A NOVEL HOB DESIGN

FOR PRECISION
INVOLUTE GEARS:

PART I

The following paper outlines the

development of a new precision
gear hob design for machining
involute gears on conventional
gear-hobbing machines.
By Stephen P. Radzevich, Ph.D.

34

GEAR SOLUTIONS

APRIL 2007

gearsolutionsonline.com

Abstract
This paper is aimed at the development of a novel design of precision gear hob for the machining of involute gears on a conventional
gear-hobbing machine. The reported research is based on the use of fundamental results obtained in analytical mechanics of gearing.
For solving the problem, both the descriptive-geometr y-based methods (further DGB-methods) together with pure analytical methods have
been employed. The use of DGB-methods is insightful for solving most of the principal problems, which consequently have an analytical
solution. These analytical methods provide an example of the application of the DG/K-method of sur face generation earlier developed
by the author. For interpretation of the results of research, several computer codes in the commercial software MathCAD/Scientific
were composed. Ultimately, a method of computation of parameters of design of a hob with straight-line lateral cutting edges for the
machining of precision involute gears is developed in the paper. The coincidence of the straight-line lateral cutting edges of the hob with
the straight-line characteristics of its generating sur face eliminates the major source of deviations of the hobbed involute gears. The
relationship between major principal design parameters that affect the gear hob per formance are investigated with use of vector algebra,
matrix calculus, and elements of differential geometr y. Gear hobs of the proposed design yield elimination of the principal and major
source of deviation of the desired hob tooth profile from the actual hob tooth profile. The reported results of research are ready to put in
practice. Part I is presented here, with the conclusion to appear in the May issue of the magazine.

Nomenclature
C g / h = center distance

do.h = outside diameter of the involute hob

Dg = pitch diameter of the gear

ht. g = gear tooth whole depth

Do.g = outside diameter of the gear

m = gear modulus

G = gear tooth surface being machining

p b.h = base pitch of the involute hob

N g = number of gear teeth

tc = normal tooth thickness

Nh = number of starts of the involute hob

Greek Symbols

O g = gear axis of rotation

= cross-axis angle

Oh = hob axis of rotation

h = hob-setting angle

Px.h = axial pitch of the involute hob

R

= auxiliary phantom rack of the involute hob

Sh = involute hob feed-rate

n = normal pressure angle

T = the generating surface of the involute hob

U = idle distance in gear hobbing operation

WR

= pitch plane of the auxiliary phantom rack R

a g = gear tooth addendum

aR

= the auxiliary rack tooth addendum

bg = gear tooth dedendum

bR

= the auxiliary rack tooth dedendum

db. g = base diameter of a gear

db.h = base diameter of an involute hob

d f .g = gear root diameter

dh = gear hob pitch diameter

b.h = involute hob base lead angle (b.h =90degg.h )

b.h = involute hob base helix angle

g = gear pitch helix angle

h = involute hob pitch helix angle

R

= auxiliary rack pitch helix angle

g = gear rotation
h = involute hob rotation

Subscripts
g = gear to be machined
h = involute hob to be applied
R

= auxiliary phantom rack of the gear hob

gearsolutionsonline.com

APRIL 2007

GEAR SOLUTIONS

35

Introduction
Gear hobs are recognized as economical cutting tools for the machining of spur and helical gears. Almost any external tooth form that is
uniformly spaced about a center can be hobbed. Application of gear
hobs of special design yields machining of internal gears as well. In
order to achieve high accuracy of hobbed gears, lateral cutting edges of
an involute gear hob are required to be located on the surface of involute worm. It is also required that this worm is in proper mesh with the
involute gear to be machined. Usually this worm is referred to as the
generating (machining) surface of an involute hob [1]. Lateral cutting
edges of the hob teeth align with the line of intersection of the generating surface of a gear hob by rake face of the hob tooth. These lines
are curved lines. For the manufacturing purposes, the required curved
lateral cutting edges of the involute hob teeth usually are approximated
with the straight-line lateral cutting edges. Approximation of that kind
results in deviations of the actual lateral cutting edges of the involute
hob from the generating surface of the hob. The deviations of that kind
are the major source of the gear tooth deviations, and are unavoidable
for gear hobs of conventional design.
Analysis of known designs of involute hobs [2], [3] and others
reveals that no design of a hob with straight-line lateral cutting edges
are developed yet for he machining of precision involute gears.
Formulating the problem at hand: To develop a method for computation of parameters of a novel design of gear hob with straight-line
lateral cutting edges for the machining of precision involute gears.
The method of computation of parameters of design of a hob with
straight-line lateral cutting edges for machining of precision involute
gears is reported in the paper.
Outline: The paper is organized in the following way. In Section 2
generation and geometry of the generating (machining) surface on
the involute hob is investigated. For this purpose, equation of the
gear screw involute tooth surface is utilized. Ultimately the generating
surface of the involute hob is determined in both ways; say, using the
DGB-approach, and analytically as well. Use of the DGB-approach is
insightful for derivation of equations for computation of major design
parameters of the gear hob. The concept of design of the precision
involute gear hob with straight-line lateral cutting edges, as well as
computation of principal parameters of its design, is considered
in Section 3. A practical example of computation of parameters of
design of the precision involute hob of proposed design is considered. In Section 4 a possible enhancement of the developed theory
to the area of hobbing of involute gear with modified tooth profile
is reported. This consideration is based largely on application of
the DG/K-approach1 of surface generation earlier developed by the
author. Part II ends with Conclusions and Acknowledgement.

