surface Broaching
Used to remove metal from an external surface to produce a flat or contoured surface. It is more economical than milling cutter because of broaches allows roughing and finishing operation be continued.
Surface Broaching Process
Surface Broach
Work
Broaches
Workpiece Sample
Work Piece Samples of Surface Broaches
Surface Broaches
5 7
Surface Broaches
Connecting Rod Broaches

This is a broach to cut connecting rod and cap which is main part of engines. NACHI can design and manufacture broaches and also broach holders.
Connecting Rod & Cap
Connecting Rod Cutting Method

7 9 11 13 19 21 1517 8 10 12 14
16
23
20 22 1618
Disc Brake Broaches

Mounting for Disk Brake
Connecting Rod Broaches NSL-T Series
5 8
Surface Broaches
Broaches
Surface Broaches
Fir Tree Type Broaches

These broaches are suitable for turbine rotor disk blade groove broaching of aircraft, ships and generators. Turbine rotors discs have a number of grooves in a christmas tree shapes which require high accuracy and their material is usually very hard to cut. NACHI can manufacture highly precise chrismas tree type broaches.
Broaches
Fir Tree Broach Cutting Method
Surface Broaches
Roughing Broach
Semi-Finishing Broach
Fir Tree Type Broaches
Finishing Broach SV-20-23M
Turbo fan engine
5 9
Surface Broaches
Steering Rack Broaches

This is used in broaching of automobile steering rack. NACHI can manufacture broaches such as variable tooth thickness type, form relief type and inserted blade type.
Steering Rack Bar Surface Broaches TSL-7.5-15
6 0
Broaches
Design of Broach
Main Design of Broach

Basic Design
1. Pull End Shape This is determined based upon the broaching machine pull head. 2. Retriever End Shape This is determined based upon the broaching machine retriever head. 3. Tooth Pitch Pitch(P)=1.22.0L The pitch is determined so that the chip do not become jammed in the chip space. The chip space must be larger 6 times than chip volume. Number of engaged cutting teeth(n) Normally more than 2 teeth cut at the same to time. n=L/P (raise decimals and above to the whole number)
Broaches
L Length of Cut
2 2
Length of Cut : L + 1
Chip SpaceChip Volume6 Workpiece t Chip Volume (Lt) Chip Space
Design of Broach
Length of cut Width of cut
Number of Engaged Cutting Teeth
Cutting Method
Cutting methods can be divided generally into, normal cutting, outline cutting and progressed cutting. Normal Cut (Outside diameter up) Form Cutting Progressed Cut
Width of Cut RISE/tooth Cutting Stock RISE/tooth RISE/tooth
6 1
Design of Broach
Calculation of Pulling Load

Estimated Load kN Width of Cut mm Cutting depth/Tooth mm Number of engaged cutting teeth Specific cutting resisitance kN/mm2 Safty Load kN 1.8 Estimated Load An example calculation Parallel side spline 201646SP Material Alloy Steels, Length of Cut=25mm Pitch1.525=7.5 Number of Engaged Cutting teeth=25/7.5=3.3 4 Cutting Depth/Tooth 0.025mm Specific Cutting Force 2.94kN/mm2 Estimated Load 46 0.0252.9447kN Safty Load 1.8712.6kN
Specific cutting Force (kN/mm2) 2.943.92 2.94 1.96 1.352.94 3.92 0.981.96 Broaches Design of Broach Stroke length Cutting depth/Tooth (m) Round Broach 1020 1020 2540 2535 2030 3550 Spline Broach 2530 2530 2540 2535 2030 3040 Surface Broach 3070 3070 5075 5075 3060 60100
Work Material Carbon Steels Alloy Steels Cast Irons Malleable Cast Irons Stainless Steels Non-ferrous Alloys
Broach Length and Machine Stroke

Broach length is limited by machine stroke and fixture Length of Cutting Teeth Rear Shank Length Max. machine stroke Length of Cut Required stroke = Length of Cutting Teeth Rear Shank Length Length of Cut Max. machine stroke
Length of work support
Length of cutting teeth
Shank Length
Length of cut
Rear Shank Length
Broach Length(Max) = A(Max) (Length of Work Support + Length of Cutting Teeth) Broach Length(Min) = B(Min) C(Min)
6 2
Design of Broach
Face Angle, Relief Angle

