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Hob Flutes - Gashes
 

Fig.1 - Gash Lead Error

Fig.2 - Gash Radiality

Fig.3a - Correctly Ground

Fig.3b - Incorrect Positive Rake

Fig.3c - Incorrect Negative Rake

Fig.3d - Incorrect Convex Rake

A longitudinal groove along the axis of the hob that forms the face of one row of hob teeth and the back of the preceding row. Although technically called 'flutes' they are more commonly known as 'gashes' and it is with this latter name that I shall refer.
The gashes, as well as providing a space for the chips (swarf) to form, also allows the re-sharpening of the hob by grinding the teeth faces. Care must be taken when re-sharpening a hob as the accuracy and alignment of the gashes has a large influence on the quality of the gear produced.

There are three main areas where errors can occur:-
1. Gash Lead
The gash's can be straight whereby they are parallel to the axis and commonly called 'straight gash' or with a lead and called 'spiral gash'.
The hob must be sharpened at the gash lead specified on the end of the hob, if there are errors, the cam relief will result in a taper on diameter.
With an incorrect gash lead ground in the hob the cam relief will cause a taper on diameter also the hob lead being increased on one side of the tooth and decreased on the other.
This will result in producing a hob with a pitch that varies from one end of the hob to the other (Fig.1) and with a reduced pressure angle on one side of the tooth and an increased pressure angle on the other side. This will cause variations in tooth form, tooth thickness and tooth depth as the hob progresses through its hob shift.

2. Gash Radiality
Hobs can be designed under certain circumstances with a negative or positive rake but most are produced with a radial face rake, (Fig.2). The rake of the hob teeth will be marked on the end of the hob and must be maintained throughout its life. Any deviation outside of the permitted sharpening tolerance will result in generating errors.
Fig.3a - A correctly sharpened hob presents a true basic rack generating a true involute profile.
Fig.3b - An incorrectly sharpened hob showing a positive rake. The cam relief on the hob causes the constant profile to drop from front to back on the hob tooth. Whilst the tip of the hob tooth is correct, an error has been created at the root of the hob. The cam effect is such that the tooth depth is enlarged and the pressure angle thus reduced. A hob sharpened like this will generate an involute profile error with plus metal at the tip of the gear.
Fig.3c - An incorrectly sharpened hob showing a negative rake. The effect will be the reverse of Fig.3b.
Fig.3d - An incorrectly sharpened hob showing a convex rake. This is one of the most common errors in hob sharpening and is normally the result of grinding a spiral gash hob with a grinding wheel that has been dressed for a straight gash hob. The helical interference as the hob spirals past the wheel will give a convex cutting face resulting in hollow involute profiles.

3. Gash to Gash
This is eccentricity in the hob tooth spacing from one gash to the next. This eccentricity will produce profile errors due to uneven stock removal, Fig. 4.

Permissible Errors for grades AA, A, B, and D hobs BS 2062: Part 1:

Gash Lead
Departure (±) from angle of gash (expressed as a linear dimension of thousands of an inch)
Hob Grade
AA
A
B
C
D
0.0006
0.0010
0.0010
0.0010
0.0015

Hob Grade
Adjacent Spacing Error
Dimensions expressed in thousands of an inch
Preferred Diametral Pitch
1 to 1.9
2 to 2.9
3 to 3.9
4 to 4.9
5 to 5.9
6 to 8.9
9 to 12.9
13 to 19.9
20 to 29.9
30 to 50
AA
-
0.0020
0.0020
0.0015
0.0010
0.0008
0.0008
0.0006
0.0006
0.0006
A
0.0040
0.0030
0.0025
0.0020
0.0015
0.0010
0.0010
0.0010
0.0010
0.0010
B
0.0050
0.0045
0.0040
0.0030
0.0020
0.0015
0.0015
0.0010
0.0010
0.0010
C
0.0050
0.0045
0.0040
0.0030
0.0020
0.0015
0.0015
0.0010
0.0010
0.0010
D
0.0060
0.0060
0.0050
0.0050
0.0030
0.0025
0.0025
0.0020
0.0017
0.0017