are known [1]. Following common practice, for generation of the surface T of an involute gear hob the single-parametric method can be
used [1]. This method is based on the first method of generation of
enveloping surfaces proposed by Olivier2 [7].
The generating surface T of a gear hob could be generated in three
steps. For this purpose it is required (a) to specify the gear tooth
surface to be machined, (b) to generate an auxiliary phantom rack R,
and, finally (c) to generate the surface T itself. Below, the generating
surface T of an involute gear hob is determined following the above
listed routine.

2.1.
Gear tooth surface. Gear tooth surface G is a screw involute surface. In the left-handed Cartesian coordinate system XgYgZg it can be
described analytically in terms of curvilinear (Gaussian) parameters
Ug and Vg [8]

rb.g sin V g U g cos b.g cos V g

G : r g (U g , V g ) =

36

GEAR SOLUTIONS

APRIL 2007

(1)

1
Here, in Eq. (1) is designated
rb.g = the gear base radius (rb.g = 0.5db.g=, and db.g is the gear base diameter)
= base lead angle
g.b
p = screw parameter of the gear tooth surface G
The interested reader may wish to go to [1], [8] for details on Eq. (1).
Equation (1) of the gear tooth surface G is of critical importance for
the analysis following below. Mostly, this is because it is helpful for
derivation of equation of the auxiliary phantom rack R, and of the
generating surface T of the involute hob.

2.2.

The auxiliary phantom rack R . The auxiliary phantom rack R of an

involute gear hob can be generated as an enveloping surface to consecutive positions of the gear tooth surface G in its motion relative
to the coordinate system XR YR ZR associated with the rack R. For
generation of the auxiliary rack R, the left-handed Cartesian coordinate system XRYR ZR has been employed. Generation of the auxiliary
rack R is illustrated in Fig. 1.

Dg

2: The Generation Surface T on an Involute Hob

Determination of the generation surface of a cutting tool is the start
point for designing the tool. We refer to the generation (i.e. to the
machining) surface of a cutting tool as to a surface that is conjugate
to the surface being machined [1], [6]. Concerning a gear hobbing
operation, the generating surface T of an involute hob is represented
by a screw involute surface that is conjugate to the gear tooth surface being machined. Parameters of shape of the surface T can be
expressed in terms of (a) parameters of shape of the gear tooth surface G, and (b) parameters of relative motion of the hob with respect
to the gear.
Several methods for generation of the surface T of a cutting tool

rb.g cos V g + U g cos b.g sin V g .

pV g U g sin b.g

Gear being machining

Og

VR
A

Eg
B

WR

R g FR Fg

FIG. 1. THE AUXILIARY PHANTOM RACK R OF AN INVOLUTE HOB.