Work Material Low Tensile Strength Steels Mid Tensile Strength High Tensile Strength Cast Iron, Malleable Cast Iron Bronze, Brass Alminum Alloys Face Angle 1320 1015 1013 10 3 1520 Relief Angle 2 2 2 2 0.5 2 Face Angle Relief Angle
Broaches
Side Relief
The relief to relieve from the form cut with remaining the part near the cutting edge.
Side relief Tooth profile Side relief Side relief angle Tooth profile
Design of Broach
Form Relief
The relief to relieve by the same form as the tooth profile .
Form relief
Back taper
The back taper is a method for making back tapered side relief on a broach for splines, serrations and involute splines.
6 3
Design of Broach
Finished size of broaches

Generally, it is set its target size of broach to the upper limit of the tolerance band of the work piece. +33 For example, if the finished size of the work piece is 25, then 0 set the target size of the broach to 25.033. However, if the work piece has a large tolerance, use a target value that is 20% smaller than the maximum tolerance of the work piece. The actual finishing size of work piece is affected by its hardness, shape, cutting length as well as the thickness of the part and the cutting conditions (cutting speed cutting, cutting fluid etc.) which may change the dimensions of the work piece after broaching. Because of this, set the broaches target size a little larger in advance, and do a few trials to decide with consideration to what is needed.
Tolerance Zone of Broach If tolerance is large, use size to have a small 20% than the work piece tolerance upper limit.
Maximum Limit of Size
Tolerance Zone of Work Least Limit of Size Design of Broach Example of deformation after the broaching The work materials while broaching in order to receive thrust, plastic deformation occurs. Because of that, the work materials after the broaching have the case that becomes smaller than the finished size of broaches.
Example of Thin Woll Thickness
Finished form
6 4
Broaches
Workpiece Hardness
Part hardness of 200230HB is generally used for broaching, however parts with a hardness up to 300HB are widly broached. If extremely soft steel is broached, it causes tearing on the surface on part. Hardness over 300HB shortens the tool life.
Cutting Speed
Cutting Speed infuences the accuracy, the workpiece roughness and tool life. The table right shows recommended cutting speed.
Broaches
Work Material Steels Stainless Steels Cast Iron, Malleable Cast Iron Bronze, Brass Alminum Alloys Magnesium Tough Free Machining
Cutting Speed 38m/min 25m/min 68m/min 10m/min 10m/min 10m/min 10m/min
Cutting Fluids
Cutting fluid influences broach life, accuracy and efficiency, according to what type it is. It is essential to select a suitable cutting fluid depending on the work piece material. The table, on the under table, shows recommended cutting fluids. Environmentally friendly chlorine-free coolants are also supported. Specifically types of cutting fluids that contain large amounts of inorganic additives,
which are not inferior in terms of maintaining performance in piece count, machining active sulfuric chloride with its large amounts of chlorine. On top of that, we have extensive experience in MQL machining, improving work environments, eliminating cleaning processes, reducing energy, and increasing tool life.
MQL : Minimum Quantity of Lubrication
Work Material Steels Stainless steels Cast Iron Copper Alloy Alminum Alloys
Cutting Fluids Active sulfur type oil Active sulfur type oil Water soluble Oil or Dry Compound Oil Water soluble Oil
6 5
Pull End
Jaw Pull End Standard Dimensions
L = L 1+ H C D A
45
E B
45
D1
= Pull Fixture Thickness (30mm)
Unit : mm Pre-broached Hole Diameter d Shank Diameter D Neck Diameter D1 Length to Neck A Neck Length B Chamfer Length C Flat Width E Flat Height H Max. Load Permitted (kN) Length to Front Pilot L Type 1 Type 2 Type 3 Broaches Jaw Pull End Standard Dimensions Pull End
10.5 d12.5 12.5 d14.5 14.5 d16.5 16.5 d18.5 18.5 d20.5 20.5 d22.5 22.5 d26 26 d29 29 d33 33 d37 37 d41 41 d47 47 d52 52 d57 57 d62 62 d67 67 d72 72 d78 d78
0 10 0.022 12 14 16 0 0.027
7.5 9 10.5 12
0 0.08
12 15 18 20 25 30
25
3 90 5 6 8 10 80
0 18 13.5 0.10 20 15 22 16.5 0 25 0.033 19 28 21 0 32 24 0.15 36 27 40 0 30 0.039 45 34 50 38 55 41 60 45 0 0.20 65 0 48 0.046 70 52 75 56
30
100 110 120 140 170
35
40
50
0.04 8.5 0.076 10.5 12 0.05 13.5 0.093 15 17 18.5 21.5 0.065 0.117 24 27.5 31 34.5 0.08 39 0.142 43.5 48 53 57 0.1 60 0.174 65
10 20 30 40 50 70 80 110 130 180 220 280 360 450 550 630 720 850 1000
150 150 150 160 160 170 170 180 180
170 170 170 180 180 190 190 200 200 210 210 225 225 225 235 235 235
180 180 180 190 190 200 200 210 210 220 220 235 235 235 245 245 245 255 255
As Length to Front Pilot is changed by type of Broaching Machine, it's necessary to select by next table.
Type Applicable Broaching Machine
1 2 3
NBV-5, 7.5 NBM BV-T5, T7.5, T10 NUV-10 NUV-15 BV-T15, T20 NUV-20
6 6
Pull End
Cotter Pull End Standard Dimensions
L = L1 + E H C D A B
= Pull Fixture Thickness (30mm)
Unit : mm Broaches Pre-broached Hole Diameter d Shank Diameter D Length to Cotter Hole A Cotter Hole Length B Cotter Hole Width W Chamfer Length C Flat Width H Flat Length E Max. Load Permitted (kN) Length to Front Pilot L Type 1 Type 2 Type 3
0 10.5 d12.5 10 0.022 12.5 d14.5 12

