Cutting Spur Gears on a Kearney & Trecker 3H Horizontal Milling Machine

[@jeanphilippepoirier6130]

Kudos to Keith for showing us where the horizontal mill shines! Those machines are greatly overlooked nowadays. I agree with Keith that in this specific scenario, centering the cutter over the gear blank is not critical. There is not speed involved and each gear might see just a few hundred revolutions in their whole life. Still I tried to figure out what is the precise way to center the cutter. I pulled my old Technology of Machine Tools book. They show 2 methods. A precision square rest against the machine table and the gear blank circumference. Then a measure is taken between the square and the cutter. The measure is repeated on the other side. When the same measure is achieved, the piece is centered. For a more precise way, the book suggest using gage blocks. Can't wait to see this helical cutter attachment put to good use!

[@johncooper6891]

I have been a machinist for 35 years its nice to see someone on KZbin that really knows what they are doing, their are so many hacks on KZbin good job.

[@erich9244]

Keith Thanks for bringing us along again. You demonstrate rather well, that being precise isn't always fast but damn well worth it. Keep on keeping on!

[@williamelliott5041]

Just love the level of detail you provide as you perform the task. You would make an exceptional teacher. Thanks

[@finnrock5558]

Recently got a mill for my garage, I'm going to try to cut some gears once I get a little more comfortable with the mill. It's always great to see experts like yourself show off your skills. I've learned a lot from watching machinists on youtube, you guys are really amazing. Thank you.

[@hackfabrication139]

45 odd years ago, when I was taking a machine shop class in college, I cut a spur gear from a cast iron blank, for an old Stover hit and miss gas engine. I used a horizontal mill to do it. It was a lot of fun. And there is a lot of 'figuring' to do to get it right. On a side note, my son is a manufacturing process engineer working for American Axle. All his work is on much more advanced CNC type machines. Love the video!

[@stevenslater2669]

I sure wish we had KZbin when I was taking machine shop courses. I probably could have had a gear come out right! Keith makes it look easy, but I don't think anyone in my class that semester made a perfect gear - including the instructor!

[@millomweb]

There's a lot of maths and data involved ! Pretty impressive you were even onto cutting gears ! We had 1 shaper (teacher only) 5 lathes and no milling machine. We also had a teacher only power hacksaw. We had 2 teachers as one retired. With the second teacher, I taught him how to cut threads on the lathe ! He knew it was possible but clearly had never done it himself !

[@elanjacobs1]

@@millomweb Most of the maths for a basic spur gear is pretty simple, the real nasty stuff shows up with bevels and worms.

[@millomweb]

@@elanjacobs1 worms are just threads ;) Bevels are cut on a taper on a taper :)

[@elanjacobs1]

@@millomweb you've clearly never cut a worm wheel or bevel gear...

[@millomweb]

@@elanjacobs1 You said worm, not worm wheel. 2 completely different gears. Perhaps you should do your homework !

[@ronnieseagraves3385]

Keith, I look forward to Mondays and Fridays to view your videos. You are a great teacher and your videos are very interesting.

[@carlwhite8225]

Keith, I have seen you do this process many times and i still find it interesting , Thanks.

[@pnwRC.]

It never gets old watching you hand craft the gear, & other precision implements you make on this channel. Thanks for another fantastic video, Keith!

[@bcbloc02]

Horizontals are handy machines.

[@honeycuttracing]

Great video!!! I have to admit, like subscribers, I sit here and stare in amazement, Would love to have a dividing head for our shop built mill, like most things we end up using whatever we find at the local scrapyard and we have couple of gear boxes with 15:1, 20:1 ratios, folks like you, Abom79, Keith Fenner and others give us the confidence to do what we'd never try, and for that, WANT SAY THANKS!!!

[@burrowbuddy3596]

With a height gauge, scribe a line centered on the gear blank ,90 degrees from vertical as the blank is set up for milling, then index 90 degrees to top, center cutter on this scribed line.

