1. Introduction to Tooth Tip Chamfering

1.1 Definition

• Prevent tooth tip interference and avoid impact and noise during meshing.
• Reduce stress concentration generated during heat treatment or processing.

1.2 Working Principle

• Preventing Interference: During gear meshing, the tooth tip may cause "undercutting" with the tooth root of the mating gear, leading to an increase in impact load. Chamfering can reduce such interference.
• Improving Lubrication: Chamfering helps in the formation of a lubricating oil film, reducing friction and wear.
• Deburring: It eliminates burrs generated after processing, improving the surface quality of the gear.

1.3 Design Key Points

Chamfer Size

• Width (b): Usually 0.1 - 0.3 × module (m).
• Angle (α): Generally 30° - 45° (45° is commonly used).

Geometric Shape

• Straight Chamfer: Slant cutting is adopted (low cost and simple processing).
• Arc Chamfer: R - angle transition is used (better stress distribution).

Process Selection

• Turning/Milling: Suitable for mass production.
• Grinding/Electrochemical Machining: Used for high - precision gears.

1.4 Applications

• High - speed gears (such as automobile gearboxes, aviation gears) to reduce impact noise.
• Heavy - duty gears (such as mining machinery, wind power gearboxes) to reduce stress concentration.

2. Introduction to Tooth Profile Chamfering

2.1 Definition

2.2 Working Principle

• Improving Meshing: It avoids local high contact stress at the edge of the tooth surface and reduces "edge load".
• Reducing Noise: It reduces vibration and noise caused by slight misalignment of the tooth surface.
• Extending Service Life: It reduces fretting wear of the gear under alternating loads.

2.3 Design Key Points

Chamfer Area

Chamfer Amount

• Height (h): Usually 0.01 - 0.05 × module (m).
• Shape: Straight type or small arc type (R 0.05 - 0.2 mm).

Process Methods

• Gear Grinding Modification: CNC gear grinding machines are used for tooth profile modification of high - precision gears.
• Hobbing Chamfering: It is completed simultaneously during hobbing processing.

2.4 Applications

• Precision gears (such as robot reducers, CNC machine tool spindle gears).
• High - torque gears (such as engineering machinery, marine transmission devices).

3. Comparison between Tooth Tip Chamfering and Tooth Profile Chamfering

4. Key Parameters for Chamfering Design

4.1 Influence of Module (m)

• Small module gears (m < 1 mm): The chamfer amount is small, and precision grinding is required.
• Large module gears (m > 5 mm): The chamfer width can be appropriately increased to improve strength.

4.2 Material and Heat Treatment

• Carburized and quenched gears: Chamfering must be completed before heat treatment to avoid processing difficulties after quenching.
• Powder metallurgy gears: Chamfering can be directly formed during pressing.

4.3 Gear Type

• Spur gears: Chamfering is usually symmetrical.
• Helical gears: The influence of the helix angle on the chamfer shape must be considered.

5. Manufacturing Processes

5.1 Traditional Machining (Turning, Milling)

5.2 Grinding/Honing

5.3 3D Printed Gears

6. Application Cases

6.1 Automobile Gearbox Gears

6.2 Robot Harmonic Reducers

6.3 Wind Power Gearboxes

7. Conclusion