Metal Planer Restoration 40: Making a Bevel Gear on the Horizontal Milling Machine

[@Xarthis]

I admire the draftsmen who made the illustrations in the machinery's handbook without 3D CAD

[@pawelm5493]

Life wasn't so bad with descriptive geometry

[@fnordhorn]

You should see the illustrations in one of the books I have in the workings of Steam Engines and Injectors I have 2 books of the set of the books from a class on Railroad Steam Engines by International Textbooks in Scranton PA From back in the days when classes where done by mail for some courses when people want to learn but did not have the time to attend a classroom-type of school

[@SuperAWaC]

they didn't do it freehand, they used all sorts of mechanical devices for drafting, as well as tracing shadow boxes

[@timsering9964]

Thats when people used there brain and not a computer

[@fnordhorn]

@@timsering9964 Took 3 years of drafting in HS along with 2 years of electronic, Love how people today CANT read a Blueprint. the classes were Vocation Education. BTW went in the field of computer repair

[@joycethomas8868]

I was a machinist for 46 years before retiring at age 62. I never made a bevel gear. Nice work. By the way, I still have a Bridgeport and South Bend with 3 phase power in the garage. The neighbors keep me busy fixing their tractors and lawn mower parts. I need a bigger garage and a surface grinder. Love your videos.

[@billmorris2613]

I felt like I was in a class room with a very knowledgeable teacher that is very talented at teaching!!!

[@farmalltomf]

Keith, well played. You did an outstanding job outlining the geometry and what is needed for cutting this type of gear. Nicely done!

[@jackdelvo5697]

Removing pet with an infrared head

[@antonmursid3505]

Antonmursid🙏🙏🙏🙏🙏🇮🇩🇮🇩🇮🇩🇮🇩🇮🇩

[@jstephenallington8431]

Like every machinist, on occasion I get questions about what a machinist does. And I try to explain what it is that I've spent so many years of my life doing and I'll get comments from different people to the effect of, "well, that doesn't sound so hard, all you have to do is set the machine and it does the work!" From now on I'm going to send them to your channel and let them see for themselves just how much work and effort has to go into a machined part like this one you just did. Wonderful work Mr. Rucker, well done.

[@SciPunk215]

Keith takes it to the next level !! You don't get a diploma or even a certificate for all this work, but you get something even better... a functional bevel gear.

[@clydebalcom8252]

You explain things so well. I'm no machinist, but I could understand everything clearly.

[@cameronmccreary4758]

I ALWAYS use the Machinery's Handbook! My Milling Machine handbook was from the 1970s and was researched and printed in Germany; it had alot of very precise information on weird machining processes. Thank you very much Keith Very nicely executed but just as important, very nicely set up so you come out with a super nice part in the end.

[@carloantoniomartinelli5418]

I wish there were something else, other than just the 'like' button, to show one's admiration for another person's skills. What I see here is a display of absolutely consummate professional competence, only possible when the operator is at the peak. Eleven-out-of-ten here, for mister Rucker. BRAVO Sir ! and thank you for sharing.

[@StreuB1]

Keith, one of the biggest things I love about you is your lack of fear to tackle things you have zero experience doing. It doesn't stop you, you just try. Even if you fail and your pride takes a hit, you chalk it up to learning. Thank you!!!

[@keithblackie969]

I’m not a machine shop guy but I love watching milling machines and people put their skills to work restoring things. When I saw you cut the initial casting I was hooked.

[@erich9244]

Awesome thanks for sharing Keith! I don't watch you because you are an "expert" I watch you because you strike me as an honest guy using what skills and experience has taught him. Keep up the good work :)

[@ianide2480]

No worries though, there are plenty of "experts" in the comments section. =P

[@fredclark4033]

I have seen a lot of bevel gears and not realize much is taken into account to cut them. Thanks for the explanation into the cutting, well done.😊

[@kurtarmbrust]

Saw someone on another channel asking for help printing a bevel gear. He couldn't stop it from binding. Now I can see why. Thanks for the great explanation of the tooth geometry.

[@avoirdupois1]

A neat exploration of something we commonly take for granted. Thanks for the great explanation and background, great shots and editing.

[@petefletcher]

"Something I've not done before" "Excellent" says Keith with a gleam in his eye!

[@parthiban7]

In the age of 3D printers, this video makes me appreciate the maths and tradesmanship behind the bevel gear. Thanks Keith.

