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The design principle and models for novel error-free shaper cutters are discussed to improve the accuracy and service life of gear cutting tools. The modified methods for designing the tooth profile of the shaper cutter are developed by including the inverse envelope method, midpoint-midline method and midpoint-displacement method based on the theory of geometrical reverse problem. The universal mathematical models for manufacturing optimal tooth profile of shaper cutters are presented. The feasibility and reliability of the proposed principle, methods and models are proved by combining the numerical examples with practical application. The design method suggested in this paper is superior to the traditional design scheme, and will be helpful in facilitating the design and manufacture of shaper cutters.

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