What is undercutting in gears?

Undercutting in gears refers to a manufacturing defect where the tooth profile of a gear is cut too deeply, resulting in a loss of material from the root of the gear teeth. This can weaken the teeth and reduce the gear's load-carrying capacity, potentially leading to failure during operation. Undercutting typically occurs in spur gears when the tooth shape is not properly designed or when excessive cutting tool engagement happens during machining. Proper design and manufacturing techniques are essential to avoid this issue and ensure the durability and efficiency of gear systems.