trouble shooting guide shaping

8/8/2019 Trouble Shooting Guide Shaping

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Property of Fairfield Atlas Ltd . Should be used only in FAL .

Shaping Troubleshooting Guide:

PROBLEM CAUSE SOLUTION

Pitchline Runout or Total

Index Error

(a) Tooling not true.

(b) Workpiece arbor not true.

(c) Cutter pitchline runout.(d) Check change gea rs on

mechanical machines.

(a) Indicate top of gear to

verify that the supportplate and base are true. Ifrunout exceeds0.00005*PD, then removesupport plate or base toensure that there are nochips, burrs, etc. on thebase or the support plate.If chips or burrs arepresent, then stonesupport plate or table toremove.

(b) Check workpiece arbor forrunout. If runout exceeds0.00005*PD, then re-truethe arbor.

(c) See Chart# 1.(d) Look and listen for runoutor bad teeth in index, speedand feed gears.

Involute Waviness (a) Make sure cutter is sharp.

(b) Cutter pitchline runout.(c) Insufficient stock on last

cut.

(d) Check change gears onmechanical machines.

(a) Cutter should be sharp onlast cut.

(b) See Chart# 1.(c) Must provide enough

bite on last cut toprevent rubbing.

(d) Look and listen for runoutor bad teeth in index,speed and feed gears.

Minus or Plus Involute Cutter produces minus or plusinvolute.

Sharpen cutter to correctinvolute. See PC program:Y: Shop programs \ ToolSharpening \ ShaperSharpening

Lead Error Support plate or base not true. If runout exceeds .0003,remove support plate or baseto check for chips or burrs, etc.If chips or burrs are present,stone support plate or base toremove.


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PROBLEM CAUSE SOLUTION

Lead Variation (a) Support plate or base nottrue.

(b) Check change gears onmechanical machines.

(a) If runout exceeds .0003,remove support plate orbase to check for chips orburrs, etc. If chips orburrs are present, stonesupport plate or base toremove.

(b) Look and listen for runoutor bad teeth in index, speedand feed gears.

Tooth Chatter or RoughFinish

(a) Tooling not tight.

(b) Feeds and speeds not setcorrectly.

(c) Check material hardness.

(a) Recheck setup and tightenall fasteners.(b) Recheck feeds and speedsand adjust if necessary.

(c) Hardness should be BHN160 or higher for good cutting.


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SHAPER CUTTER TOLERANCES

Chart# 1

MAXIMUM PROFILE TOLERANCE OF CUTTERInches

WHOLE DEPTH:

Thru 0.395 0.0002

Over 0.395 thru 0.610 0.0003

Over 0.610 thru 0.980 0.0004

Over 0.980 0.0006

0.0002 maximum indicating band runout with respect toshapers pitch diameter and mounting face and hole or shank.

Is the parts pitchline runout or involute profile problem due to the cutters sharpening oryour setup?

a) Always true up the cutter with the indicating band , do not true up from the cuttersoutside diameter. The cutters manufacturer is allowed up to .0015 runout between thecutters outside diameter and the cutters pitch diameter.

b) Always indicate the sharpened face of the cutter also. The face runout should be 0.0002or less. If the face runout is more than 0.0002, you either have a nick or chip on the cutteradapter face or on the splindle face, or, the cutter was not seated properly on the sharpeningmachines table. The sharpening machines table surface should be reground periodically.

From USAS B94.21-1968/1974W H Hayward 1 / 2000


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