Involute Gear Cutting on the Shaper final

[@EmmaRitson]

clapperbility in the backward direction. love it when you get all technical!

[@baccus61]

Ok. Done and dusted. Now to make a BEVEL gear attachment. I saw one on a shaper years ago where I worked and it was pretty neat how it rocked under the cutter generating the form. I didn't get a very good look at it, maybe for 10 seconds, so I am no help in starting the design process. Great videos fellers and keep up the good work.

[@JBFromOZ]

Thanks heaps for your comments! Bevel gears would be pretty cool!

[@halstoolroom5985]

I was getting worried if you would make the deadline, but you did it and well done, you are another serious contender for first place. Best of luck.

[@JBFromOZ]

Hal Pickering thanks mate! Was touch and go for a bit today managed to slice my fingers up on a knife at the sink! Pretty stupid, and the most unexpected injury to occur on this project

[@sblack48]

That's awesome. Didn't realize you were cutting an involute gear with a straight cutter! Nicely done fellas. Cheers from Canada.

[@JBFromOZ]

Yeah it’s pretty cool solution to involutes!

[@peterpeterson7665]

Haha great video guys. Starting to notice a bit of a pattern in how someone gets inspiration for there video content. Looks like it's been going on for years. I just stumbled across this vid because I recently picked up a Douglass shaper that looks identical to yours. Seems like a great little machine. I have a strong interest in DIY renewables, permaculture and self sustainability, just browsing your channel now and loving the content. I'm in Sydney too. Cheers.

[@JBFromOZ]

Fantastic Peter, glad to have you on board mate :-) hopefully have some more fresh vids up soon as some projects come together :-)

[@rovermuc]

Hi from Munich/Germany, former home of long time vanished Friedrich Deckel Company. How sad, great machines

[@rovermuc]

Ups, wrong video

[@JBFromOZ]

We have a deckel in our stable, 3D pantograph, which we are planning to modify for ER11 collets

[@houseofbrokendobbsthings5537]

Well done. Thanks for the very detailed breakdown. The crossfeed looks to approximately the involute very well.

[@thang010146]

Thank you. I haven't seen it in real life before.

[@JBFromOZ]

thang010146 it was your video that helped us to make it, we only just got it finished yesterday :-).it works very well also !

[@DantesAlvesdeSantana]

Muito bom amigo

[@JBFromOZ]

thanks heaps for watching and commenting mate

[@9neil]

his guys. great outcome and nicely done. Question..why not not make a single point involute vutter uding the two button method, then simpky plunge cut each tooth on the shaper?

[@JBFromOZ]

neil9 great question! Our plan with this build was to use a single cutter for all of the range of gears that we need, as we are wanting to reproduce the full range of thread cutting gears. An involute cutter will only generate the approximate form tooth on a fairly narrow range of tooth count. By generating the gear using the pitch circle disc and index wheel, the tooth form is accurate to the rack for any number of teeth :-) thanks heaps for watching and commenting Neil!

[@theshed8802]

great project guys. great to see the old shaper making chips. only observation that I make is that the feed screw on the clapper is 12tpi so it is .08333" per revolution. i always planned to cut a proper dial for it but i was going to make it .0.084" per revolution because it was easier to index, and a 0.0007" error per revolution just didn't worry me. There is your next project lol

[@JBFromOZ]

The Shed ahh yeah, we fudged around a bit with DTI to confirm the depth we needed off camera, but the Douglas performed admirably, didn't miss a beat, you did some good work getting that old girl up and running mate

[@millomweb]

I'd need a day studying the maths to work this lot all out to understand it fully ! Sadly, I didn't spot an explanation of all that in this video. I look forward to seeing your setup for helical gears ;)

[@JBFromOZ]

There are a couple of different videos in this series, one of them goes more into the theory and calculations, might be helpful in understanding the geometry involved, it’s really cool how it all comes together in the end, and very rewarding when the last tooth lands correctly!

