PRECISION PERFORMANCE PERFECTION HOME PRODUCTS & SERVICES NEWS Universal Gear Company Why use U.G.C. Shank Shaper Cutters? Because Performance = Profits! The cutting of internal gears and splines presents an interesting challenge to the designer and manufacturer of shank type shaper cutters. Deflection (of the cutting edge by cutting forces) increases by the fourth power with the reduction in shank diameter – and also increases by the third power with the increase in length. It is therefore very important to make every effort to control the design of the cutter in such a way as to reduce the deflection as much as possible. Standard norm for the maximum number of teeth that can be used in a cutter is between 7 and 9 teeth less than a fillet root internal spline (with 30˚ P.A.). Here’s an Example: Assuming a 12 tooth 24/48 DP. 30˚ P.A. full fillet internal spline starting ½” below the face of the part and 1 inch long, requires a fluted cutter with a cutting length of 2 inches. 1½” to reach the end of the spline plus 1/8 inch for overstroke plus 3/8 inch of cutter life. The accepted rule would be to use a 5 tooth cutter. This cutter would have a shank diameter of approximately .250. Applying 10 lbs. of load radially at the cutting edge would cause a deflection of over .004 (.00464 to be exact). An 8 tooth cutter designed by U.G.C. to produce the same part would have an approximate shank diameter of .355. Applying the same 10 lbs. Load at the cutting edge would cause a deflection of .00114 inches – less than ¼ the deflection! It does not require much study to understand that the durability of the cutting edge will be greatly improved by using an 8 tooth cutter vs. a 5 tooth cutter. Another Point to Consider: How many times each tooth of the cutter gets used while cutting one single part. Assuming the part will rotate 2½ times in order to rough and finish cut, each tooth of a 5 tooth cutter will be used 6 times (12/5 x 2½ turns) while each tooth of an 8 tooth cutter will be used 3¾ times (12/8 x 2½ turns). Considering the difference in deflection and the number of times the teeth are getting used – our calculations and tests show that an 8 tooth cutter will outperform a 5 tooth cutter by at least 6 to 1. Adding in the time required to sharpen the 5 tooth cutter more frequently, there should be little doubt that the 8 tooth cutter in this scenario would be a far better investment, even at a slightly higher acquisition cost. For Over 25 Years We have Continually Refined Our Shank Cutter Design Software. This allows us to use the maximum number of teeth without trimming interference and while maintaining the utmost in geometric tooth accuracy. This is but another example how we at Broach Masters Universal Gear (U.G.C.) continue to devote our efforts and resources to provide our customers with superior quality gear cutting tools that provide not only the utmost accuracy, but also the highest value for the dollar. Experience the Difference! Shank & Disc Type Shaper Cutters: SPUR Our shank cutters are specially designed for maximum rigidity and minimum deflection. This insures the integrity of the spline feature and tool life. Our base material for cutters is Rex 45, but includes other Top H.S.S. such as M42, & Rex 76 as required. TYPES: Shank & Disc Cutters for internal & external Spur Gears, Spline, Hex, Square, Serrations, Form Cut Keys, Specials. RANGE: Diametral Pitch: 10/20 D.P. to 150 D.P. Module Conversion: 2.540 to .211667 Mod. SPECIALTIES: Small shank cutters with maximum number of teeth in cutter to dramatically reduce deflection without trimming. ADDED NOTE: No one does this better. Experience the difference! Click here to check our stock cutter inventory. Generated Form with Ground Fillet Radius Go NoGo Plug Gages and Ring Gages All spline and gear gages are element checked and charted on our Klingelnberg P26 and Wenzel WGT350 Gear Analyzers for final acceptance. They are laser marked for easy reading and identification. TYPES: Gears & Splines, Hex, Serrations, Squares, Select fit gage sets RANGE: Size & Range: .100 to 6.0 P.D. Diametral Pitch Range: 6 D.P. to 150 D.P. Module Conversion: 4.2333 to .169333 Mod. ADDED NOTE: Re-calibration based on your set requirements (quarterly or annual) at below industry pricing. “Posi-Loc” Spline Arbors: P.D. Location The “Posi-Loc” Arbor is an easy to use method to quickly check part run out tolerances. The arbors are typically custom fit to an internal spline for proper placement. They can be used in some cases as grinding arbors if the part has allowable parameters. TYPE: Tapered spline mandrel on one “profile” only. USE: For checking concentricity of spline P.D. to location diameter. Some grinding applications. ADDED NOTE: If a spline has excessive taper or lead, the “Posi-Loc” may not seat properly. The concentricity should then be verified by other methods before use. Master Gears: SPUR All master gears are ground on state of the art C.N.C. equipment and checked on a Klingelnberger P26 Gear Analyzer for qualification. RANGE: Pitch Diameter: .500 to 5.0 P.D. Diametral Pitch: 10/20 to 96 D.P. SPECIALTIES: Non standard gears. Small Gears It is difficult to lay specific boundaries for making small gears as each part is unique and presents its own set of challenges. RANGE: Pitch Diameter: .100 P.D. Diametral Pitch: up to 150 D.P. HISTORY: The below-pictured gear was internally broached. Ref. Data: 12T 120 D.P. 20` The Broach Masters, Inc. and Universal Gear Company 2160 Precision Place Auburn, CA 95603 Email: info@broachmasters.com Phone: 530-885-1939 Fax: 530-885-8157 Questions? 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