Structural Design of Slice Cutter Based on Free-form Surface

In order to meet the requirements of actual produce for the design method of slice cutter, a new cutter design method for involute cylindrical gear is proposed based on free-form surface. According to the design principle and the realizability of manufacture, sphere is chosen to be as initial rake face and its free-form mathematical model is established. From the theory of conjugation, the model of the plane conjugating to the surface to be processed is built. Taking the error-free design as the goal, the major is designed to be the intersection between the rake face and the conjugate surface and its mathematical model is established. The mathematical model of free-form major flank which consists of a series of major edges is built. Then the mathematical model of top edge and top flank face are established based on the same theory to major flank face. A calculation example is given to verify the availability and feasibility of the design method and mathematical model.