[@millomweb]

@@JBFromOZ If I was forced to do a degree in a subject, gears would be a high candidate in the list ! The transmission of power from one gear to another is a fine art - not only for the fact of power transmission but also the sound created - where helical gears win. Bevel gears - where you additionally have to take into consideration the different speeds between the two ends of each tooth - and then there's hypoid gears - which most car diffs use - even more complex tooth form !

[@JBFromOZ]

pmailkeey some really interesting gear developments with 3D printed gear sets, eg the herringbone planetary gear set. Manufactured as an assembly, the herringbone gears provide the balancing force vector removing side loads of a traditional bevel gear, thus producing thrust and reduction in a single, quieter assembly... very cool!

[@millomweb]

@@JBFromOZ For "traditional bevel gear" I guess you mean helical. Are you saying you can 3D print a gear train that's impossible to make by assembly ? I can quite believe that !!

[@JBFromOZ]

@@millomweb check out "Gear Bearing" on Thingiverse www.thingiverse.com/thing:53451

[@hellboytermoligian2600]

Hello Mr. The plastic gear you use is the number of teeth to cut ? Can bevel gears be cut? Is there a project of this interesting method? I hope you can help me. I await your reply, thanks for your attention.

[@JBFromOZ]

Hi there! The plastic gear sets the number of teeth yes! To cut a bevel gear, the shaft would need to be adjusted so that the path of the cutter (the shaper) is in the correct orientation, and the pcd disk set to the correct size to rotate the shaft but yes, it should be possible

[@drubradley8821]

That was really neat. I like the idea of how the shape of each tooth will come out smooth on the pressure angles.. Fine work, guys. I must mention.... Stefan, would have hand scraped the whole thing with-in (0.000000000000000000000000000000001mm) of its life. What is the hold up guys..LOL. Although, I don't know that hand scraping would serve a serious function on that other then looking more beautiful than it already is... Fine work, guy's.

[@JBFromOZ]

Dru Bradley yeah that was the giveaway really ;-) I mean even we commented on the surface finish of the tool :-)

[@lookcreations]

Most excellent work there fellas. Am very impressed. Is it possible for you to show a really close up image of the cut tooth vs a similar tooth cut with a rotary cutter on a mill. I think that would explain the benefits of this approach. Best of luck chaps . Mat

[@JBFromOZ]

lookcreations we can certainly look into close ups, as for the benefits of this approach, as with many shaper operations is that you can make your own tooling! A set of seven gear cutters for a single size (eg DP32) was going to cost close to $100 bonza bucks, and would be different set for different DP or different pressure angle. This one hand ground cutter can be used for a range of DP and module at 20 degree PA. the pitch circle discs could be easily turned up on a wood lathe or laser cutter or 3D printer, and the index wheels although a bit more fiddle were simple to laser cut as well. With the 7 set gear cutters, each is used for a tooth range, so while they cut a nice profile, they are not the "correct" profile to mate with the rack across all teeth counts. With the generated profile here, each gear would mesh very closely with the rack or other gears generated by the same method

[@lookcreations]

Watched this again and finally I grasp the subtlety of the rotation of the cutting action - I had to see gear hobbing at work to appreciate the benefit. I think i might be tempted into making up the rig for my shaper. Still got the problem of indexing 127 for the changewheel I need for my lathe. Cheers chaps. Mat

[@mzurran1003]

I need this in my life. Where is your dimensions or source material? I need to know.

[@JBFromOZ]

I have many videos in this series including drawings of the parts. If you have further enquiries let me know!

[@tobyw9573]

So, I guess cutting a rotating gear blank forms the involute with a straight-sided cutter as the blank rotates vs cutting the whole space between teeth in a stationary blank with an involute-shaped cutter. Does this mean your method can cut any gear that fits with the same cutter vs needing a hundred different cutter profiles. Cutting one tooth at a time looks more efficient, though. Thanks! So when do you plan to cut some spiral bevel gears, mates?

