Even contact design for the plunge shaving cutter

Gear shaving is a highly efficient and economical cutting method in gear finishing. The tooth profile of the plunge shaving cutter is usually sharpened by a cone grinding wheel on the cutter resharpening machine. The resulting radial prestressing force between the work gear and shaving cutter is constant in the final stage of the shaving process. Assuming that the cutting force on the work gear is evenly distributed on the instantaneous contact lines, and the cutting depth of each cutting mark is inversely proportional to the total length of the instantaneous contact lines. This paper thus proposes a mathematical model that summarizes these instantaneous cutting marks and estimates the final shaved tooth surface of the work gear. It also provides guidance for designing the geometric data for a plunge shaving cutter to satisfy the even contact condition.