Shaving Troubleshooting Guide:
PROBLEM
Pitchline Runout or Total
Index Error
Involute Waviness
Minus or Plus Involute
Property of Fairfield Atlas Ltd. Should be used only in FAL
CAUSE
(a) Tooling not true.
(b) Workpiece arbor not true.
(c) Check change gears on
mechanical machines.
You can improve pitchline
runout but you can not remove
total index error. This is
produced by hobbing/shaping
pitchline runout. Consult your
supervisor.
SOLUTION
(a) If runout exceeds
0.00005*PD, then remove
support plate to ensure
that there are no chips,
burrs, etc. on the support
plate. If chips or burrs are
present, then stone
support plate to remove.
(b) Check workpiece arbor for
runout. If runout exceeds
0.00005*PD, then re-true
the arbor.
(c) Look and listen for runout
or bad teeth in speed and
cross feed gears.
See “Setup Instructions”
below.
If nothing works, include a
profile chart in the cutter
container and notify tool stores
that the cutter needs to be
correctively reground.
See “Setup Instructions”
below.
If nothing works, include a
profile chart in the cutter
container and notify tool stores
that the cutter needs to be
correctively reground.
Lead Error Support plate not true. If runout exceeds .0003,
remove support plate to check
for chips or burrs, etc. If chips
or burrs are present, stone
support plate to remove.

See “Setup Instructions”

below.

PROBLEM CAUSE SOLUTION

Lead Variation Support plate not true. If runout exceeds .0003,

remove support plate to check
for chips or burrs, etc. If chips
or burrs are present, stone
support plate to remove.

Bad Finish See “Setup Instructions”

below.

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

 SHAVING
SETUP
INSTRUCTIONS

LEADS: ALWAYS AIM FOR BOTH FLANKS IN TOLERANCE ON M&M CHARTS

BOTH LEAD LEAN AND CROWN AMOUNTS.

LEAN:

• MAKE SURE CHART “END OPENINGS” ARE THE SAME.

IF “END OPENINGS” ARE NOT THE SAME, ADJUST STOPS TO EQUALIZE.

• IF “ESSING” OCCURS, CHECK HOBBED LEAD CHARTS FOR TOO MUCH OR

TOO LITTLE LEAN.

CROWN:

• ALWAYS BE SURE LEAN IS CORRECT BEFORE MAKING CROWN ADJUSTMENTS.

PROFILES: ALWAYS AIM FOR BOTH FLANKS IN TOLERANCE ON M&M CHARTS.

TIPS:

• TO BRING TIPS “IN”, INCREASE CUTTER R.P.M., THEN

• WATCH SURFACE FINISH,
• RECHECK LEADS,
• RECHECK SIZE.

• TO BRING TIPS “OUT”, LOWER CUTTER R.P.M., THEN

• WATCH SURFACE FINISH,
• RECHECK LEADS,
• RECHECK SIZE.

HOLLOWS OR BULGES AT MIDDLE (MORE THAN .0003”):

• TO REDUCE HOLLOWS OR BULGES, REVERSE CUTTER DIRECTION, THEN

• WATCH SURFACE FINISH,
• RECHECK LEADS,
• RECHECK SIZE.
• IF HOLLOWS OR BULGES ARE EXCESSIVE, CHECK HOBBING PROFILE CHART.

BOTTOMS:

• TO BRING BOTTOMS “IN”, INCREASE CROSS FEED (PINIONS) OR

DECREASE CROSS FEED (GEARS), THEN
• WATCH SURFACE FINISH,
• RECHECK LEADS,
• RECHECK SIZE.
• TO BRING BOTTOMS “OUT”, DECREASE CROSS FEED, THEN
• WATCH SURFACE FINISH,
• RECHECK LEADS,
• RECHECK SIZE.

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

 SHAVING
SETUP
INSTRUCTIONS

FINISH:

• THE TOOTH FLANK FINISH SHOULD BE SMOOTH AND FREE OF CUTTER MARKS AND
TEARS.

• SUGGEST 2.38 TO 4.60 INCHES PER MINUTE CROSS FEED FOR PINIONS OR
1.76 TO 2.76 INCHES PER MINUTE CROSS FEED FOR GEARS.

• TO REDUCE TEARING AT TOOTH TIPS, REDUCE CUTTER R.P.M. AND INCREASE CROSS
FEED, THEN
• WATCH SURFACE FINISH,
• RECHECK LEADS,
• RECHECK SIZE.

• TO REDUCE CUTTER MARKS ON ENDS OF TEETH, REVERSE CUTTER DIRECTION, THEN

• WATCH SURFACE FINISH,
• RECHECK LEADS,
• RECHECK SIZE.

• IF CUTTER MARKS ARE ON SAME END, THEN CUTTER IS ROTATING IN PROPER

DIRECTION.

• IF CUTTER MARKS ARE ON OPPOSITE ENDS, THEN CUTTER ROTATION SHOULD BE

REVERSED.

• USE 5 TO 10 DEGREES DIAGONAL FEED TO ENHANCE FINISH AND CUTTER LIFE.

• CHECK PART HARDNESS LEVEL, SHOULD BE BHN 190-250 FOR CARBURIZING MATERIALS.

W H HAYWARD 9-99

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