[@JBFromOZ]

yeah that is correct, the same tooth profile could essentially cut 20 degree pressure angle gears up to whatever depth you set (and therefore whatever DP set you want to produce), given an appropriate grind on the cutter, index wheels and PCD wheels. extremes of DP would probably need the dedendum edge cut short though.

[@dickda1]

Yikes, I think I would have lost my mind with all the adjustments needed. Congratulations

[@JBFromOZ]

Thanks Dick! once the gear cutter attachment is built, it uses interchangeable index wheels and the re-index and cutting is quite relaxing to watch/do. I was considering doing a "reverse feed" on every second tooth, but I was concerned there might be backlash in the reverse direction cut/forces of cutting. something to play with down the track perhaps, to make a faster process. thanks for watching and commenting!

[@rdrnd928]

Nice work! I like to watch a shaper in action. It figures Stefan would be in on it! :D Hey Emma- isn't the use of a time machine against the rules???? :))

[@tobyw9573]

I saw a great shear pin made from an aluminum nail. If that one breaks too easily, or dents under normal use, try a steel nail or a wire coat hangar.

[@JBFromOZ]

+Toby W great idea!!

[@rafikshaikh7530]

Thanks 👍👍

[@JBFromOZ]

Most welcome!

[@nickvee9468]

AWESOME project! I am about to copy you but I have a question as to the diameter of the Pitch Circle Disc. Is the actual PCD diameter = Calculated Pitch Diam. - (less) twice the wire diameter? (Or should I ask the German lol)

[@JBFromOZ]

G'day Nick, The driven attachment point wants to run tangentially to the pitch circle for the given number of teeth. As a result the pitch circle drive disk wants to be made at "pitch circle" diameter - drive wire diameter. As diameter is 2xradius, the centreline of the drive wire will intersect the tangent to the pitch circle as required :-) Good luck with your build, we would love to see your results linked back here please :-)

[@sharkrivermachine]

Very nice project but I am confused. What does Stefan have to do with it?

[@JBFromOZ]

R. Steven Lang one of the things Emma asked for was some interesting camera tricks or Cameo call outs. Stefan and This Old Tony have previously had a bit of crossover so I faked a video produced by Stefan by cutting together a voiceover from some of Stefan's other videos. This old Tony also has used a time machine in his video on making an adjustable boring head (using the finished head to make the boring head). The idea here therefore is that we get the idea for how to make the index wheel latch work by seeing how Stefan did it on his, and then later in our video once we finish making it, we send it back in time to Stefan so he can "make his video" :-)

[@sharkrivermachine]

I understand the whole video trick thing, the time machine and all. Was just a little confused about the tie in with Stefan. Very nice project. There is some stiff competition here. Emma has her work cut out for here. Best of luck to you.

[@JBFromOZ]

R. Steven Lang Stefan is one of dad's inspirations, Seeing Stefan building the same thing on KZbin but being further ahead on his project solving some of the "problems" we hadn't yet solved helped him to finish. I forwarded him draft of the audio prior to using his voice in this way which he graciously approved as well

[@sharkrivermachine]

I don't recall Stefan working on this type of project. If I had it would have made sense. I guess I will have to search through his videos and try to find it.

[@JBFromOZ]

R. Steven Lang that's the thing, he does so many cool things "on the shaper"and has also done gear cutting vids as well, my premise is that if anyone has, it would have been Stefan

[@bushratbeachbum]

You fukker. I'm getting hooked on another KZbin channel (albeit slightly late). I'm supposed to be getting things built but I'm drinking coffee and chilling cider and seeing another phone battery draining session ahead!! -I'm supposed to be building the enclosure for my lithium bank to hang under the bus! Hohum. Every day is for learning!! Cheers JBFromOZ!

[@JBFromOZ]

Happy to have you on board mate!!

[@shawnlund]

I’m trying to figure out why you wouldn’t just grind a single point gear cutter?