14.5 d16.5 14
16 18 20
16 18 20 25 32
3 3.5 4 5 5.5 6.5 5 6 8 4 3
9 10 12 14 16 18 20 22 25 28 33 36 40 45 50 55 58 63 68 90 80 55 50
20 30 40 50 60 70 100 130 170 230 280 340 420 530 660 770 950 1080 1270
170 175 175 180 180 185 185 195 195 195 205 205 205 215 215
190 195 195 200 200 205 205 215 215 215 225 225 225 235 235
220 225 225 230 230 235 235 245 245 245 255 255 255 265 265 270 270 280 280
Cotter Pull End Standard Dimensions
0 0.027 16.5 d18.5 16 18.5 d20.5 18 20.5 d22.5 20 22.5 d26 22 0 0.033 26 d29 25 29 d33 28 33 d37 32 37 d41 36 41 d47 40 0 0.039 47 d52 45 52 d57 50 57 d62 55 62 d67 60 67 d72 65 0 0.046 72 d78 70 d78 75
60 65 70
Pull End
7 8
22 25 30
9 11 13 14 16 18
40
45 50 55
100 110
10
1 2 3
6 7
Pull End
Threaded Pull End Standard Dimensions
W
1
L = L1 + T
B A
2 Part
= Pull Fixture Thickness Length2 Unit : mm
Keyway Width W Minimum Diameter Keyway Depth T A
Height of Finshing Teeth H
Broach Width B
Thread Size d
Thread Length
1
Max. Load Permitted (kN)
Length to Front Pilot L Type 1 Type 2 Type 3
31.5 31.5 42 42 42 52.5 52.5 52.5 63 63 73.5 73.5 83.5 104 124 155.5
10 12 10 12 15 13 15 18 18 22 18 22 24 30 40 50
9 10 9 10 13 11 13 16 16 19 16 19 21 26 32 36 6 5
7 8 9 11 9 11 12 15 17 19
0 0.012
20 M 61.0 20 20 25 M 81.25 25 25 M101.5 30 30 30 M121.75 M101.5 M121.75 35 30 35 40 40 50 50
10 10 10 12 12 12 19 19 19 28 19 28 39 54 66 85
125 125 125 130 130 130 135 135 135 145 140 145 150 150 160 160
145 145 145 150 150 150 155 155 155 165 160 165 170 170 180 180
175 175 175 180 180 180 185 185 185 195 190 195
Threaded Pull End Standard Dimensions Pull End
0 0.015
0 0.018 0 0.015
0 0.018
M142.0 M162.0 M182.5
200 200 210 210
0 0.021
M202.5
1 2 3
6 8
Broaches
Pull End
Pin Pull End Standard Dimensions

