Spur-typed cutters with multiple cutting angles are important tools frequently used in the manufacture of many machine elements. Due to their complex geometry, the production of these cutters involves milling and several grinding processes. Such a complex manufacturing process, coupled with the need for expensive manufacturing tools, makes the cutters costly. Undercutting is a phenomenon that causes weakness at the root of a gear. Engineers use shifted gears, modified tooth profiles, or changes in the pressure angle to overcome undercutting in gears. However, in this paper, by utilizing the undercutting phenomenon, a novel design of straight-sided hob cutter with multiple pressure angles is proposed for the manufacture of spur-typed cutters. With the simultaneous application of multiple pressure angles, this tool design concept significantly simplifies the manufacturing process. The effects of cutting angles, the degree of undercutting, and the width of the top land of the cutter are studied. The concepts and results proposed in this paper are beneficial as design guidance for tool designers and manufacturers.
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