Keywords
shaver-roller
cutting speed
accuracy
roughness
finishing
CNC
40X steel
How to Cite
Abstract
The relationship between the accuracy and surface roughness of the tooth flanks of cylindrical gears and the cutting speed during finishing with a shaving–rolling tool (shaver–roller) was investigated and described mathematically. The goal was to identify patterns governing the formation of flank micro-geometry under different cutting conditions and to develop a predictive model that estimates quality indicators without requiring labor-intensive production-scale trials.
The experimental study was conducted on a Vturn-46 CNC lathe using a special two-axis fixture that ensures stable positioning and coordinated relative motion between the tool and the workpiece. The workpieces were spur gears made of 40Kh steel (GOST 4543-71) with parameters m = 3 and z = 24. Initial geometry was generated by gear hobbing, followed by finishing through shaving–rolling. Tests were performed at various cutting speeds, with each regime tested on batches of 10 workpieces to assess reproducibility and reduce the effects of random factors. Surface quality was evaluated based on the accuracy and roughness of the tooth flanks, as well as the microprofile changes relative to cutting speed and feed parameters.
The developed mathematical model accurately captures how cutting speed and feed conditions influence micro-geometry formation and shows good agreement with experimental data. It demonstrates that changes in cutting speed cause systematic shifts in contact interaction conditions and plastic deformation behavior in the processing zone, which directly affect roughness levels and the stability of tooth profile formation. The model can be used to select optimal finishing parameters and plan processes more efficiently, reducing the need for extensive full-scale experiments. The results confirm that shaving–rolling can be effectively performed on gen-eral-purpose CNC equipment as an alternative to specialized gear-finishing machines. This method improves accuracy and lowers the surface roughness of the tooth flanks, broadening opportunities for finishing operations in small-batch and repair production environments..
Keywords: cylindrical gears; shaver-roller; cutting speed; precision; roughness; finishing; CNC; 40X steel
References
1. Маликов, А. А., Валиков, Е. Н., & Ямников, А. С. (2007). Прогрессивная технология зубообработки.Известия Орловского государственного технического университета. Серия: Фундаментальные и прикладные проблемы техники и технологии, (4-3), 107-110.
2. Маликов, А. А., & Сидоркин, А. В. (2008). Шевингование прикатывание цилиндрических колес с круговыми зубьями.Известия Тульского государственного университета. Технические науки, (2), 69-75.
3. Мардонов, Б. Т. (2018). Управление точностью обработки эвольвентного профиля по высоте зуба колеса.Universum: технические науки, (8 (53)), 9-12.
4. Мардонов Б.Т. (2018). Исследование точности цилиндрических зубчатых колес, обработанных при различных установках обкатного инструмента (шевер-прикатника) // Научно-технический журнал ФерПИ. -Фергана, №3. С. 103-107.
5. Goutte, C., & Gaussier, E. (2005, March). A probabilistic interpretation of precision, recall and F-score, with implication for evaluation. In European conference on information retrieval (pp. 345-359). Berlin, Heidelberg: Springer Berlin Heidelberg.
6. Anikeeva, O. V., Ivakhnenko, A. G., & Erenkov, O. Y. (2017). Modeling the influence of geometric errors of turning machine for accuracy machinable surface. Procedia Engineering, 206, 1127-1132.
7. Lohr, D. J., & Komogortsev, O. V. (2017, May). A comparison of smooth pursuit-and dwell-based selection at multiple levels of spatial accuracy. In Proceedings of the 2017 CHI Conference Extended Abstracts on Human Factors in Computing Systems (pp. 2760-2766).
This work is licensed under a Creative Commons Attribution 4.0 International License.
Copyright (c) 2026 Mardonov, B.T., Shakulov, B.K., Sayfidinov, O.O. (Muallif)