L = L 1+
C A
R = Pull Fixture Thickness (25mm)
Unit : mm Broaches Pre-broached Hole Diameter d Shank Diameter D Length from Pin Center A Chamfer Length C Pin Gullet Height H Gullet Radius R Max. Load Permitted (kN) Length to Front Pilot L Type 1 Type 2
3.3 d 3.7 3.7 d 4.1 4.1 d 4.6 4.6 d 5.1 5.1 d 5.6 5.6 d 6.2 6.2 d 7.2
Pull End
3.2 3.6 4 4.5 5 5.5 6 7 8 9 10 11 12
10
0.5 1 1.5 2
2.2 2.5 2.8 3.2 3.5 4 4.5 5 5.5 6.5 7 8 8.5
0 0.1
2.5 4
2 3 4 0.2 0 5 6 7 9 13 14 0.3 0 19 23 29 35
145
0 0.018
12
165
13
0 0.15
150
170 175 180
7.2 d 8.2 8.2 d 9.2 9.2 d 10.2 10.2 d 11.2 11.2 d 12.5
14 0 0.022 16 18 20 0 0.027 22 25
0 0.2
4.5 5 5.5
155 160
0 0.25
6 7
Pin Pull End Standard Dimensions
d 12.5
As Length to Front Pilot is changed by type of Broaching Machine, it's necessary to select by next table. Type 1 2 Applicable Broaching Machine NBV-5, 7.5 NBM BV-T5, T7.5, T10 NUV-10 NUV-15
6 9
Retriever End
Spring Retriever End Standard Dimensions
45
45
C K L G
45
45
C K L G
Unit : mm Pre-broached Hole Diameter d Shank Diameter D Flat Width or Neck Diameter H, N Length to Neck G Neck Length K Chamfer Length C Length to Rear Pilot L Broach Weight Permitted (kg)
18d 23 23d 29 29d 35 35d 41 41d 47 47d 55 55d 65 65d 75 75d 100 d 100
15 20 25 30 35 40 45 50 60 75
11 14
16 0 0.1 20 0 0.15 25 0 0.2 30
16 20 25 30
60 70 80 90
12.6 17.5 19.6 21.7 23.1
0.007 0.04
18 22 26
34 38
55 59 89 105
0.01 0.056
48 63
12
7 0
Spring Retriever End Standard Dimensions
0.009 0.048
30
10
51
Retriever End
0.006 0.033
Broaches
GPA
GPA Engineering provides total solutions for gear cutting systems.

Recently in the automotive sector, concerns for the environment, energy savings, and greater comfort are increasing. This is pushing the need to produce precision gears to a new level and driving demand for machinery and machine tools in both packaged and full turnkey systems. To meet this demand, GPA Engineering is fusing "tools" and "machine tools", the two core elements of the manufacturing industry. Kashifuji, KANZAKI, and NACHI have combined their capabilities to jointly develop and propose tools, machine tools, and more efficient production line designs. Moreover, combining engineering and support services makes it possible to provide a full turnkey delivery that satisfies customer requirements and schedules. GPA Engineering provides full support, from facilities design through after-sales service.
Gear Cutting Process Task Assignments for Tools and Machinery
Materials for gears
Heat treatment
Inner end surface grinding
Hard hob cutting
Turning work
Broaching
Hob cutting
Shaving
Heat treatment
Inner end surface grinding
Honing
Inspection
GPA
Nachi
Nachi
Kashifuji
Kanzaki
Nachi
Kashifuji
Kanzaki
Kanzaki
Nachi
Nachi
Kanzaki
Nachi Sumitomo Electric Hardmetal Corp.
Nachi
Nachi
Nachi
Nachi
Nachi
Nachi
Kashifuji
Nachi
Core technologies
Gear cutting, dry cutting, cutting conditions and synchronicity
Cutting equipment
Hobbing machines, shaving machines, broaching machines and honing machines
Gear cutting tools