gearsolutionsonline.com

The gear being machined is rotating about it axis Og with a certain

angular velocity g. A pitch plane WR of the rack R is moving straightforward. Velocity of this translational motion is designated as VR.
The rotation g and the translation VR are synchronized in a timely
manner. This results in that the pitch plane WR is rolling without sliding over the pitch cylinder of diameter Dg of the gear. Without going
into details, one can come up with the conclusion that the lateral
surfaces of the auxiliary rack R teeth are the planes. Face-width FR
of the rack R is identical to the face-width Fg of the gear ( g R ).
Pitch helix angle R is identical to the pitch helix angle g of the gear
(Fg FR ). The auxiliary rack R makes contact with the gear tooth surface G along straight-line segment AB, which is often referred to as
the characteristic Eg.
The intuitive understanding of the shape of the lateral tooth surfaces of the rack R is helpful but not sufficient. For further consideration, equation of the rack R tooth surface is required to be derived.
The major coordinate systems to be used in this research are the
following: (a) the coordinate system XgYgZg embedded to the gear, (b)
the coordinate system XRYR ZR associated with the auxiliary rack R
(Fig. 2), and ultimately XhYhZh connected to the involute hob. A few
more intermediate coordinate systems were used as well.
The auxiliary rack tooth surface R could be represented as an
enveloping surface to consecutive positions of the gear tooth surface
G, while the pitch plane WR is rolling without sliding over the pitch
cylinder of diameter Dg. This concept can be used for derivation of
equation of the surface R.
In order to derive equation of the surface R, it is necessary to
represent (a) the gear tooth surface G, (b) the pitch plane WR, and
(c) their relative motion in a common coordinate system XRYR ZR. Therefore, the operator
Rs(g0 R 1) of the resultant coordinate system
transformations is required to be composed.
The resultant coordinate system transformation could be analytically represented as a
superposition of several elementary coordinate
system transformations (Fig. 2). The elementary coordinate system transformations could
be analytically described by (a) the operator
Rt( ,Zg) of rotation about Zg axis through an
angle , (b) the operator Tr(0.5Dg,YR ) of

translation along YR axis at a distance 0.5Dg, and (c) the operator

Tr(l,XR ) of translation along XR axis at a distance l . The considered
operators of the elementary coordinate system transformations yield
equation for Rs(g0 R1)

Rs ( g0

R 1 ) = Tr (l , XR ) Tr (0.5 Dg , YR ) Rt ( , Z g )

The interested reader may wish to go to [1] [9] for details of coordinate system transformations.
Angle
can be computed from equation
= gt, and length
l=|V |t, where t designates time. Therefore, the gear tooth surface
Gt in its current location in the coordinate system XRYR ZR could be
analytically described by equation

Gt : rg .t = Rs ( g 0

R 1 ) rg

Equation (3) for Gt can be cast into the form rg.t (Ug,Vg,t), which is
expressed in term of the parameter t of relative motion. This immediately yields analytical representation for the lateral tooth surface of
the auxiliary rack R

rg .t = rg (U g , Vg , t )
rg .t
(U g , Vg , t ) = 0
t

Exploding Eq. (4) and eliminating the enveloping parameter t, one

can come up with an equation of the lateral tooth surface of the auxiliary rack R in matrix representation

rR = [ X (UR , VR ) Y (UR , VR ) Z (UR , VR ) 1] T

X g .1

Dg

Og

X g .0

VR

XR
Y g .0

WR

Y g .1

.0

XR

.1

l
YR .0

YR .1

FIG. 2. TO GENERATION OF THE AUXILIARY RACK

R OF AN INVOLUTE HOB.

gearsolutionsonline.com

APRIL 2007

GEAR SOLUTIONS

37

Equation (5) for R could also be derived using equation of contact ng V .g= 0 [1], [4]. Here ng designates the unit normal vector
to the surface G , and V .g designates velocity vector of relative
motion of the surface G and of a coordinate system embedded to
the auxiliary rack R . Unit normal vector ng could be computed from
the equation ng =ug x vg, where ug =Ug |Ug|, vg =Vg |Vg|, and Ug =rg Ug,
Vg =rg Vg. Relative motion of the gear G and of the auxiliary rack R
yields representation in the form of instant rotation about pitch point
P . Therefore,vector V .g could be represented as the vector of linear
velocity of instant rotation about P .
The actual value of the auxiliary rack normal pressure angle R is
equal to the gear normal pressure angle at the pitch point when it
meshes with the rack R . Variation of kinematics of relation motion
results in corresponding variation of normal pressure angle R (see
[10] for details). In a gear hobbing operation, use of hobs with different normal pressure angle causes transition curves of different
parameters (see [10] for details).

configuration (location and orientation) of the plane R , an auxiliary

plane of projections 4 is constructed. The axis 1/4 is orthogonal
to the trace R 1 .
The hob base helix angle b.h is the angle that the lateral rack surface R makes with a plane that (a) is orthogonal to the horizontal
plane of projections 1 , and (b) is orthogonal to the trace R4 . Use
of conventional descriptive geometry rules yields construction of the
hob base helix angle b.h, as well as the hob base lead angle b.h that
complements the angle b.h to 90 (Fig. 3).
The derived solution (Fig. 3) to the sub-problem of determining of
the base helix angle b.h gives an insight to how an expression for
d2
R 2