[@1ocean515]

Had no idea bevel gears had so much going on with them. Fascinating to watch, and very informative. Thank you for doing the video. 👍

[@gatekeeper65]

I respect your honesty, and admire your craftsmanship. Outstanding work. Take care.

[@welshpete12]

I didn't understand half he said at the beginning, it was to technical for me . But later in the video I understood more. When he actually started making it. But I never knew there was so much to making bevelled gears . A very well made explanation of a very complicated subject !

[@waitdrew]

This is great! I enjoyed the math and attention to detail. Your amount of homework put in is clearly evident. Thank you Keith!

[@smudgemo]

I like your teaching style, Keith. I don't have dividing head or horizontal mill, but I have a vertical mill and was mentally converting your setup to what I'd need to do in the other direction.

[@chuckinwyoming8526]

Keith, You did a great job hitting the high points of the 3 pass approximation method. A full detailed discussion is beyond the scope of this video. I made bevel gears on my K&T 2HL with the same setup but only had spur gear cutters as you mentioned. There are ways to "generate" a much more accurate bevel gear on the mill but they take a lot more passes with careful setups. The CNC has pretty much taken over and allows you to generate a good involute with constantly varying tooth pitch with a 4 to 6 axis machine. As you say the dedicated gear shaper is the way to do volume production generated involute bevel gears.

[@paulputnam2305]

That was a blast watching The Doctor of Machining in action! Great Job. Thanks

[@johnsamu]

Very interesting to watch. It just shows how smart people had to be in the past to make complicated objects with very basic tools. Nowadays with CNC machining many things have become much easier(faster/cheaper). It makes you appreciate the skills of workers/machinists in the past.

[@timothypaulson6779]

Im not meaning to talk bad about other channels, but this channel consistently makes me feel like ive learned something new. Thoughtfully explained, wonderfully filmed, by a guy that is humble as the day is long. No wonder i get excited everytime i get a new video notification!! Best machining channel on KZbin!

[@tonyschiffiler4816]

Keith , your the man , its been 48 years since i studied this method , you did great , you have patience , thank you !

[@kenny5174]

Great Video! Makes me appreciate the effort needed over a hundred years ago, and just to think of the effort, and thought process, needed to start making any gear, not just those. What about the tiny ones in a pocket watch winder!! Mind blowing!!!!

[@MrShobar]

It's now easy to see why gear hobs are used to form gears like this. An excellent job, Keith. Many thanks.

[@elanjacobs1]

Bevel gears are actually not hobbed. Each tooth is cut individually like this kzbin.info/www/bejne/h4XPoGmYfq6cm6c

[@BruceBoschek]

I appreciate the effort you made to explain what is necessary to cut the teeth of a bevel gear. I have never seen a discussion of this before and you explained it so I could understand it. Thank you very much.

[@AlmostMachining]

Fantastic Keith. Nothing simple for the one shot home setup. Getting it done and correct within means is always a win. Way to get after it and get it done. Thank you for sharing this and some of the issues you encountered. The math alone as you said isn't straight forward and while trivial is easy to mistake. Even the face angle can be mind blowing. Pitch angle is the rolling relative center angle between the mating gears allowing the resulting shaft angle to be in this case 45deg. Awesome to see you do this.

[@Caspiankhw]

Super video, very educational and insightful, bevel gears are so useful and undervalued. Really appreciate your take on making them.

[@ukulelefatman]

Great explanation, actually wrapped my head around it. Well done.

[@taxicamel]

Very impressive video. I recently made my first spur gear reduction to replace a very awkward hand crank on the side of a vertical milling head machine. Gear reduced 96:15 ratio ...an estimated ratio ...and lucky me, the ratio turned out almost perfect. I simply attach a cordless hand drill to an input shaft and let the drill raise and lower the head. I planned ahead to reduce more if needed in the gear frame mechanism ...but it wasn't needed. As it was a first attempt, and spur gear was the "easiest". I was interested in looking into a bevel gear design to have the input shaft pointing forward toward the operator. Your video answered ALL the questions! Thank you very much for sharing your knowledge and time.