Hob Grade
Cumulative Spacing Error
Dimensions expressed in thousands of an inch
Preferred Diametral Pitch
1 to 1.9
2 to 2.9
3 to 3.9
4 to 4.9
5 to 5.9
6 to 8.9
9 to 12.9
13 to 19.9
20 to 29.9
30 to 50
AA
-
0.0040
0.0040
0.0035
0.0025
0.0015
0.0015
0.0015
0.0015
0.0015
A
0.0080
0.0060
0.0050
0.0040
0.0030
0.0030
0.0030
0.0025
0.0025
0.0020
B
0.0100
0.0090
0.0080
0.0060
0.0050
0.0050
0.0050
0.0040
0.0035
0.0030
C
0.0100
0.0090
0.0080
0.0060
0.0050
0.0050
0.0050
0.0040
0.0035
0.0030
D
0.0120
0.0120
0.0100
0.0100
0.0080
0.0080
0.0070
0.0060
0.0060
0.0040

Hob Grade
Radial Alignment of Gash over Cutting Depth
Dimensions expressed in thousands of an inch
Preferred Diametral Pitch
1 to 1.9
2 to 2.9
3 to 3.9
4 to 4.9
5 to 5.9
6 to 8.9
9 to 12.9
13 to 19.9
20 to 29.9
30 to 50
AA
-
0.0010
0.0010
0.0008
0.0006
0.0005
0.0005
0.0003
0.0003
0.0003
A
0.0030
0.0015
0.0010
0.0008
0.0006
0.0005
0.0005
0.0003
0.0003
0.0003
B
0.0050
0.0025
0.0015
0.0010
0.0008
0.0007
0.0007
0.0005
0.0005
0.0005
C
0.0050
0.0025
0.0015
0.0010
0.0008
0.0007
0.0007
0.0005
0.0005
0.0005
D
0.0100
0.0075
0.0050
0.0040
0.0020
0.0020
0.0020
0.0015
0.0015
0.0010

Common Sharpening Problems
Problem Cause Correction
Worn index Worn index plate or latch
Loose index plate
Centres (workholding) misaligned
Replace worn item
Tighten retaining nut
Align centres
Incorrect radial position and rake offset Diamond incorrectly positioned
Dull diamond
Incorrect wheel position
Excessive feed or wheel breakdown
Work eccentric or loose on arbor
Dirt on faces of collars, nut or in centres
Faces of collars and nut not parallel
Worn index plate or latch
Loose index plate
Centres (workholding) misaligned
Reposition diamond
Turn or replace diamond
Reposition wheel
Reduce feed and dress wheel
True between neutral centres. Do not use shims
Clean faces and centres
Grind faces parallel
Replace worn item
Tighten retaining nut
Align centres
Curved or stepped flute Incomplete wheel dressing

Wheel not properly lowered into flute
Excessive feed or wheel breakdown
Wheel head swivelled incorrectly
Dress wheel, ensure diamond traverses entire cone face
Lower wheel
Reduce feed and dress wheel
Set wheel head at proper helix angle
Incorrect lead Tangent bar set incorrectly
Tangent bar not clamped
Wheel 'sings'
Excessive table speed
Work eccentric or loose on arbor
Dirt on faces of collars, nut or in centres
Faces of collars and nut not parallel
Worn index plate or latch
Loose index plate
Centres (workholding) misaligned
Reset
Clamp
Dress with sharp diamond or faster traverse
Reduce speed
True between neutral centres. Do not use shims
Clean faces and centres
Grind faces parallel
Replace worn item
Tighten retaining nut
Align centres
Index errors Work arbor incorrectly tensioned between centres
Excessive feed or wheel breakdown
Wheel 'sings'
Feeding at same flute each revolution
Work eccentric or loose on arbor
Dirt on faces of collars, nut or in centres
Faces of collars and nut not parallel

Tension correctly
Reduce feed and dress wheel
Dress with sharpened diamond, one pass only
Change feed cam setting
True between neutral centres. Do not use shims
Clean faces and centres
Grind faces parallel
Burned teeth Improper coolant action
Glazed wheel
Excessive feed
Insufficient table speed
Sparking out too long
Increase or redirect flow, change to different coolant
Turn or replace diamond
Reduce feed
Increase speed
Reduce number of revolutions of sparkout
Rough finish Dressing too rapidly
Wheel is too soft
Excessive feed or wheel breakdown
Excessive table speed
Dress wheel more slowly
Use harder wheel
Reduce feed and dress wheel
Reduce table speed

 

 

 

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