Hobs, shaving cutters, broaches, dress gears
7 2
GPA
EUROPE
Overseas Sales Companies
NACHI EUROPE GmbH
CZECH BRANCH Sezemicka 2757/2, VGP Park-A1 Prague 9,193 00, CZECH Tel: +420-255-734-000 Fax: +420-255-734-001 U.K. BRANCH Unit 7, Junction Six Industrial Estate, Electric Avenue, Birmingham B6 7JJ, U.K. Tel: +44-(0)121-250-1890Fax: +44-(0)121-250-1899
Bischofstrasse 99, 47809, Krefeld, GERMANY Tel: +49-(0)2151-65046-0Fax: +49-(0)2151-65046-90 URL: http://www.nachi.de/ SOUTH GERMANY OFFICE Pleidelsheimer Strasse47, 74321, Bietigheim-Bissingen Tel: +49-(0)7142-77418-0Fax: +49-(0)7142-77418-20 SPAIN BRANCH Av. Alberto Alcocer 28, 1-A, 28036, Madrid, SPAIN Tel: +34-(0)91-302-6440Fax: +34-(0)91-383-9486 BARCELONA OFFICE Josep Tarradellas, 58, 1-5, 08029 Barcerona, SPAIN Tel: +34-(0)93-430-6247Fax: +34-(0)93-419-0807
Overseas Manufacturing Companies

NACHI CZECH s.r.o.
Prumyslova 2732, 440 01 Louny, CZECH Tel: +420-415-930-930Fax: +420-415-930-940
AMERICA
NACHI AMERICA INC. HEADQUARTERS NACHI MEXICANA, S.A. DE C.V.
17500 Twenty-Three Mile Road, Macomb, Michigan, 48044, U.S.A. Tel: +1-586-226-5151Fax: +1-888-383-8665 URL: http://www.nachiamerica.com/ INDIANA BRANCH 715 Pushville Road, Greenwood, Indiana, 46143, U.S.A. Tel: +1-317-535-5527Fax: +1-317-535-3659 WEST COAST BRANCH 12652 E. AIondra Blvd. Cerritos, California, 90703, U.S.A. Tel: +1-562-802-0055Fax: +1-562-802-2455 MIAMI BRANCH-LATIN AMERICA DIV. 2315 N.W. 107th Ave., Doral, Florida, 33172, U.S.A. Tel: +1-305-591-0054/0059/2604Fax: +1-305-591-3110
NACHI ROBOTIC SYSTEMS INC.
Urbina No.54, Parque Industrial Naucalpan, Naucalpan de Juarez, Estado de Mexico C.P. 53370, MEXICO Tel: +52-55-3604-0832/0842/0081Fax: +52-55-3604-0882

NACHI TECHNOLOGY INC.
713 Pushville Road, Greenwood, Indiana, 46143, U.S.A. Tel: +1-317-535-5000Fax: +1-317-535-8484 URL: http://nachitech.com/
NACHI MACHINING TECHNOLOGY CO.
17500 Twenty-three Mile Road, Macomb, Michigan, 48044, U.S.A. Tel: +1-586-263-0100Fax: +1-586-263-4571 URL: http://www.nachimtc.com/
NACHI PRECISION NORTH CAROLINA INC.
22285 Roethel Drive, Novi, Michigan, 48375, U.S.A. Tel: +1-248-305-6545Fax: +1-248-305-6542 URL: http://www.nachirobotics.com/
NACHI CANADA INC.
1836 Lindbergh Street Suite 400, Charlotte, North Carolina, 28208, U.S.A. Tel: +1-704-391-1511Fax: +1-704-391-1648
NACHI BRASIL LTDA.
89 Courtland Ave., Unit No.2, Concord, Ontario, L4K 3T4, CANADA Tel: +1-905-660-0088Fax: +1-905-660-1146 URL: http://www.nachicanada.com/
~ ~ Avenida Joao XX, No.2330, Jardim Sao Pedro, Mogi das Cruzes, S.P., BRASIL, CEP 08830-000 Tel: +55-11-4793-8800Fax: +55-11-4793-8870 URL: http://www.nachi.com.br/
ASIA and OCEANIA

NACHI SINGAPORE PTE. LTD.