[@cavemansmancave9025]

Having cut bevel gears on a horizontal mill myself, I can vouch for the attention to detail required to make these gears. Nice job. My take on this subject is don’t be afraid to take it on, just do your homework. I’m starting to sound like Keith. 😁 Thanks Keith, John

[@taxicamel]

I only have a small vertical mill, but it has some degree of rigidity ...but certainly not a two ton Cincinnati. At least a box column. Very impressive video. I recently made my first spur gear reduction to replace a very awkward hand crank on the side of a vertical milling head machine. Gear reduced 96:15 ratio ...an estimated ratio ...and lucky me, the ratio turned out almost perfect. I simply attach a cordless hand drill to an input shaft and let the drill raise and lower the head. I planned ahead to reduce more if needed in the gear frame mechanism ...but it wasn't needed. As it was a first attempt, and spur gear was the "easiest". I was interested in looking into a bevel gear design to have the input shaft pointing forward toward the operator. Your video answered ALL the questions! Thank you very much for sharing your knowledge and time. ------ I am thinking I might like this new challenge!!

[@mikefendley1471]

Keith, like you I've cut many spur gears repairing lathes and other machines. But bevel gears, ugh! I have a beautiful 1897 Flather lathe and a nice adjust-tru chuck that have been waiting for me to cut bevel gears so they can get back to work. Your "course" has given me what I needed! Thanks for your wisdom and insight. Can't wait to get back to the shop and get these two bevel gears cut!!

[@Ujeb08]

Nice ! I never had to make a bevel gear so I didn't realize there was so much to it. So I'm happy you did this demonstration as it was something new to learn about. Thanks. I hadn't watched your channel for a while but I have to say your shop is looking great! That's an impressive collection of too boxes in the background - especially the Gerstners!

[@williammalenfant4864]

Keith, you sure made that look easy! Great job!

[@williamcarboni2614]

Keith you are a Master of your craft, I could understand some of it (not being a machinist) but got lost about 3 minutes after you started explaining the angles of cut. It can out great, can't wait til it's finished. Thanks for sharing and stay safe.

[@tedsykora1858]

This was the first bevel gear fabrication I have seen so this was a good subject. Well done Keith!!!!

[@howardosborne8647]

Fantastic demo on how to cut a bevel gear with limited equipment 👏👏 I can see how the addition of one of the electronic indexing kits with stepper servo attached to the dividing head would greatly simplify and speed up the indexing. Nice job,Keith.👍

[@kennethgilbertdds7249]

Thank you Keith. I really appreciate the look over your shoulder to see such amazing projects.

[@Workshopfriend]

Thanks Keith. Appreciated the step-by-step explanation and good shots in the mill.

[@dmarquis4963]

Keith....great job. I love these videos. I'm an engineer and I enjoy seeing the details of what goes on when parts are built by skilled craftsmen like you. Keep up the great work. Cheers. Also, you're presentation is really good.

[@DavidKutzler]

I could have read and reread the information in the Machinery's Handbook multiple times without getting the insight that I obtained by watching this video. While not a comprehensive treatise on bevel gear cutting, Keith pulled together the essential elements that would make deeper study easier.

[@johnmcdyer7297]

That was brilliant kieth thanks for posting all your films it learns me a hell of a lot and I’m 64

[@timshelton4041]

Keith, a privilege to witness your first bevel gear cut.

[@jrhalabamacustoms5673]

Lots of magic sauce! Like most things in life, do your homework. Good demonstration on making intricate parts with what equipment is available vs ideal equipment designed for one job.

[@erickieffer8440]

I have much respect for the effort and talent you put into this rewarding project. Thank you for sharing this.

[@steveshoemaker6347]

Keith you make great...Videos l could watch you work for hours....Thank my friend....Blessing you way for sure....!

[@OldIronMachineWorks]

Keith, Never cut a bevel gear before, but also never thought it was any big deal. But watching you go through the steps I now realize that its a bigger deal than I thought. Thanks for sharing. And maybe its time for me to get one of those fancy machining hand books :) Gary

[@ronnieseagraves3385]

Keith, you are The Best Teacher on KZbin.

[@Herr_Bone]

I went through this 30 years ago, using similar equipment like you did. You are right, to understand what and why you do it is more than half way. About 5 years ago I made a bevel gear on a 4 axis CNC using ball endmills - that was in comparison really easy.

[@gagasmancave8859]

Nice one Keith I learnt a lot mostly how I need to read my machinist's handbook

[@phillipyannone3195]

Very good explanation and demonstration on cutting bevel gears. One of your more interesting videos.