[@JBFromOZ]

The goal is to cut a complete set of metric change gears for Dad’s CVA, which ranges from 40T through to 154T

[@JBFromOZ]

Each would require a different involute grind. With the rack form tooth and the indexing process, the involute is formed by the cutter passing through the gear as the rack would, generating the perfect involute for each gear size

[@shawnlund]

JBFromOZ I guess I’m not quite as ambitious as you guys. I have bought full sets of involuted Gear cutters for $120.00 from China. They won’t last forever but they get the job done and I’ll get more gears out of a set then I will ever need. Cool setup though and it did seem to work fairly well. You might find his hard to believe but I got one of your Aussie shapers in my shop here in Canada. 10 1/2” Douglas just like yours, wonder what brought it halfway round the world?

[@allenhunt3070]

Audio is really important. I suggest a wireless mic to improve the quality.

[@JBFromOZ]

Thanks Allen! I have a camera gimbal and a wireless mic on the wishlist, but funds are presently being diverted into tooling and machinery instead of video gear. Your encouragement is helpful thanks mate

[@JBFromOZ]

www.neme-s.org/Shaper%20Books/Michael_Moore/shaper%20gear%20cut.pdf is the location of the drawings that we used for our initial review. We have modified as required to suit our needs

[@geoffmatthews6283]

A challenge for part 2, bevel gears?

[@JBFromOZ]

Bevel gears 'should' be achievable by angling the shaft with respect to the cutter... maybe for our part 3!! For our next trick we are working out how to cut the Multix A tool carriers as we need to make another dozen blanks up, we should be able to use a similar rotary attachment to cut the radius interlocks... a video WILL follow for that for sure :-) thanks for watching and commenting Geoff

[@tobyw9573]

Don’t forget to put a shear pin somewhere in the works, you don’t want to break something expensive if the lathe crashes.

[@JBFromOZ]

great idea! another thought was to use a fibre (phenolic) gear, two functions, reducing the noise of the drivetrain, and possibly act as a shear gear as well?

[@tobyw9573]

JBFromOZ , Good idea reducing the noise with the fiber gear. I wonder if you can make a hybrid gear that is durable yet quiet.

[@hilltopmachineworks2131]

Very cool.

[@JBFromOZ]

thanks for watching and commenting mate!

[@basharalngar1567]

Pray to the Lord to protect your father, what is the name of this tool?

[@JBFromOZ]

Gear cutting attachment for the shaper

[@johnhili8664]

Very very complicated you could have cut that gear in one hour on the milling with one pass of the cutter!!!!

[@JBFromOZ]

One of the challenges when considering making a set of gears is what tooling you have available. By using a single point method we are able to cut any DP or Module gear, any Pressure Angle, Pricing up a set of 8 involute cutters to cover a single DP or Module at $80 or more, if a set is even available. Would you use this method if you had to make a gear? Depends if you have a shaper. Cutting the 60 tooth gear took a couple of hours, but I believe there is room for speeding up the process. I think more importantly for us, it was cheap, made from materials we had around the workshop. Thanks heaps for watching and commenting! Cheers mate

[@johnhili8664]

I do have a 24" shaper but I would not even think of cutting a gear on it!!! I do have quite a lot of involute cutters my self which I bought from an auction, and when I do not have the right cutter I go to friends, that is one of the privileges of living on an island like Malta everybody knows everybody :-) Just for your information actually I am a stationary engine collector with a collection of over 120 engine here is some of my steam engines kzbin.info/www/bejne/n6rZoqZre8dnhdE

[@JBFromOZ]

oh very cool! We have a Macdonald Imperial Super Diesel (a couple of videos attempting to start it on my channel here as well) Will take a look at your engines, thanks for sharing :-)

[@paulwomack5866]

Here's how to cut a 4 foot (roughly) diameter spur gear on a shaper. Or at least it's one way. kzbin.info/www/bejne/jX-qgoCKesSClck