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Gears are mechanical components used to transmit power and motion through the successive engagement of their peripheral feed gears perform certain key functions within machines and assemblies such as reversing the direction of rotation or altering the angular orientation of rotary motion gears are also used to convert rotary motion into linear motion and vice versa or to alter gear speed ratios the methods of machining gears can reclassified into two primary categories gear generating and gear form cutting many of the processes used to machine gears may also be used to finish gears gear generating involves gear cutting through the relative motion between rotating cutting tool and the generating motion or rotation of the workpiece the primary gear generating processes include robbing and shaping in hobbinggear teeth are progressively generated by a series of cuts using a helical fluted cutting tool called a hob both the hob and the gear blank rotate as the hob is fed axially across the face of the blank robbing is the principal method for producing spur gears and helical gears and is also used to produce many special gears forms the main limitation of robbing is that it can only be used to produce external gearshobbing can be performed on a single gear blank but also allows for the stacking of work pieces to increase production rates shaping generates gear teeth by rotating the workpiece in contact with a reciprocating cutter the reciprocating cutter may be opinion cutter a multi toothed rack shaped cutter or a single point cutter the pinion shaped cutters' axis is parallel to the gear blank and begins cutting by reciprocating while feeding gradually into the blank to a predetermined cutting depth the cutter and gear blank rotates slowly at the same pitch circle velocity as the cutter enters and exits the cut incremental e generating the gear teeth rack shaped cutters typically have between 6 and 12 teeth that reciprocate into the gear blank once the rack cutter finishes a pass the cutters disengaged and returns to a starting point to begin cutting again when shaping with a single point cutter the cutter reciprocates making successively deeper cuts until a predetermined depth reached gear shapers are used to make internal gears shoulder gears and many other gear types that cannot be produced with ha burs shapers can also produce non-involute shapes such as a cam and gear on the same shaft gear form cutting typically involves the use of formed toothed cutters that have the desired gear shape or profile the primary gear form cutting processes include broaching and milling broaching is the fastest method of machining gears and is performed on many machine types using a multi toothed cutting tool called a broach the broach or the gear blank are pushed or pulled relative teach others to remove material each tuition the broach is generally higher than the preceding tooth as a result the depth of cut increases with each toot has the broaching operation...
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