[@kimber1958]

Thanks Keith

[@PetesNikon]

Thank you, Keith, for another excellent video, your steady flow of narrative and great explanations of what is about to happen and why. I appreciate you even more when I return from exploring other KZbinrs who waffle on and chitty-chat about all kinds of irrelevant details and don't get the job done and I have to stop their videos in exhaustion and frustration. Thanks again.

[@jamesstanlake4064]

Thank you for a simple, detailed examination of the process. Much appreciated!!

[@garthbutton699]

Brought back a lot of memories from my high school shop class 55 yrs.ago thanks for the video😂

[@mikebaldwin9972]

Always fun when you get to play with your Favorite Toy , THANK YOU SIR!!!

[@millomweb]

Getting to use a proper machine after seeing all these others (not Abom79) using toys is always good. Incidentally, is MB your real name ? Famous name in the UK !

[@mikebaldwin9972]

@@millomweb Has been for 75 years,born and bred in the states. I really enjoy watching Mr. Rucker,he reminds me of my grandad who was also a blacksmith.....

[@paulmace7910]

One of you KZbinrs needs to get a gear hobber. It would be interesting to see how they did it back in the days before CNC.

[@elanjacobs1]

search for gear hobbing, there's a good video from oldfangled film

[@jimc4731]

Gear hobbing is still the way to do it today! JIM

[@elanjacobs1]

@@jimc4731 Yep, just that modern hobbers are all CNC

[@the_hate_inside1085]

Gear hobbing is witchcraft.

[@elanjacobs1]

@@the_hate_inside1085 it's really not that complicated

[@MrPatdeeee]

Good show Keith. Thank you.

[@jrat104]

I have watched a lot of your videos. This one stands out as amazing. Just the right about of information, great changing of camera angles, good use of increased speed, and improved audio. You have shown this process a couple of times but this seems to me to be the best demonstration to date. Again great job.

[@tiredoldmechanic1791]

We were taught to make two cuts at 180 degrees on even numbered teeth or three cuts on odd numbered teeth to get the pin measurements to spec then cut the rest of the teeth.

[@tiredoldmechanic1791]

@@flat-earther With an odd number of teeth, you have to cut the two directly opposite of the first on, put pin in all three and measure. One pin on one side and two next to each other on the opposite side.

[@donaldgarmon7368]

I really enjoyed these videos on cutting these gears! Thank you!

[@pneumatic00]

Nice. That cutter cut like fresh-churned butter.

[@danielwolf2192]

Great video as always, particularly nice explanations as to why and what you're doing.

[@kitmaira]

This just the information I have been looking for. I need to cut change gears for my little South Bend 9”. Thank you.

[@pwbpeter]

Good job Mr Keith.

[@sjmazzoli]

good job Keith

[@18robsmith]

Something very soporific watching a milling machine cutting gears

[@billmckillip1561]

Always interesting to watch the creation of gears.

[@millomweb]

It has all the interest of tunnelling from both ends. Will they meet in the middle ? UK BBC programme called QI. (from Quite Interesting) talked about getting tunnels to meet underground. Host, Stephen Fry, revealed in one case they missed - and the 'architect?' was so annoyed that he shot himself. So one of the panelists quickly asked: "Did he miss?". It is a factual comedy programme !

[@richardw64]

!st year Toolmaking, making a helical gear using a horizontal mill with dividing head and gearing on the end of the table to create the helix. Haven't made one since.

[@elsdp-4560]

THANK YOU...for sharing. Very much enjoyed.

[@ralphnorman4636]

My father taught me, The day you stop learning you start degrading. thank you

[@ramosel]

My Dad had the 1st corollary of your father's lesson: Any day you learn something new is a good day.

[@angelarichards3588]

Well done Keith. Very clear. Good tutorial xxx

[@andrewBwinter]

Gear cutting, metal shapers and threading. I just sit there and stare for hours.

