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Gear cutting

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chipenter:
Made a 20 DP 20 tooth gear today , there wasn't enough metal to cut the key way and it split , guess I should have cut the key way first , the cast iron came from a dumbbell so something had to go wrong .

awemawson:
Bad luck - how frustrating.

There's not a lot of meat left between the dedendum and the keyway, can the keyway be reduced in depth?

chipenter:
Thank Andrew I will try the fit before I cut the next one , I want a 20 tooth one as well my have to make that from steel .

Meldonmech:
Hi Chip
                   Can the size of the shaft be reduced, it looks large in comparison to your gear?


                                                                    Cheers  David

Pete.:
What kind of tool are you cutting the teeth with? Looks like you have a burr or it's dragging the back edge of the tool and carving a small step in one side of every tooth.

Crack looks like it's due to built-up stresses in the cast iron. I sometimes have to cut out cast iron tunnel sections and I've had quite a few split with a loud bang half way through cutting.

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