A2

Q2

H2

g2

a2

g3

2.3.
The generating surface T of an involute hob. The surface T of an
involute hob can be generated as enveloping surface to consecutive
positions of the auxiliary phantom rack R in its screw motion relative to the hob axis. In order to get a comprehensive understanding
of the involute hob geometry, it is helpful to consider two different
approaches for determining of the surface T . The first approach is
a descriptive-geometry-based approach to which we refer to as the
DGB-approach3. The second approach is an analytical one. It is usually referred to as the DG/K-approach4. The DGBapproach gives a
fruitful insight to the development of the DG/K-approach. It could be
considered as a perfect filter for the elimination of rough errors
of the analysis. Both the approaches complement one another, and
together they provide the user with profound understanding of the
involute hob geometry and kinematics of the surface T generation
[8], [11], [12].

f2
f1

1
4

b2

e2

b1 d 1

c2

R 4

Q1

a4

R 1

f3

s3

b.h

H2

A1

2 3

a1

e1

c1

s2

g1

b.h

s1

FIG. 3. DETERMINING OF BASE HELIX ANGLE

B.H

OF AN INVOLUTE

HOB.

2.3.1.
The DGB-approach of the surface T generation. It is convenient to
subdivide the problem of generation of the gear hob surface T onto
several sub-problems.
Base helix angle. For solving of the problem of determining of the
hob base helix angle, actual values of normal pressure angle n and
the hob-setting angel h are required been known.
The solution to the problem under consideration is represented
in the system of three planes of projections. They are 1, 2 and 3
respectively. An auxiliary plane of projections 4 is also used.
In order to determine the hob base helix angle b.h using DGbased method, the lateral tooth surface of the auxiliary rack R is
required been constructed. Lets start from an arbitrary plane A that
is orthogonal to the axis of projections 1 2 (Fig. 3). The plane A
is specified by the traces A1 and A2 . After being turned about the
trace A2 through the hob-setting angle h the plane A occupies the
position of the plane Q . The plane Q is specified by the traces Q1
and Q2 . Then the plane Q is turned about the trace Q1 through the
normal pressure angle n of the hob tooth. In this final location, the
plane is designated as R , and it is specified by the traces R1 and
R2 respectively.
In order to construct the hob base helix angle b.h in this particular

38

GEAR SOLUTIONS

APRIL 2007

computation of b.h can be derived. Using the above solution (Fig. 3),
one can come up with the equation [1], [13], [14].

cos b.h = cos n cos h

Equation (6) could also be represented in the form

tan b.h =

sin 2 n + tan 2 h
cos n

Here is designated
= normal pressure angle
n
= hob-setting angle
h
Base lead angle b.h can be computed from the equation

b.h

=90

b.h

Base diameter of an involute hob. The generating surface T of a

gear hob can be represented as an enveloping surface to consecutive
positions of the plane R that is performing a screw motion around
the hob axis of rotation.
Consider the plane R in a system of planes of projections 123
(Fig. 4). The plane R is performing a translational motion along the
axis 1/2 with a certain velocity VR . Simultaneously, the plane R is
rotating about that same axis 1/2 with an angular velocity R .

gearsolutionsonline.com

a2

NR

Vb.2 Vbv.2

Va.2 Vav.2

b2

E2

.2

Va.3 Vav.3

a3

b3

= R R
= R R

R2

NR

.1

Va.1

Va.1

Vb.3

db.h

2 3

Vav.1

a1

Pr v Vb.3

R3

Pr h Vb.3

E3

VR
Va.1
Vb.1

this purpose, velocity of translational motion

VR is required to be considered together with
linear velocity of rotation R . Those points of
the plane R at which the resultant velocity V
is orthogonal to NR belong to the characteristic E . The characteristic E is the straight-line
at a distance 0.5 db.h from the hob axis of
rotation that crosses the axis at the base
helix angle b.h of the hob.
The solution to the problem of determining
the base diameter db.h is depicted in Fig. 4.
The developed solution to the sub-problem
under consideration is insightful for derivation of the equation

b.h

R1
E1
R

b1

Vb.1

Vbv.1

db.h =
Vb.1

b.h

tic E it is required to select those points of

the plane R at which the resultant speed
of the plane points is perpendicular to the
normal vector NR to the plane R itself. For

gearsolutionsonline.com

1 cos 2 n cos 2 h

for computation of the diameter db.h .

Here is designated
m = hob modulus
Nh = number of starts of the hob

FIG. 4. DETERMINING OF THE INVOLUTE HOB BASE DIAMETER dB.H.

