Gear shaping is commonly used for cutting spur gears, herringbone gears, and ratchet gears. The cutter starts carving its way to the desired depth, as seen in Figure 3, then the cutter and gear blank rotates slowly as the gear teeth are cut in the gear blanks. In this method of gear generation, a cutter and gear blank are connected by gears so that they don’t roll together as the cutter reciprocates. And because the Sunderland principle has been maintained since its invention, manuals and documentation are widely available and relevant even for new machine designs. So, gear designs that require high precision - even double helix gears - can be fabricated with this method. The Sunderland method is excellent at creating teeth of uniform shape, and all gears that are cut by the same cutter will, in theory, gear correctly with one another. The teeth profiles follow a geometry that consists of an involute of a circle - basically a spiraling curve traced by the end of an imaginary string unwinding itself from that stationary circle - or if you trace the point of contact from one tooth to another as shown on Figure 1. It uses specific relative motion between the workpiece and the cutter during machining to produce teeth profiles and is similar to a rack and pinion as depicted in Figure 2. The process is also known as the Sunderland method, which consists of a rack cutter that has rake and clearance angles to create the teeth profile on a gear blank. Rack type cutters are used in one of the primary methods of gear generation.
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