NACHI TECHNOLOGY (THAILAND) CO., LTD.
No.2 Joo Koon Way, Jurong Town, Singapore 628943, SINGAPORE Tel: +65-65587393Fax: +65-65587371 VIETNAM OFFICE 614 Hong Bang Street, Ward 16, Dist 11, Ho Chi Minh City, VIETNAM Tel: +84-8-9602-303Fax: +84-8-9602-187
FUJIKOSHI-NACHI (MALAYSIA) SDN. BHD.
5/5 M, 2, Rojana Industrial Estate Nongbua, Ban Khai, Rayong, 21120, THAILAND Tel: +66-38-961-682Fax: +66-38-961-683
NACHI INDUSTRIES PTE. LTD.
No.2 Joo Koon Way, Jurong Town, Singapore 628943, SINGAPORE Tel: +65-68613944Fax: +65-68611153 URL: http://www.nachinip.com.sg/
NACHI PILIPINAS INDUSTRIES, INC.
No.17, Jalan USJ 21/3, 47630 UEP Subang Jaya, Selangor Darul Ehsan, MALAYSIA Tel: +60-(0)3-80247900Fax: +60-(0)3-80235884
PT.NACHI INDONESIA
1st Avenue, Manalac Compound,Sta. Maria Industrial Estate, Bagumbayan, Taguig, Metro Manilla, PHILIPPINES Tel: +63-(0)2-838-3620Fax: +63-(0)2-838-3623 MANILA OFFICE Km23 East Service Road, Capang Muntinlupa, City Metro Manila, PHILIPPINES Tel: +63-(0)2-850-0864Fax: +63-(0)2-850-0864
JI.H.R.Rasuna Said Kav.X-O Kuningan,Jakarta 12950, INDONESIA Tel: +62-021-527-2841Fax: +62-021-527-3029

NACHI (AUSTRALIA) PTY. LTD.
Unit 1, 23-29 South Street, Rydalmere, N.S.W, 2116, AUSTRALIA Tel: +61-(0)2-9898-1511Fax: +61-(0)2-9898-1678 URL: http://www.nachi.com.au/

NACHI C.Y. CORP. No.109, Kao Young North Rd, Lung-Tan Hsin,Tao-Yuan Hsien, TAIWAN Tel: +886-(0)3-47l-7651Fax: +886-(0)3-471-8402
NACHI (SHANGHAI) CO., LTD. Yitong Industry Zone 258, Fengmao Rd. Malu Town, Jiading, Shanghai 201801, CHINA Tel: +86-(0)21-6915-2200Fax: +86-(0)21-6915-5427 TAIPEI REPRESENTATIVE OFFICE 3F No.276, Sec3, Chung Ching N. Road, Taipei, TAIWAN Tel: +886-(0)2-2596-0118 Fax: +886-(0)2-2596-5346 KOREA REPRESENTATIVE OFFICE 2F Dongsan Bldg. 276-4, Sungsu 2GA-3DONG Sungdong-Ku. Seoul 133-831, KOREA Tel: +82-(0)2-469-2254Fax: +82-(0)2-469-2264 THAILAND REPRESENTATIVE OFFICE Chai-ho Wongwaiwat Bldg. 889 Srinakarin Road, Samutprakarn, 10270, THAILAND Tel: +66-2-748-7322~4Fax: +66-2-748-7325 INDIA REPRESENTATIVE OFFICE A/9A, Sector-16, Noida-201301, Distt. Gautam Budh Nagar, U.P. INDIA Tel: +91-120-4272257Fax: +91-120-4272256
DONGGUAN NACHI C.Y. CORPORATION Dangyong Village, Hongmei Town Dongguan City, Guangdong, CHINA Tel: +86-(0)769-8843-1300Fax: +86-(0)769-8843-1330 SHANGHAI NACHI BEARINGS CO., LTD. Yitong Industry Zone 258, Fengmao Rd. Malu Town, Jiading, Shanghai 201801, CHINA Tel: +86-(0)21-6915-6200Fax: +86-(0)21-6915-6202 SHANGHAI NACHI SAW CO., LTD. Yitong Industry Zone 258, Fengmao Rd. Malu Town, Jiading, Shanghai 201801, CHINA Tel: +86-(0)21-6915-5899Fax: +86-(0)21-6915-5898
NACHI-FUJIKOSHI CORP.
NACHI (SHANGHAI) PRECISION TOOLS CO., LTD. Yitong Industry Zone 258, Fengmao Rd. Malu Town, Jiading, Shanghai 201801, CHINA Tel: +86-(0)21-6915-7200Fax: +86-(0)21-6915-7669 DAESUNG-NACHI HYDRAULICS CO., LTD. 289-22, Yousan-Dong, Yangsan-Si Kyungnam 626-800, KOREA Tel: +82-(0)55-385-7891~3Fax: +82-(0)55-384-3270 D-59-60, Sector-6, Noida 201301, Distt. Gautam Budh Nagar, U.P. INDIA Tel: +91-120-425-8372Fax: +91-120-425-8374
NACHI
NACHI MOTHERSON TOOL TECHNOLOGY LTD.
Tokyo Head Office Toyama Head Office
Shiodome Sumitomo Bldg. 17F, 1-9-2 Higashi-Shinbashi, Minato-ku, Tokyo 105-0021Tel: +81-(0)3-5568-5111Fax: 03-5568-5206 Web Site URLhttp://www.nachi-fujikoshi.co.jp/E-mail webmaster@nachi-fujikoshi.co.jp 1-1-1 Fujikoshi-Honmachi, Toyama 930-8511Tel: +81-(0)76-423-5111Fax: +81-(0)76-493-5211
CATALOG NO.
T2301E
2009.04.Z-MIZUNO