The base diameter db.h of the involute hob

is equal to the shortest distance of approach
between the characteristic E and the axis
1/2. In order to determine the characteris-

m N h cos n

2.3.2.
The DG/K-approach of generation of the surface
T of an involute hob. Equation of the generating

APRIL 2007

GEAR SOLUTIONS

39

surface T of an involute gear hob can be derived using elements of theory

of enveloping surfaces, which is a part of DG/K-approach of surface
generating.
In order to derive equation of the surface T , it is convenient to consider
the relative motion that the auxiliary rack R is performing with respect to
the coordinate system XhYhZh embedded to the hob. The coordinate system XhYhZh is the left-handed Cartesian coordinate system (Fig. 5).
Similarly to Eq. (2), the operator Rs(R T) of the resultant coordinate
system transformation could be composed

T ) = Rt ( , Z h ) Tr (0.5d h , Y h ) Tr (l , X h )

Rs (R

In Eq. (9), the hob angle of rotation is equal to =| h | t , and translation of the auxiliary rack R can be computed from the equation l =|VR |
t.
The hob pitch diameter is designated as dh .
The derived Eq. (5) together with Eq. (9) could be employed for analytical description of the auxiliary rack R that is performing a screw motion
with respect to the hob axis of rotation Oh . Corresponding equation for the
auxiliary rack Rt in its arbitrary position is as follows.
Gear

For computation of the hob base diameter db.h and the hob base helix
angl b.h Eq. (6) and Eq. (8) can be employed.
Equation (12) is of critical importance for the development of a novel
design or gear hob for hobbing of precision involute gears. Important features of geometry of the surface T are the major reasons for this. It is easy
to verify that for a specific value of Vh , Eq. (12) describes a straight-line
on T , the so-called the characteristic line Et . Further, the lateral cutting
edge of the involute hob will be aligned with the straight-line characteristic
Et . Therefore, the straight-line characteristic Et will serve as a vital link
between the geometry of the generating surface T of the involute hob and
the principal features of its design. Again, this intermediate result is of
critical importance for the analysis that follows.
Equation (12) for the surface T could also be derived using equation
of contact nR V .R =0 [1], [4]. Here nR designates the unit normal vector
to the surface R , and V .R designates velocity vector of relative motion
of the surface R and of the coordinate system XhYhZh embedded to the
hob. The unit normal vector nR could be computed from equation nR =uR
vR , where uR =UR /|UR |, vR =VR /|VR |, and UR = rR /
UR , VR = rR
/VR. It is convenient to decompose V .R onto V .R =V(n)
+VR(t) . Motion with
R
V(n)
is directed perpendicular to the auxiliary rack R . This motion results
R
in enveloping surface T . Motion with VR(t) is directed along the auxiliary
rack R. This motion results in sliding of the auxiliary rack surface R over
itself. It doesnt affect the shape of the surface T and, therefore, it is out
of our current interest. Ultimately, the decomposition of V .R yields elimination of VR(t) , and simplifies further analysis.

d w.g
Og

3: Principal Parameters of Design of the Involute Gear Hob

Xg

Yg

XR

YR

VR

Yh

Oh

Zh
d w.h

FIG. 5. CYLINDRICAL GENERATING SURFACE T OF AN INVOLUTE HOB.

R t : rR .t = Rs (R

T ) rR = rR .t (UR , VR , t )

The generating surface T of the involute gear hob can be analytically

described by the set of two equations

rR

.t

rR
t

= rR .t (UR ,VR , t )
.t

(UR ,VR , t ) = 0

After substituting of Eq. (4), the Eq. (11) casts into

0.5 db.h sin Vh U h sin b.h cos Vh

0.5 db.h cos Vh + U h sin b.h sin Vh
T : r h (U h , Vh ) =
p hVh U h cos s b.h
1

40

GEAR SOLUTIONS

The above consideration (see sub-section 2.3) yields a conclusion, which

is significant for further development of an involute gear hob of the novel
design. The concept of the novel design of an involute hob is based on
the following considerations: (a) lateral cutting edges of one side of an
involute hob tooth belong to the corresponding screw involute surface; (b)
lateral cutting edges of the opposite side of the involute hob tooth belong
to the opposite screw involute surface; (c) the screw involute surfaces of
the opposite sides of the involute hob tooth intersect each other, and the
line of intersection is a helix; (d) two characteristics El and Er are passing through every point of the helix; (e) the two characteristics El and Er
through the common point of the helix intersect one another at that point
and, thus they specify a plane; (f) that plane is used as a rake-face of the
involute hob teeth.
The above listed steps yield determination of orientation of the rakeface of the involute hob teeth.

APRIL 2007

3.1.
The DGB-approach of determining of orientation of the rake-face. The DGBsolution to the problem of determining of orientation of the rake-face of the
involute hob teeth is depicted in Fig. 6.
For solving of the problem of determining of orientation of the hob tooth
rake-face, the following parameters of design of the hob are required to be
known: the hob tooth modulus m , normal pressure angle n , the hob-setting angel h , number of starts of the hob Nh , the hob outside diameter
Do.h , and the hob base diameter db.h.
The solution to the problem under consideration is represented in the
system of three planes of projections 1, 2 and 3 respectively. Two auxiliary planes of projections, say 4 and 5, are also used. The auxiliary axis
of projections 1/4 makes the hob-setting angle h with the axis of projections 1/2. The axis of projections 1/5 is parallel to the axis 1/4. Use

gearsolutionsonline.com

of the plane of projections 5 yields considerable size reduction of Fig. 6.