[@millomweb]

Have you seen that Russian video - cutting 2 10-start threads, one left hand and one right hand onto the same bar at the same place ! ?

[@andrewBwinter]

@@millomweb yes and I think he wrecks the first try by a mm or so and he starts all over again

[@millomweb]

@@andrewBwinter Yes - advanced the tool for the next cut but moved it too far !

[@silasmarner7586]

There's definitely a lot going on!

[@MaturePatriot]

Heavy feeds and speeds dull cutters, and cost the small shop money! I bought a small Steinel S4 Horizontal mill for my home shop. I have a soft spot for Horizontal Mills and Shapers. Great video.

[@tomcross6567]

Keith...have you ever tried the trick where you lay a thin 6” scale across the top of your piece and bring the cutter (with one tooth at bottom) down to touching. Then move the table back and forth until the scale is horizontal? A good trick.

[@merlegr]

I've done that

[@millomweb]

That's what I thought he was going to do ! :)

[@jn8601]

He hit dead center right off the rip! Nice

[@artszabo1015]

Keith A little clarification on fotopfanatic's post. Lay a 6" rigid rule on top of the gear blank. Pinch it with the cutter and move the table in and out till the rule is perfectly level. You are now on center. This is NOT instead of the way you did it, but only an alternate method. Obviously, your way worked just fine. Art

[@DavidKutzler]

11:00 The special gear measuring calipers pictured on your Gear Measurements spreadsheet once appeared in one of mrpete222's "Mystery Tool" episodes.

[@a.bakker64]

Excellent explanation

[@monadking2761]

Another great video Keith. It looks like you will have a nice set of gears soon.

[@caseysmith1718]

Keith, I eagerly await your eventual purchase of a gear hobbing machine! Dont deny it, we all know its coming 😁

[@terminalpsychosis8022]

One more gear closer to making some spirals. Oh my, this is going to be intense, awesome, spiral gear cutting goodness.

[@TheKnacklersWorkshop]

Hello Keith, Nice work today... well done... Take care. Paul,,

[@staciedziedzic8706]

Hi Keith! I love this video! I love to watch teeth being cut! Gear teeth that is! Take care!

[@aquilux-vids]

With all this talk of "If this were a production job," it would be interesting to see what that would look like. Maybe next time you have to make two identical parts you could go through the process of dialing everything in to run at maximum speed, and then show us what that winds up looking like when you blast through a part without having to do the setup?

[@tropifiori]

Every time I see the arbor on horizontal mills, I always reach for my throat to see if I have a necktie on.

[@rc166honda]

Lovely job, beautiful mill 😁

[@billmorris2613]

Good morning from St John Parish, Louisiana 29 Jan 21.

[@millomweb]

4:40 Keith - I note a number 1 cutter is for 135T to a rack. Presumably then a number 0 cutter is for an internal gear of 55-134T ;) Then do they go further: a -1 cutter for 35-55T internal and so on ? :)

[@moogie621]

I just have to ask was run out checked on the shaft holding the gear being cut that is very important to avoid inconsistent mesh and to avoid possible binding

[@kentuckytrapper780]

Great video Keith, the price of my model k just went up. Great mill's.

[@propulsar]

Some nice gear you got there Keith.

[@ramsay19481]

Looks like you have an open oil hole on top of that dividing head.....A short 1/4 inch machine screw should fit there and prevent swarf from entering the bearing...... Cheers from Louisiana.. Mike...

[@tnekkc]

My father was chief engineer and told me to never let engineers design gears, just buy them from Boston Gear. In 1969 there was a hot girl two blocks from our house. Her father designed gears for my father. I never got anywhere with that girl.

[@rescobar8572]

RIGHT ON THE MONEY!!

[@kerrygleeson4409]

Always very interesting Keith thanks 🇦🇺👍

[@Larry-325]

Keith awesome video. Great content! 👍👍

[@alirahmani4351]

Nice

[@darmah1959]

Wonder if the gears are case hardened or through hardened? Many/most gears normally have different heat treats for different parts of the gear and teeth?

