Getting a perfect gear chamfer is not easy. In many cases, many people aren’t even aware that it could be done better; they probably don’t even know why they aren’t seeing better results.

There are many variables that affect the outcome of a chamfer: grinding wheel speed, grinding wheel pressure, grinding wheel angle, rotary table speed, etc. Keeping all these components in mind can be a headache! Who knew such a process could be so complicated?

Well, James Engineering has a couple of tips that will help you achieve the cleanest chamfer possible:

· Make sure the grinding wheel engages the part gently. If it’s too quick in engaging, you might notice a small cloud of dust burst up from the point of contact, gouging the part in a way that is noticeable to the eye. This small cloud will contain 3 to 4 times more material removed in that single instant than what you’d see after chamfering the entire part!

· Be sure that the grinding wheel produces an even spark pattern. Any interruption in that pattern is a loss in efficiency, and can be caused when the wheel lifts and bounces back down onto the part. Whether that bounce is subtle or extreme, it will still cause a decrease in wheel life and leave you with an inconsistent chamfer.

· To eliminate heavy chamfer marks, or what we call striations, use a wheel that has natural shock-absorption, such as the wheel we sell at James Engineering. Most companies use rigid cutoff wheels made of fiberglass reinforcing material, bonded with a dense (and usually black) open-cutting resin. But we at James Engineering suggest using a reinforced open-cutting, resin-bonded wheel with shock-absorbing properties, which also happen to be a lighter color and won’t break when forced to flex slightly. The best way to see the difference between the two kind of wheels, other than overall performance, is to bounce the cutting edge of the wheel off your desk. The competing wheel will bounce instantly, while ours will absorb some of the impact’s shock and not bounce as wildly—it’ll even sound quieter!

If you implement these three tips, chamfering becomes a whole different animal. You’ll be able to hear the difference between a good and bad chamfer; the good will sound smooth, while the bad will sound choppy. You’ll be left with a chamfer so clean, so perfect, you won’t be able to help but call it the champion of all gear chamfers. If you have any questions, or would like to receive a wheel sample, please feel free to contact us at Sales@James-Engineering.com.