In the system of three planes of projections 1, 2 and 3 , the axis of
the hob rotation O is oriented parallel to the axis 1/2 (Fig. 6).
Normal plane section of the auxiliary rack R tooth is shown in the
plane of projections 4 .
Consideration of images of the hob elements in the planes of projections 4 and 3 (that are connected to one another through the planes of
projections 1 and 2) yields determination of location of the point A within
3 . Two straight lines through A3 that are tangent from the opposite sides
to the hob base cylinder of diameter db.h represent straight lines which the
lateral cutting edges of the hob align to. The rake-plane of the hob tooth
is the plane through these two straight lines. Conventional methods of
descriptive geometry are used for the construction of all others projections
of these two straight lines that initially are constructed in 3 .
Angle that the rake-plane makes with the hob axis of rotation O is
constructed in the plane of projections 1.
The hob tooth profile in the rake-plane is shown in the plane of
projections 5 .

l2

A3

e3

n2

do.h

dh

d f .h

Base Cylinder

O2 f 2
b2
f1

b1

e1

P1
d1

l1 A n1
1

P3

Er

El

do.h

The DG/K-approach of determining of orientation of the rake-face. Figure

6 provides a clear understanding of the geometry of the precision involute
gear hob with straight-line lateral cutting edges. Understanding features
of the hob geometry (see sub-section 3.1) is very helpful for derivation
of equations for computation of major parameters of the gear hob of the
developed design.

db.h
g3

O3 a3

b3

O1

1
4

1
5

a1
g1
O4

a4
g4

f4

d3

T1

b4

db.h

l3

f3

g2
a2

1
2

n3

T3

1 3

K4

3.2.

A2
e2

d2

M4

dh

d f .h

ht
n5

n4
l4
d 4 e4
tc
A4

Sc

l5
tr

Pn

FIG. 6. DETERMINING OF THE ORIENTATION OF THE RAKE-FACE

OF AN INVOLUTE HOB TEETH.

3.2.1.

An auxiliary parameter R . Lateral tooth surfaces of the auxiliary rack R

intersect each other along a straight line through the point A (Fig. 7). This
straight line is at a distance R from the hob axis. For the distance R Fig.
8 yields

R = 0.5 ( d h + tc cot n )

trf

The rake face

Yh

(13)

th

3.2.2.
The angle r between the lateral cutting edges of the hob tooth. Prior to
deriving the equation for computation of the angle r that make the lateral
cutting edges of the gear hob tooth, it is convenient to derive an equation
for computation of projection of the angle r onto the coordinate plane
XhYh.
The projections of the lateral cutting edges of the involute tooth onto the
coordinate plane XhYh make an angle .
For computation of the actual value of the angle , the following expression can be used

tan =

R C
B

Er

El

D
E

db.h
4 R

db.h

db2.h

Then, consider three unity vectors A, B, and C. These vectors yield the
following analytical representation

A = [cos h

Zh

Xh

0 sin h 1] T

B = [sin n sin h

C = [ cos r tan

cos n

cos r

sin n cos h 1] T

FIG. 7. ORIENTATION OF RAKE-FACE OF THE PRECISION GEAR HOB.

sin r cos 1] T

gearsolutionsonline.com

APRIL 2007

GEAR SOLUTIONS

41

tr
Yh

The idea of the hob-setting angle can be traced back to the publication
by Buckingham (1963) [11].
As the vectors A , B , and C are located within the common lateral
surface of the auxiliary rack R , therefore the following identity AB C 0
observes. The last expression yields a determinant

A
A

Prxy C
El

R
D

El

Er

db.h

Er

Yh

0.5 d h

Pr A

Xh

Oh

Prxz E

Prxy C

cos h
sin n sin h
cos r tan

sin h
sin n cos h = 0
sin r cos

0
cos n
cos r

db.h

db.h cot

0.5 do.h

~ 0.6
Zh

0.5 d h

h
n

tc

0.5 d h

d b.h

Xh
Er

Prxy C

A
B

tr

d w.h

do.h

db.h
El
FIG. 8. THE EMPLOYED CHARACTERISTIC VECTORS.
Fig. 8. The employed characteristic vectors.

