Building a Gear Shaper (Part 2) 

"It's just an 8 bit controller, programmed in assembly language" I love how you make that sound so easy 😂

You programmed a microcontroller for several axes and added a GUI… in assembly! Andy, your machines and your videos are the cream of the crop on RU-vid. Thank you so much for sharing with us. I appreciate the multi part videos because it means I can more frequently learn from your adventures. Cheers! 🤘

Beautiful work. For a couple of years now, I've fantasized about projects requiring ring gears. You've shown us how it's done, so all I have to do is get to work. Some more information on how your cutters are made could be very helpful.

You have got to be the most talented versatile person on the Internet. I enjoy watching your videos. How did you learn all these different disciplines? Computers, electrical engineering, programming, machining, mathematics and so on?

Thank you Andy for sharing your excellent video, and description. You are very clever and kind for passing on your knowledge to others.

Great project. We shared this video on our homemade tools forum this week 😎

A fantastic project as ever. I love how it evolved and the thought processes behind each change.

These animations are incredible. Many thanks for your time and the information.

I've been thinking about doing EXACTLY this for a long time. I will DEFINITELY BE BUILDING THIS. Thank you for reading my mind.

I'm glad you know about backing off the cutter... I was told the gear shapers I used backed off 0.050". We also had the gears cut at least 2 passes (rotations of the blank), the second pass mostly being a "spring pass" that improved tolerances and surface finish.

You are a genius man

Well done. It’s amazing the number of skills it takes to do these operations e.g. machinist, electrician, programmer, etc.

Fantastic,. My only thought with the flexing of the rotary table is maybe don't cut at full depth for the first complete rotation. Take most of the material off then, do a secondary cut and final tooth depth. This will double the process time, but may give a cleaner finished product. Very excited to see this in action, as very envious of your achievements. Keep up your great work work and Hello from little New Zealand

The man's a wizard!

Wow that is amazing. I can’t wait to see it used for real in another project.

Brilliant, Andy. Just brilliant. I am fascinated by your ingenuity.

Awesome AndysMachines, thanks for sharing!

Thank you for your effort I truly enjoyed watching your skills at work please keep sharing and God Bless

Very impressive, Thank you. Lee

bravo anzi bravissimo sia nella teoria e nella pratica e nelle spiegazioni.Ti seguo sempre nei tuoi video e cerco di produrre le tue apparecchiature grazie e un caloroso saluto.

Congratulations! You are fantastic! Please make more videos. It is like the best school for me. Thank you.

Fascinating 👍👍😎👍👍 Thanks for sharing

Fascinating Thanks for sharing Cheers

It would be incredibly interesting if you could do a video on how you built and programmed the controller.

This is very clever, nicely done. I learned to run manual gear shapers a few years ago-Drummond maxicut and Lorenz. Purely mechanical, quite complex to set up but fascinating. The lorenz's were particularly good, dated from the mid 40's and still ran perfectly. They had a pull back mechanism for the return stroke, it is quite important to stop the cutter dulling. I would highly recommend adding the pull out in the y axis. Also means you don't need to worry about stopping the rotation. Perhaps you could get easier programming if you left the spindles turning constantly, and had a separate pull out system running independently? Sorry to be an internet know all, but maybe it'll be useful

Great show! Sure you will figure out the bugs. Thanks for the look and your time.

Amazing work 👍

Outstanding and inspiring.

Impressive, as always!! Thanks for sharing!

As always Andy, very impressive 👍

Brilliant!

So cool! Wow. Inspiring.

really very impressive!

Beautiful work.

Fantastic work, at a level I could only dream of. Very well explained in the way you described each step logically.

He's a wizard Harry

Amazing work once again, definitely my favourite engineering channel 👍

Wow great video

Great work! Love the idea and your skills…

It's just an 8bit uC programmed in assembly 😅 More like black wizardry

nice work

very interesting

I greatly appreciate your videos

That is freaking awesome

I’m in awe. You have inspired me to try something similar. Maybe with a lathe? Replace the compound slide…

10 lines of gcode is too much, let's do 2k lines of assembly instead 😂 You're our hero

Impressive! Wow!

Very well done indeed.

Fantástico!!!! Como sempre você trás os melhores vídeos em Mecânica

good job andy

You are a genius!!!

Fantastic!!!!!

Programmed in Assembly Language 😅 Mad respect!

Incrível! Obrigado por compartilhar seu conhecimento, muito bom mesmo!👍

An nice to see you back again in Part2D2. :)

Excellent work!I agree on the stroke aswell. The longer stroke on the quil eventually leads to less rigidity anyways.Its common to see wear on gear shaper quil and a mill quil technicall not engineered to do what you do, needs to be taken care of. Im addited to this guys content.Thank you for such valuable working experiments!

love your content thanks

you are my master !!!

That's amazing ❤❤❤

I think that your assumption (at 10:34) that the profiles should match is incorrect. This would help to explain the tight fit of the gears. However, this is an impressive project. Thanks for taking us along.

impressive!

Master!!!

Grandios! 👍👍👍

My intro to gear cutting was on This Old Tony's channel, and boy have you taken it to a whole other dimension. Really glad YT suggested your vids to me. Different approaches are based on a needs must basis I'm guessing. Now that you have the gear shaper, are you likely to retire the hobbing approach or are there scenarios where that is more efficient?

Impressive..