[@WilliamTMusil]

Hiya Keith

[@tonyschiffiler4816]

Do you need to heat treat that gear , or will it go the way it is . Nice work .

[@davidstreeter9426]

The principal advantage of these more manual machines is the versatility over cnc machines which are probably faster for production machining.

[@millomweb]

Err - and you don't need to be a computer programmer ! I guess CNC is all setup time. After a test run, it's then simply one green button - where's the interest in that ?

[@millomweb]

@@JorgTheElder Is that just one control and you have to pick which axis it operates ? It could be better like that as it could be set for multi-axis angle cutting ! Which would of course mean cutting a circular path etc.

[@nevetslleksah]

Thanks for making the video. Would you be willing to share your handy-dandy gear calculation sheet as a pdf or Excel file?

[@robertbamford8266]

As usual, very clear explanation - even for someone who never has, never will actually use the information. Question: do the pins ride high enough in the tooth cut that chips are not an issue? Thanks for the video.

[@paulkoomen5262]

Keith Nice work as always. I sure would like a copy off your excel spread sheet with the formulas.

[@CraigLYoung]

Thanks for sharing!

[@henrypasini6827]

How do you easily deburr the gear ⚙️?

[@ghl3488]

Nice job Keith, very interesting. regards

[@silasmarner7586]

That arbor has visible runout, but I don't know how much difference that makes in this case. It'd bug me tho. .. I correct myself. The sleeves, when installed, have the runout. The arbor might not be half-bad.

[@brucecolgate4254]

Are you going to heat treat these gears?

[@jayjay6804]

I'm looking forward to the cutting of helical gears !

[@millomweb]

Very helical ones are called threads and are cut on the lathe ;)

[@craigread179]

How do you keep all your cutting tools sharp?

[@robertbamford8266]

Especially if sharpening changes the shape of the cutter (when is a #6 no longer a #6?).

[@kevinmartin7760]

If you want to measure using pins or wires to set a final depth of cut, your first "pass" should just cut two opposite sides the minimum required to measure the exact depth.

[@MadDawg91108]

Wow...don't think I've ever seen Keith use a micrometer. I was waiting for the ol dial caliper to come out.

[@millomweb]

Really ? I can't say I've noticed him not use one when it was relevant !

[@jimc4731]

I was also surprised that he didn't clean the chips off before applying the measuring pins! JIM

[@ericmcrae7758]

Hi Keith Is there any reason you don't fill the sight glass halfway on the support arm. It looks well lubricated but just curious. Will we get a demo of the spiral attachment in operation once it is all together?

[@WhatAboutTheBee]

Hopefully!

[@freethought2296]

Are those gears heat treated?

[@pdschu6599]

Thanks for another great lesson. I have two questions. It looks like the horizontal shaft has some eccentric movement, is that real or illusion? When measuring over the pins would the measurement be more accurate if all the chips were cleaned from the teeth holding the pins?

[@ParsMaker]

interesting , thanks for shear

[@alanmahaffey3265]

How will you mark the new tooth number on the gears you modify?

[@alangknowles]

Please cover the casting pattern. Why did you have the dome ends that were cut off?

[@geoffmorgan6059]

I have always wondered how to determine if the "pressure angle" is 14 1/2 degrees or 20 degrees. I think most of the gears that we would encounter on vintage machinery would be 14 1/2 degrees, but that is nothing but a guess. Help!

[@catfishgray3696]

GREAT JOB, GREAT VIDEO, [ NOW LET'S GO TO WORK...]

[@OldIronShops]

Keith i would love to have that excel file you have set up is it available ?

[@joopterwijn]

Keith, are you needing to harden the gears again?

[@ellieprice3396]

Joop Terwijn: The original gears were not hardened. and there's a good chance hardening would distort the gears enough to make them unusable.