Here h designates the hob-setting angle of the involute hob. The angle
is measured in the auxiliary rack R pitch plane. It is the angle that
makes a perpendicular to the rack R tooth and axis of rotation of the hob
(Fig. 9) [8],[14]
Required for further computations, the hob-setting angle h can be chosen by a designer of the gear hob. Usually it is recommended to assign
the actual value of the hob-setting angle h equal to the pitch helix angle
of the hob. As it is proven in our earlier work [14], in order to satisfy the
h
equality h= h (this condition is the best possible) the actual value of the
hob-setting angle is required to be computed from the equation.
h

tan h =

m Nh

(d o.h 2 1.25 m do.h ) 2 m 2 N h2

Here do.h designates reduction of the hob outside diameter do.h due to
re-sharpening of the worn gear hob (Fig. 10). Figure 10 yields very simple
(worn)
formula for computation of do.h = (do(new)
do.h
).
.h
0

Oh
+

Og

Face

+ h
C

Face

FIG. 9. HOB-SETTING ANGLE

42

GEAR SOLUTIONS

WR

OF AN INVOLUTE HOB.

APRIL 2007

After exploding of the determinant, and after the necessary formulae

transformations are performed, one can come up with the equation of two
unknowns, namely of r and .

3.2.3.
The angle of intersection of the rake-face and of the hob axis of rotation.
Rake-face of the involute hob is inclined to the hob axis at a certain angle
. In order to determine the required value of the angle , the following
three unity vectors C, D, and E were used. For the vectors D and E Fig. 8
yields

D = [0 1 0 1] T
E = [sin

0 cos 1] T

As of the vectors C, D, and E are located within the rake-face of the hob
tooth, therefore the following identity CD E 0 observes. This yields a
determinant

Oh

Oh

FIG. 10. THE INVOLUTE GEAR HOB AFTER BEEN REGROUND.

FR

cos r tan

cos r

sin r cos

0
sin

1
0

0
cos

=0

After exploding of the determinant, and after the necessary formula

transformations are performed, one can come up with the one more equation of two unknowns, namely of r and .

gearsolutionsonline.com

Further, consider the set of two equations, say of Eq. (19) and Eq. (22)
of the two unknowns r and . Solution to the set of the above equations
can be represented in the form

tan =

cos h tan
tan n + sin h tan

tan r =

tan
sin

The hob-setting angle h specifies inclination of the gear hob axis of

rotation Oh with respect to the auxiliary rack R . It is necessary to point
out here that the angle h is a parameter of the gear hob design, and is
not a parameter of gear hobbing operation. Figure 9 reveals that it could
be either positive ( + h > 0 ), or negative ( h < 0 ), as well as it could
be of zero value ( h = 0 ). Under special conditions, the hob-setting angle
could be equal to the gear hob pitch helix angle R (i.e. the equality h = R
could be observed).

The design of gear hob with the computed parameters (Table 1) satisfies all the necessary and sufficient conditions of proper surface generating on machine tool [1], [4], [6] and, what is especially of importance,

The above Eq. (23) and Eq. (24) are necessary for computation of the
required values of the angles r and . These angles are necessary been
indicated in the involute hob blueprint.
The involute hob of novel design [15] with the angle computed from
the Eq. (23), and the angle r computed from the Eq. (24) (a) has straightline lateral cutting edges, and (b) it is free of the major source of the tooth
profile deviations. Two more modifications of the gear hob design [16],
[17] are developed as well.
Example of computation. The above derived equations yield computation of parameters of the novel hob design for machining of precision involute gears. Such computations can be done, for example, for the singlestart FETTE gear hob (DIN 8002A, Cat.-No 2022, Ident. No 1202055) of
module m =10 mm , outside diameter do.h = 180mm, and pressure angle
= 20 [18].
n
Results of computation are collected in the Table 1 below.

it satisfies the fifth necessary condition of proper surface generating

[10]. The conclusion of this article will appear in the May issue of Gear
CONTINUED ON PAGE 50 >
Solutions magazine.