You can make the Gcode more generic by adding parameters. #50=outer ring and #51 = cutter tooth count #52=ratio #53 = radial move. So in this case you would add the four lines #50=31 (outer ring tooth count), #51=8 (cutter tooth count), #52=[#50/#51] (ratio) and then #53 = 9.25 (radial move). Put these lines before G0 Y0.0 . Then in the line where it has the comment (cut full circumference) you replace x1395 with x[360 * #52] and the Y move becomes G01 Y#54 F3..... This saves you calculating the ratio each time and so is less error prone and makes it easier to copy the code and just make a simple modification to the two main parameters (three if you change the cutter) for different tooth counts. You can also add a pause into the program that asks if the tooth count is correct if wanted. This parameterisation is a useful technique for simple home written code that is required to do the same job but with slightly different numbers and where you don't want to work through the code trying to figure what needs changing each time it changes. You can also add feed rate parameters to suit different materials if required. Something you could consider is adding a parameter calculation that calculates the radial move that brings the cutter up to the workpiece for the first actual cut and put a G0 Y move in before the G01 Y move starts the cutting process. Probably not important for small tooth counts but maybe for large ones it would help and because it is a calculation done in the code it only needs to be worked out once. What about calculating the radial move in the program as well? You could come up with generic code for inside gears, outside gears, module or DP gears and different cutters. The only problem I have with the Gcode in Mach3 is that is does not allow the use of IF branching. What this means is that you need a generic program for inside module, then one for outside module, one for inside DP and one for outside DP. Still only 4 generic programs for all you need, unless you start doing helical cutting as well but that would need more synchronisation. . . G71 G91.1 #50 = 31 (outer ring tooth count) #51 = 8 (cutter tooth count) #52 = [#50/#51] #53 = 9.25 (cutter radial move) G0 Y0.0 . . . . G01 Y#53 F3 (feed cutter outwards radially, chip load 0.02) G01 A360.0 X[360*#52] F130 (cut full circumference) . .

really nice work! I wonder if you can also lock the rotary axiis during the cutting stroke, and the other axxis as well.

From my point of view, gear shaping is the best application for flexible home gear production. Personally, I wouldn't make a external gear to gauge the tooth thickness . I would attach the desired balls to a telescopic/snap gauges to measure the OBD. For the correction of the OBD an adjustment block would be beneficial. (just my humble opnionion)

Doesn't the linkage for the vertical stroke only have one length ? An arm with multiple attachment points to change the vertical stroke length ? Enjoying the build, btw.

You make it look simple, while dropping casual bombs "it's just an 8 bit microcontroller written assembly N.B.D." With something like this could you make a strain wave gearbox?

👍👍👍Beautiful (electronic and mecanic)👍👍👍 On Atmega 328p, you use Arduino programing?

That's a hell of a build! I was going to make some arguments for going to LinuxCNC, but I can't think of a kinematics style that would work with your setup. Maybe issuing a feed hold anytime the quill is not in its "safe" state. Did you write all the motion control yourself or are you using some libraries? For the ATMegas, AccelStepper is really handy.

Thanks for the video. Why does the cutter need to rotate?

i like the gear videos; is it possible to make a bevel gear with the slitting saw method?

Would this machine work for bevelled gears, I think it would if you could mount the rotary table at an angle? Also helical gears would be possible as well I think but the code would be a bit more complicated for that i think

That steel internal looked like you just need a new cutter and then a stack of bank deposit slips. ;) Maybe a look inside the rotary table.

The cutter for internal and external gears is the same? Same tooth shape?

Очень хорошо😃👍

I mean, it was impressive, but any code you wrote for the controller to generate gcode you could have written on your connected PC to generate it too. Do you find going to the effort of making dedicated hardware control boxes like this worth it? edit: I should say, "because I preferred it" is of course absolutely a very valid answer if that is the answer!

so cool to watch! wouldn't it be easiest to mount an encoder to the up-down linkage? then you'd know the position of the cutter at all times. I must admit that I have no idea on cost for 'hobby' equipment nor any clue on the processing capabilities of such a microcontroller.

Folks this was not done by just any skilled individual - it had to be done by an extraterrestrial life form.

Could you not store those feed rates in macro variables and call those in the middle of your code, then just change the macro variable to update the whole program at once?

great !!!, when will you be taking orders for 65-T 32-DP 20-PA internal ring gears for nine-cylinder radial model engines ? :-) !!!

Ok ok ok great! I actually just asked this quesiton over at the Terminator reddit, could theoretically, the T600 or T800 actually work. Or was it more of them just placing things on a skeleton that looked like it would work. I guess we get to test that with your work!?! I was thinking one would want to test the theories on CGI first, as there might be major reworks needed, and or considering we have come a long way in most these technologies, a redesign would be in order to make things work more smoothly.

Does derilin plastic smell fishy when it's cut? I have an odd piece at work that seems the same that's a bit stinky when drilled or sawn.

do a"rough" cut first leaving .010 then the finish cut....

Honestly I find this so intresting but I'm like a old black Barry phone or erlyer model trying to be a new IPhone my brain just isent smart enough .you sure are way to smart to play with gears your so intelligent I hope you make millions .I'm just amazed even never even working with macheanist wow .I'm like way back in iron age welding and using torches and plasma cutter macheanist are so dam smart

If i was doing this, I'd need a black box to record the data for the catastrophic crash that would inevitably happen.. love your work but this is over my head

Seeing all the cutting oil leads me to think that this could also do gear EDM if you made the stroke (or something) current controlled...

yet another machine "I need"....., 🙂need to fix the slop of my x-axis which causes similar flex on the rotary table.

Is that windows xp, on the Mach 3 pc? I mean, if it works, it works. But, damn that's pretty old.

why assembly?

I wish I was a fraction of this intelligent...

Mr. Pete (TubalCain) latest build is an Atlas Lathe gear cutting attachment. It's less sophisticated and works entirely on a lathe. It might inspire your design. ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-ZXdk_MSTp04.html

👏👏👏👏👏👏👏😍