Gear Grinding - using a Process Cost Model

User Input

1. Select the "Part Weight Range"

2. Enter the "Face Width"

This is the thickness of the tooth form from front to back.

3. "Approach Distance" is preset to 1.000 (25.4mm).

This is the distance for the grinding wheel to approach and overtravel to get on and off the work piece gear tooth surface.

4. "Travel Dist per Pass"

is the total travel distance for each gear tooth including the face width and approach distance added together.

5. Enter the "Stock Removal".

This is the amount of stock to be removed for grinding only. Since the gear was previously gearcut on a shaper or hobber, the amount of stock to be removed here is expected to be .002 - .045 or .05-1.15mm max off of the gear tooth surface.

6. Enter the "Diametrical Pitch" (1-16 Imperial only).

This equates to 25.4 - 1.587 mm pitch in Metric.

The metric number is obtained by dividing 25.4 by the imperial pitch.

For example: A pitch of 1 = 25.4 mm and a pitch of 16 = 1.587 mm (25.4/16). However, do not enter a metric number.

Use this table for input: An entry of "1" is equivalent to 25.4mm in Metric. 2 = 12.7mm, 3 = 8.47mm, 4 = 6.35mm, 5 = 5.06mm, 6 = 4.233, 7 = 3.63mm, 8 = 3.174mm, 9 = 2.822mm, 10 = 2.54mm, 11 = 2.3mm, 12 = 2.12mm, 13 = 1.95mm.

7. Enter the "Number of Gear Teeth"

8. "# of Passes per Tooth" is calculated by the system

9. "Feed rate (IPM or mm/m)" is defaulted to 300 inches per minute (7620mm per minute).

10. "Grind Time per Tooth" is calculated.

11. "Grinding Time" is calculated.

12. "General Handling" is defaulted to 1 and can be changed by the end user.

13. "Indicate Part" is calculated.

14. "Load + Unload" is calculated.