gearsolutionsonline.com

APRIL 2007

GEAR SOLUTIONS

43

< CONTINUED FROM PAGE 43

REFERENCES:
[1] Radzevich, S.P., Fundamentals of Surface Generation. Monograph, Kiev, Rastan, 2001, 592p. Copy
of the monograph is available from The Library of Congress.
[2] Bregi, B.F., Erxleben, R.F., Tersch, R.W., et al, Modern Methods of Gear Manufacture, 4th Edition,
National Broach & Machine Division/Lear Siegler, Inc., 5600 St. Jean Ave., Detroit, MI 48213, 1972,
160p.
[3] Townsend, D.P., Dudleys Gear Handbook. The Design, Manufacture, and Application of Gears, 2nd
Edition, McGraw Hill, Inc., New York, 1991.
[4] Radzevich, S.P., Sculptured Surface Machining on Multi-Axis NC Machine, Monograph, Kiev, Vishcha
Shkola Publishing House, 1991, 192p. Copy of the monograph is available from The Library of
Congress.
[5] Radzevich, S.P., Diagonal Shaving of an Involute Pinion: Optimization of Parameters of the Pinion
Finishing Operation, The International Journal of Advanced Manufacturing Technology. (In press).
[6] Radzevich, S.P., Conditions of Proper Sculptured Surface Machining, Computer-Aided Design,
Vol.34, No 10, September 2002, pp.727-740.
[7] Olivier, T., Theorie Geometrique des Engrenages, Paris, 1842.
[8] Radzevich, S.P., About Hob Idle Distance in Gear Hobbing Operation, ASME J. of Mechanical Design,
December, 2002, Vol. 124, Issue 4, pp.772-786.
[9] Radzevich, S.P., Design of Shaving Cutter for Plunge Shaving a Topologically Modified Involute Pinion,
ASME J. of Mechanical Design, September 2003, Vol. 125, Issue 3, pp.632-639.
[10] Radzevich, S.P., A Novel Approach for Computation of Constraints on Parameters of Modification
of the Tooth Addendum of Precision Involute Hob, ASME J. of Mechanical Design, July 2006, Vol.
128, Issue 6, pp.000-000.
[11] Buckingham, E., Analytical Mechanics of Gears, Dover Publications, Inc., New York, 1963, 546p.
[12] Radzevich, S.P., A Descriptive-Geometry-Based-Solution to a Geometrical Problem in Rotary
Shaving of Shoulder Pinion, ASME J. of Manufacturing Science and Engineering, November, 2005,
Vol. 127, Issue 4, pp. 893-900.
[13] Radzevich, S.P., Design and Investigation of Skiving Hobs for Finishing Hardened Gears, Ph.D. Thesis,
Kiev Polytechnic Institute, 1982, 286p.
[14] Radzevich, S.P., Cutting Tools for Machining Hardened Gears, Moscow, VNIITEMR, 1992, 60p.
[15] Pat. No. 990.445 (USSR), A Precision Involute Hob./S.P. Radzevich, Filed: October 08, 1981, Int.
Cl. B23F 21/16.
[16] Pat. No. 1.114.505 (USSR), A Precision Involute Hob./S.P. Radzevich, Filed: October 18, 1982, Int.
Cl. B23F 21/16.
[17] Pat. No. 2.040.376 (Russia), A Precision Involute Hob./S.P. Radzevich et al, Filed: January 03, 1992,
Int. Cl. B23F 21/16.
[18] FETTE. Gear Cutting Tools: Hobbing, Gear Milling, Leitz Metalworking Technology Group, 196p.

FOOTNOTES:
1) The DG/K-approach is based on fundamental results obtained in differential geometry of surfaces, and
in kinematics of multi-parametric motion of a rigid body in E3 space (For details see (i) Radzevich, S.P.,
Sculptured Surface Machining on Multi-Axis NC Machine. Monograph, Kiev, Vishcha Shkola Publishers,
1991, 192p Copy of the monograph is available from The Library of Congress [4]; and (ii) Radzevich,
S.P., Fundamentals of Surface Generation. Monograph, Kiev, Rastan, 2001, 592p Copy of the monograph is available from The Library of Congress [1]). A perfect example of application of the DG/Kapproach is disclosed in the paper: Radzevich, S.P., Diagonal Shaving of an Involute Pinion: Optimization
of Parameters of the Pinion Finishing Operation, The International Journal of Advanced Manufacturing
Technology. (In press) [5].
2) Olivier, T. disclosed two principal methods of generation of enveloping surfaces in his work published
as early as in
3) The DGB-approach proved to be useful for solving variety of gear related problems (see, for example, the
monograph by Buckingham [11], as well as more recent publications [8] [12]).
4) The DG/K-approach is based on fundamental results obtained in differential geometry of surfaces, and
in kinematics of multi-parametric motion of a rigid body in E3 space. The method is disclosed in two
monographs [1], [4] by the author. Both the monographs are available form the Library of Congress.

ABOUT THE AUTHOR:

Stephen P. Radzevich, Ph.D., is with the Innovation Center in the Eaton Corporations
automotive business segment. He can be reached at (248) 226-6831 or stephenpradzevich@eaton.com. Go online to [www.eaton.com]. This article appears courtesy
of the American Society of Mechanical Engineers (ASME).

50

GEAR SOLUTIONS

APRIL 2007

gearsolutionsonline.com