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Bevel Gear Mill

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Thanks Joules, that's a great video. I do have several books on gear cutting, and also Machinery's Handbook, but good to see a bevel gear cut on video.  :thumbup:

I do have a horizontal mill, and could probably follow suit, but again this project would be a simplified standalone cutter. For my purposes of small Westinghouse type engines 2" gear diameter is actually excessive, and I think I'll modify that one capacity spec to 1" dia. max. That will make it easier.  :coffee:

Andrew, I'm not down on 3D printers or what people use them for, just not interested, personally. Mini hand operated gear shaper is possible, and a good call, with some definite appeal, but I had started thinking about a mill style with a small gear motor. I'm not sure what the power requirements are, or prices and availability. Could be prohibitive.  :coffee:

But anyway, as a start I'm rough guessing 400 RPM working speed for say a 1" dia cutter would handle mild steel or cast iron gears, or softer. There are a bunch of new 12-24VDC gear motors in the $20 range on Ebay, roughly 7 to 8 watts. I don't know if such low power could cut, and then there's the question of bearings. probably can't just put a cutter on the geared output shaft. So we'd need a supported spindle.  :loco:

Also part of the spec is I'd just be cutting 1:1 ratio gears for the engines. This probably means some of the machine setup angles can be built in rather than needing to be adjustable.

If the material being cut is brass or cast iron I expect that the power requirements are minimal.

The shaper has the advantage of much simpler tooling. I've only once cut a bevel gear 'for real' rather than playing about - (it was the table feed for a Richmond universal mill) - the thing I got tangled up with was the offsetting of the cut to create the varied clearance at different diameters - (I was using a standard involute cutter and a table of offsets).

It worked OK but I'd not like to make a regular habit of making bevel gears that way  :bugeye:

It might make sense to think carefully about the most LIKELY gear diameter and tooth number I'd need, and really focus on just doing that one job. That would allow a single indexing row of holes, a single cutter, some stops to do the change of angle and the set-over for doing the second and third cuts.

Or, maybe have separate modules for individual gear sizes that are comprised of a cutter and a set of stops that could interchange into the basic machine. I think being able to make 4 different standard bevel gears would fit my needs for a LOT of different size engines. I really don't need to make an infinite variety of bevel gears.

Really, starting with just one size would be fine.

Yes Andrew, your shaper idea is wearing away at my mill determinations. I may give in, after thinking rotary for a bit more.

But wouldn't we still have to offset and rotate for 3 cuts?


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