[@joopterwijn]

@@ellieprice3396 thx, I did not realize that (Keith mite have said it, I have to pay more attention)

[@joopterwijn]

Fun viewing it a second time (ssssssttt ,....first time my eyelid though it was bedtime 🤪)

[@polakis1975]

Very nice! How do you line up the dividing head exactly parallel on the table? Thanks! Greetings from Greece

[@millomweb]

Dial test indicator, as usual.

[@geoffbrumpton8544]

Is that shaft bent or just the spacers out that make it look bent?

[@geoffbrumpton8544]

@@flat-earther if you cover the shaft and only look at cutter it seems ok, what ya think ?

[@geoffbrumpton8544]

@@flat-earther slow it down 😳, I’m lucky to be able to play and comment on it 🤣. I think we’re flogged this dead horse enough. The cutter worked so all is good 👍

[@HEADDYNAMICS]

Keith, quick question. I am cutting a pinion for a KR WIlson 75 ton press that has a 8 DP and only has 10 teeth. All my books only go down to 12 teeth for anything. Just wondering if there is another solution. Thank you

[@newandoldtech5634]

No heat treatment?????

[@robertgoth5570]

Hi Keith I noticed that sometimes you tighten things down at other times your tighten things up is there a difference haha

[@watomb]

Did you do a video on how you heat treat the part after machining it. Guessing you have an I think I remember something

[@chrisbaker3844]

Hi Keith Great video, I have some gears to cut but as it is the first time I am unsure what cutters to buy. Gear 1 is 72 teeth 24 dp pressure angle is 20 or 14.5 degree, depth of cut is 0.090 and od of blank is 3.083 Gear 2 has 14 teeth and blank is 0.666, everything else is as gear 1. All the cutters I can find on the web refer to a module number, how does this relate to the dp or doesn’t it. Does module refer to metric gears and dp imperial gears Hope you or anyone else can help

[@RambozoClown]

Yes module is a metric standard. Diametral pitch is imperial.

[@TheTkiller9999]

Keith.. I have a question on making these gear's... I do not know if it matters with these gears (I believe it doesn't) but is there any relation between the inner splines that have already been cut and the outer teeth... i.e. are they in any way need to be at a specific angle to the inner splines.? (an example where this matters is like a camshaft for any motor the gear teeth are at a specific angle to the inner keyed slot)

[@TheTkiller9999]

@CurlyG65 OK.. I saw that, but I was not sure when he went over the internals on the radial attachment if they needed to be timed... but ok

[@Angus_McGyver]

Crazy idea i had. What if:, you made two cuts on opposite sides of the blank, used your measuring wires and tuned in your depth of cut on just those two, and then you could cut the rest of the teeth at full depth right off. Would it work, or am I just dumb?

[@WhatAboutTheBee]

Yes, the depth of cut would then be established. I still would not want to remove all the material for the other teeth in one pass. For a better finish, first a roughing cut, then a finishing cut. For those with lots of time, 3 or more passes is desired.

[@ben4735]

Is that a Milwaukee k vertical?

[@mkegadgets4380]

Are these gears too soft for use? Are you going heat treat them?

[@ellieprice3396]

Good question. If they're mild steel he could case harden them. If the carbon content is higher, such as 1144, they can be heated to critical temperature and quenched in oil.

[@mkegadgets4380]

That’s what I was thinking. By the way I really like your belt grinder great job.

[@firearmsstudent]

How would you get the cutter exactly in the center if you didn't want to eyeball it?

[@firearmsstudent]

@@JorgTheElder I thought so too, but then it seemed like the cutter diameter was too small and the top of the blank would hit the spindle before you could reach the sides. Am I imagining things?

[@andreblanchard8569]

@@firearmsstudent Take the blank out of the chuck and replace it with an indicator on an arbor. Zero off one side of the cutter, back off and rotate the dividing head 180 check the indicator. Adjust and repeat until you get the same reading on each side.

[@firearmsstudent]

@@andreblanchard8569 That is quite nice, thanks!

[@classicrestoration]

Was your arbor support low on oil?