[@markthompson4885]

You did a great job explaining the process. i understood it perfectly. You would make a good instructor. I have only cut 1 spur gear back in tech school 40 years ago. It was a prime no, 89 tooth gear. I did it as a favor for a job shop. He was very happy with it .

[@reginaldcrudstump383]

This was super interesting. I guess I never thought about the fact that a bevel gear tooth had tapered faces. Well done Keith for a great explanation and some good footage of the cutting stages.

[@jtjjbannie]

Gearing is a world all it's own. I really wish I was younger and learning/ memory was still part of me..... Great work Kieth.

[@bret_Lambky]

Great 👍🏼 job Keith! I have cut a lot of different configurations never had to get really involved in gear cutting. Your general public has no clue what a machinist has to do to calculate completion of an operation. I have been blessed to work I. The manual machine side. NC machinist use to be what the industry was always looking for. I understand the logic for high speed production. But as soon as they know you have manual skills your gold and you get all the problem projects!! Keep the great videos coming!

[@leeklemetti1887]

Remember those calculations are very OLD! Those old machinists really did their homework way back in the day. No CAD or computers either. LOL

[@bret_Lambky]

Lee Klemetti very true! Growing up we always thought our parents were clueless! They had more cognitive thinking going on than we can imagine! My machinist handbook saved my butt several times! My dad was a carpenter, he also had what he called his carpenter bible. It had all types of calculations. Pitch and rise, footings and foundation load calculators tons of structural formulas. Even though the engineer has already done it. The old timers validate everything! Be blessed!!

[@scottvolage1752]

One step closer Keith. Cant wait to see it all finished.

[@danbreyfogle8486]

Very interesting Keith. I had no idea how this would be made so watched it with great interest.

[@robertharker]

Another great video. You did an excellent job explaining a very complex topic in an easy to understand way. Well, maybe not easy but clearly.

[@matthewhelton1725]

Amazing work! I have a weekly lunch with a great friend, and we discuss many YT channels... the Bevel Gear Project caused much musing: This musings are now answered. Again Great work!

[@jerrycoleman2610]

Keith, Awesome video and content intriguing to also watch, thanks for sharing your video.!.!.!.

[@RookieLock]

Wow, quite an involved process.. Great work Keith..

[@MattysWorkshop]

Gday Keith, you did a great job explaining the makings of a bevel gear, I really need to get a machinery’s handbook, there is a lot of maths that goes into this and sadly mathematics and I don’t tend to mix, I appreciate the effort you go to to help people like me understand how things work, thank you, Take care. Matty

[@LostMountainRestoration]

That's a pretty impressive result for your first time. Congratulations and I appreciate your honesty and sincerity as you explained this difficult operation. Well played.

[@listerine-pr5lt]

I admire your sense of learning and your persistence.

[@pyromedichd1]

Thanks for posting this video. There is a real dearth of information on bevel gear cutting and this helps a lot. Of the many things I learned probably the most important one is that if you can find an off the shelf bevel gear for your application it will probably be cheaper than trying to find the cutters and do all the work to make one, unless you're just up for a challenge. If you can't find a proper gear you don't have any other choice. Thanks again!

[@GRMS_Ian]

That’s a good result Keith. I feel like I could do it too. Thanks for sharing.

[@tomthumb3085]

Fascinating engineering.. probably the best video I’ve watched this year. Thanks for the insight into the complexity of this task. Really enjoyed it.

[@larrysmurthwaite773]

Wow🤔, probably the highest challenging task yet. Well done! Thanks for allowing us to look over your shoulder and the well though out description of the complexities.

[@MaturePatriot]

This is why I watch. Great machining, and interesting parts to be machined. Keep up the good work.

[@DavidLasoff]

Nicely presented. As a non-machinist, I was able to understand you and appreciate both your explanation and the fine job you did with old machinery making what appears to be a very serviceable bevel gear. Good Job!

[@rodneykiemele4721]

Excellent video, Keith. Thanks for taking the time and showing it.

[@mdouglaswray]

Beautiful video work too. Seeing the profile of the gears appearing was pretty hawesome.

[@kris4362]

Keith, sir, you have my admiration. Thank you 👍👍👍👍👍👍👍

[@larrysperling8801]

very interesting video. great camera shots. thanks keith

[@SunnnyDay]

An intense segment, well done !!