NACHI - Precision Tools

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NACHI - Precision Tools

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Precision Tools

Other Types of Gear Cutting Tools Gear Shaper Cutters

Essential Points and Notice for Broaching Process

Gear Cutting Tools

Gear Cutting Tools

Materials and Coating of Gear Cutting Tools

FAX55 Carbide Surface Treatment

Hardened Steels 40HRC

Carbon Steels Cast Irons

Coating Technology Creation

Compound Multilayer Increase of Film

Performance of Dual Coat Hob

2000 3000 Number of Gears

Carbide Hob Technical Introduction After Carbide Hob with shank

1500 1000 500 0

NACHI Hard Hob

Gear Cutting Tools

Hobbing of hardened gear is possible

Gear Cutting Tools

Realize High Speed Dry Hobbing of 250m/min

High Speed Dry Hobbing

Dual Cut Hob Technical Introduction High Speed Dry Hobbing

Comparison of Tool Life

1.5 times the tool life of competitors

1.8 times the tool life of conventional products

Dual Cut Hob

Dual Cut Hob

Workpiece Module 2.5

Cutting Conditions Feed Rate 2.5mm/rev

Workpiece Module 2.8

Cutting Conditions Feed Rate 2.2mm/rev

Number of Teeth 65 Tooth Width Material 30mm SCR420

Cutting Method Climb Cutting

Number of Teeth 48 Tooth Width Material SCR420H

Cutting Method Climb Cutting Cutting Length 210m

HSS dry (Dry)

Hyper Dual (Dry)

Hyper Dual Cut Hob

200 Hobbing speed

Convention Hyper Dual

More than 5 times the tool life of conventional hobs

Hyper Dual Hobs

40m Cutting Length

40m Cutting Length

200m Cutting Length

Hob Specifications Outside Dia. Threads Flutes 90mm 3 12

High Speed Dry Hobbing

Gear Cutting Tools

Hyper Dual Cut Hob Features

Gear Cutting Tools

Realize High-speed Shaving

High Performance Shaving Cutter

High Performance Shaving Cutter Technical Introduction

Tool Life (pcs)

High Performance Shaving Cutter

Competitor HSS NACHI

Serration Form to Leave Both End Land

Number of Teeth 75 Tooth Width 25mm Helix Angle 28 RH

Dual Forming Rack

Dual Forming Rack

MQL Roll Forming

MQL Dual Forming Rack

MQL Roll Forming Example by Use of NC Roll Forming Machine.