ABSTRACT
This chapter considers some essential issues of asymmetric gear fabrication. A form gear cutting or grinding tool profile is the same as a space profile between gear teeth. Gear form machining process is typically removing material from one space between teeth after another. Fly cutting uses conventional gear hobbing machines that operate when a cutter and a gear blank are in constant synchronized rotation. In traditional gear design, the tooling profile is known at the beginning of gear design. The optimized asymmetric tooth and whole gear profiles are described without using any preselected tooling rack parameters or its position relative to a gear center. In many applications, including automotive transmissions, gears are machined by the protuberance hobs that leave a required tooth flank grinding stock and finally cut the tooth root fillet. Forming gear fabrication technologies like plastic and metal injection molding, powder metal processing, net forging, die casting, extrusion, gear and worm rolling.
