Shaping is a subtractive process where the gear is cut into a blank or a partially formed gear using a cutting tool, which is usually a gear-shaped cutter.
Shaping is typically used for producing spur and helical gears, but it can also be used for bevel gears. The process begins with selecting the material for the gear blank, which can be any material that is suitable for the application. The gear blank is then mounted on a rotating mandrel or arbor, which holds it in place during the shaping process.
The gear cutter is mounted on a reciprocating ram that moves back and forth across the gear blank, cutting the teeth into the gear. The shape and size of the gear cutter determine the final shape and size of the gear teeth. The cutter is fed into the gear blank gradually, removing material with each pass until the teeth are formed to the desired shape and size.
Shaping is a versatile method for producing gears of various sizes and shapes, and it can achieve high precision and accuracy. However, it is a slow process compared to other methods such as hobbing, and it requires skilled operators to ensure that the teeth are cut correctly.
Another advantage of shaping is that it can produce gears with complex shapes and profiles that may be difficult or impossible to achieve with other methods. This makes it a popular choice for gears used in high-performance applications, such as aerospace and racing.