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Fundamentals and Design Considerations of Tungsten Carbide Shaving Cutter
Tungsten carbide shaving cutter is a kind of high-precision gear machining tool, which is mainly used for the finishing of gears, so as to ensure the precision and surface quality of gears.
Working principle of tungsten carbide shaving cutter
During the shaving process, the shaving cutter meshes with the gear to be machined at a certain angle of intersection of the shafts (typically 10° - 15°).There is a relative sliding speed between the shaving cutter and the gear, which enables the cutting edge of the shaving cutter to remove a very thin layer of metal (usually between 0.02 - 0.05mm) from the gear tooth surface.
Tungsten carbide shaving cutters remove material primarily by shearing. During the shaving process, the contact pressure between the tool and the workpiece causes plastic deformation of the material on the gear tooth flanks, which is then removed in the form of chips by the shearing action of the cutting edge.
Structural design of tungsten carbide shaving cutter
Tungsten carbide is used as the cutting tool material mainly because it has high hardness, high wear resistance and good thermal stability. The hardness of tungsten carbide can reach HRA89 - 92.5, which is able to maintain the sharpness of the cutting edge during a long cutting process.
The tooth shape of tungsten carbide shaving cutter should be matched with the tooth shape of the gear to be processed. Its tooth shape design needs to consider the modulus, pressure angle, tooth width and other parameters of the gear. At the same time, in order to ensure good cutting performance, the tooth top and root portion of the shaving cutter will be appropriately trimmed.
The design of the helix angle of the cutter teeth should be determined according to the helix angle of the gear to be machined and the requirements of the machining process. A suitable helix angle can ensure good meshing conditions between the shaving cutter and the gear, so that the cutting force is evenly distributed and vibration is reduced.
The precision of tungsten carbide shaving cutter includes many aspects such as dimensional precision and form precision. In terms of dimensional accuracy, the dimensional tolerances of the shaving cutter's outer diameter, inner diameter and other dimensions should be strictly controlled to ensure the installation accuracy of the tool and the machine tool and the versatility of the tool.