[@CarlinComm]

Wow, every time I thought, ok, not too bad, then you'd add the next part to the plan. Good to be very methodical! I liked how you explained, or didn't explain! The spreadsheet! Well Done.

[@charlieromeo7663]

Very well done Keith, thanks for posting

[@Hvtesla]

I suppose the next learning step is to make a rear axle for a car (both crown AND pinion)? - OK maybe not. But makes you appreciate the minds who worked all this out - with no computers, only slide rules and log tables!

[@garthbutton699]

Thanks for letting us to look over sholder,you explained the process very well and made the operation understandable....but way above my pay grade.🤗🤗

[@edwardkawecki8101]

Nice job and excellent explanation! And as the saying goes the parts just need to get used to each other. Thanks for all the videos.

[@karroome]

Now I am convenced I NEED the handbook👍👍👍👍

[@joelherzel1599]

Keith, I think that was your best video ever! Learned a lot, as did you apparently. Thanks.

[@csnelling4]

Nice one Keith , a bit of head scratching there mate, well done👏👏👏👍🇬🇧

[@2tana22]

That was great, your quite the teacher, I’m learning more and more through your channel

[@altonwhipkey2411]

Good Job Keith, Learning as you go, That's Great!

[@MrPatdeeee]

Our Mr Keith always keeps us interested in the "Gems" he does. Mighty fine man indeed.

[@stevestrohacker8436]

Thank you my friend. I've been intimidated by cutting gears and didn't have tooling needed to cut them so no need to learn. After watching your process, your studying, your abilities I would entertain cutting a gear now. Still no guarantee it would be right but I'd try it with more confidence than I had. Hope that makes sense Keith. Thank you for enlightening me.

[@Tf9500]

You made that look easy, I would have screwed it up at the point when you took the backlash out of the head. Great video. Definitely learned a lot

[@mikecabe6127]

Very tricky but you did a great job........well done!!!

[@elcheapo5302]

There's a lot more to bevel gears than I'd ever thought. Thanks, Keith!

[@11LowDown11]

Appears the spacers (left of cutter) ID could be a scoche oversize creating a ‘wobble effect’. Just speculative! But for all I know it could be bent like a banana! Enjoy your videos and thanks sharing them!

[@bigtrev8xl]

Seriously impressive work Keith..

[@DavidSmith-ib5jl]

I need to cut 6 pinions for my new Shay project and this video should be of great help. Thanks Keith!

[@srfurley]

Keith, I’ve only ever cut spur gears, both involute and a different tooth form for clocks, and haven’t touched any machine tool since 1990 when I moved to a new workplace and lost access to workshops. Interesting to compare the cutting of this bevel gear to the helical gear which you did more recently. The helical gear was quite simple; it took a lot of time and different videos, but most of that work was in finding or making missing, broken or incorrect parts. There was also the need to use the universal head due to the large helix angle of that gear. Now you have everything set up cutting another helical gear would be a fairly simple matter. The bevel gear is more complicated to set up. I then thought about whether it would be possible to combine the two techniques to cut a spiral bevel gear on a horizontal mill without needing a specialised machine. Looked on KZbin and there’s a video of somebody doing it; looks like they’re using a fly cutter. Amazing what you can get a horizontal milling machine to do. Have noticed that both of your dividing heads have two handles, the one with the plunger pin to fit the holes in the index plate and a plain handle. Obviously you couldn’t turn the plain handle while the pin was engaged in the plate, and it would be difficult to hold the pin out with one hand while turning the plain handle with the other. Is it possible to lock the pin back while turning the plain handle? This would seem like a good idea but I’ve never seen it on any devising head that I have used. Can either of your dividing heads do differential indexing? Might be useful on the k type with it’s 5:1 ratio where you might need to turn the handle by a small amount to index a large number of divisions. I had never heard of K&T until I watched your videos. Do you have a copy of one of their catalogues showing all of the various attachments they made? If you do it would be interesting to see a scan of it. Best wishes.

[@nigelspender4931]

Really enjoyed this video. Thank you for your time. Really easy to listen to. Like you I've cut a good few spurs but no bevel. Great to see. Thank you.

[@ronwhite6719]

Great tutorial and great hands on step-by-step. Thank you. Great videos Keith.