Chip geometry and cutting forces in gear shaping

Kaan Erkorkmaz*, Andrew Katz, Yasin Hosseinkhani, Denys Plakhotnik, Marc Stautner, Fathy Ismail

*Corresponding author for this work

Research output: Contribution to journalArticleAcademicpeer-review

27 Citations (Scopus)


Shaping is a versatile process for machining gear teeth on complex monolithic components, which cannot otherwise be produced using other methods (like hobbing) due to geometric constraints. This paper presents a new model to accurately predict the chip geometry and cutting forces in shaping. Kinematics of gear shaping is modeled and verified. Cutter–workpiece engagement is predicted using a dexel-based geometric modeler, and refined by alpha-shape reconstruction. Varying rake and oblique angles are resolved along the cutting edges and used in three-dimensional force predictions. Simulated forces are shown to agree closely with those measured on a gear shaping machine.

Original languageEnglish
Pages (from-to)133-136
Number of pages4
JournalCIRP annals : manufacturing technology
Issue number1
Publication statusPublished - 2016
Externally publishedYes


  • Cutting
  • Gear
  • Shaping


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