Depending on the company with which you work, they may use different tools or processes. It’s important to work with someone who can explain exactly how they chamfer gears and why this will meet your needs. Make sure before you place any gear order that a) they offer chamfering and b) you understand their process.

One can accomplish gear chamfering in many ways, including rolling, contour milling, hobbing, skiving, grinding, and hobbing. Each of these slightly different processes creates a chamfered edge, either with a clearly defined angle between two facet, or with an undefined edge whose goal is simply to wear away sharp edges and remaining burrs. The basic process goes like this:

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The gear chamfering process is similar to beveling, in which an angle is cut into the side of the finished edge. However, rather than creating that angle on the entire edge (so that the top of the edge is longer than the bottom, for instance), chamfering only cuts part way through the top. That means a beveled edge is entirely not perpendicular to the face, while the two facets of a chamfered piece of metal are perpendicular – with a transition zone.

In addition to our range of standard carbide inserts we can also offer a custom special carbide insert design and manufacture service. Inserts range from a simple modified TC insert, custom ground chip-breakers with a hone to an interpolating form insert and ‘hockey stick’.

Gears can be chamfered in many places. Depending on your needs, gear chamfering may be ideal for the length of the gear’s tooth or across the top of each tooth, usually both. Gear chamfering is also useful at the base of each tooth, where it transitions to the next. If there is space between the teeth, then you will likely want to chamfer the lateral edges of the gear where it meets the top (circular area).

Gear chamfering is a process whereby the edges of gears are finished to create smooth transitions between angles. Rather than leaving an abrupt right angle, for instance, a small 45-degree angle may be created between the horizontal and vertical slopes to ease the transition. There are variations on the placement and angle of the transition between two facets, but that’s the general idea.

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If you’ve spent any time researching parts fabrication, chances are good you’ve come across the term “gear chamfering.” This is a step in the finishing process that any professional pulley and gear company should offer. While it might seem optional, it is actually a very important factor in finishing parts to the highest possible quality.

You can also accomplish gear chamfering on bevel machines. These contour milling or fly-cutting processes create a seamless chamfered edge, often using carbide tips. In this process, each tooth is chamfered separately. However, due to increases in automated technologies, machines now perform this process (rather than by hand), so individual edges are identical.

Whether you are cutting cast iron, aluminium, steel, plastics, or titanium alloys, Rigibore technology offers you a wide and varied range of cutting edges in the form of indexable ISO carbide, PCD & CBN inserts.

Chamfer rolling uses large, round surfaces that roll past a spinning gear, taking off sharp edges and again creating identically chamfered surfaces along the teeth and edges of the gear.

Note: In many ways, deburring provides the same services – reduction of wear, protection of gears and equipment, and prevention of projectiles. Whatever company you work with to source your gears, make sure they provide both services.

Hobbing uses gear-shaped protrusions called “hobs” to create the chamfers on the gear itself. Each hob is dedicated to a tooth of the gear, and they work in tandem to create identically chamfered surfaces on each tooth. This works best for creating large quantities of gears.

As with beveling, chamfering is sometimes confused with deburring. This latter process does not involve cutting an edge between two facets, however. Instead, it means using tools to remove the small bits of metal and imperfections that naturally occur during the machining process. However, there is a natural line of burring where two perpendicular angles meet, which the chamfering process naturally takes care of.

Looking for high-quality chamfered gears for your industry needs? IPG prides itself on providing custom products, built to your standards, that will stand the test of time. We specialize in timing belt pulleys and timing pulley stock, but create a wide range of other parts for our many partners.

Our team of experienced engineers can help design and manufacture custom specification carbide inserts for your specific application.

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Use our knowledge base and support centre for technical product information. There are mounting dimensions, CAD file downloads, technical documentation, product catalogues. We have a speeds & feeds calculator and our Boring 101 guide will give you all the information you need to know about boring a hole.

Before we address that, however, let’s take a closer look at gear chamfering: what it is, why we do it, how it’s done, and what tools we use. Once you understand its uses and process, you’ll never want an unchamfered gear again.

Gears may be chamfered in dry-cutting environments or using lubricants. However, dry cutting is significantly faster and easier to automate, and so is increasingly gaining ground over other methods.