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In form milling, the cutter called a form cutter travels axially along the length of the gear tooth at the appropriate depth to produce the gear tooth. After each tooth is cut, the cutter is withdrawn, the gear blank is rotated, and the cutter proceeds to cut another tooth. The process continues until all teeth are cut
Such cutting operations may occur either after or instead of forming processes such as forging, extruding, investment casting, or sand casting. Gears are commonly made from metal, plastic, and wood. Although gear cutting is a substantial industry, many metal and plastic gears are made without cutting, by processes such as die casting or ...
Woodbury, Robert S. (1958), History of the Gear-Cutting Machine: A Historical Study in Geometry and Machines, MIT Press, ISBN 9780262730013, OCLC 1689960. At p. 105, "But it had been recognized that the worm was a form of continuous rack and all that was necessary to cut gears with it was to provide cutting edges on it — to make a hob (Fig. 45).
Gears produced by powder metallurgy often require a sintering step after they are removed from the mold. Cast gears require gear cutting or other machining to shape the teeth to the necessary precision. The most common form of gear cutting is hobbing, but gear shaping, milling, and broaching may be used instead.
A diagram of a solid single-form thread cutting tool A solid multiple-form thread milling cutter. Whereas a hob engages the work much as a mating gear would (and cuts the blank progressively until it reaches final shape), a thread milling cutter operates much like an endmill, traveling around the work in a helical interpolation.
Form diameter. Form diameter is the diameter of a circle at which the trochoid (fillet curve) produced by the tooling intersects, or joins, the involute or specified profile. Although these terms are not preferred, it is also known as the true involute form diameter (TIF), start of involute diameter (SOI), or when undercut exists, as the ...
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There are cutting tools typically used in milling machines or machining centers to perform milling operations (and occasionally in other machine tools). They remove material by their movement within the machine (e.g., a ball nose mill) or directly from the cutter's shape (e.g., a form tool such as a hobbing cutter).
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