4 minutes in and I’m already blown away by your intense, excellent production values. I was a professional video editor back in my youth. I know of which I speak. Well done! It’s not necessary for every machinist to aspire to this level of quality, but it’s a joy to watch. Thanks for sharing.
That took me back.... the number of helical gears and shafts I made during my trade. Loved seeing it again. A dying trade with NC and CNC. Great to see thank you for showing this
Very impressive and detailed video. Very easy to understand. Please make Video Showing Step by Step procedure on how to Cut Spiral or Helical Bevel Gear on Milling Machine. Please include also your computation.
"Thanks for watching"...we should be the ones thanking you.takes so much time to complete the set up,& then the job.& then the video itself.quite inspiring.
It just amazes me that this guy took his time to meticulously put together this video yet you have 96 haters. Guy thank you so much for putting this together, I learned more than a few things today. THANK YOU
Entirely fascinating. The "skiving" marks on the involute teeth are interesting and I'd be curious to hear your thoughts on why they would not contribute to noise or dangerous wear in a working gear set, and what the dynamic is that contributes to them. Your cutter seems to have no detectable run-out and your change gears seem to roll smooth. I'd also be interested to hear your estimation of what AGMA rating a gear like this might have. I converted a Bridgeport turret mill to four-axis servo control in 2001 and subsequently built a servo-driven shaper machine in 2002 - both for cutting straight splines. They were in profitable service for years. I have always wanted to try to cut helical gears with the milling machine, but lacking an encoder on the mill spindle, knew I couldn't use a hob instead of a single form cutter. Our current project is the conversion of a 1950's Gould-Eberhardt vertical gear hobbing machine to servo control, using a Galil controller and two Yaskawa servos - one for down feed (not timing-critical) and the other to the rotary table worm (timing-critical, to an encoder on the hob shaft). Very excited to see it run. Whatever the case, your techniques here are outstanding and the video is beautifully shot / edited.
Thank you very much, Eric. The feed marks are due to the cutting process and professional made gears have them, too. These marks have no influence on noise or vibrations as literature states.
What an Exceptional job you've done there. Always dreamed of making a machine like this, Now I've seen you do it, I think I'll be seeing you for a set of gears if I need a set.
Great job figuring this one out. I had planned to do this in my own shop eventually. The only advice I could give, is leave the cutter running when you back up. It would have left much cleaner tooth faces. Also, climb milling in steel is very risky. It looked like you had enough room, to conventional mill on both gears. Much safer way to do it. Again... Good job!
How would you account for the backlash. I have used climb milling successfully many times to produce very long slender parts and very long thin parts where there was nowhere or way to clamp them only the force of the cutter holding them down. Like an airfoil shape out of high temp material 10mm thick 30wide 300+ long. First in a rectangular pocket that only exposed half of the thickness using a form cutter in a horizontal machine running the cutter over the part then filling the pocket partially with devcon forcing the part down into the devcon as perfectly as possible assuring flatness and alignment to the airfoil shape then repeating the process. The end of the pocket was the only stop and the pressure of the cutter holding the part in the pocket. You would think it would catch at the other end but it never did some say God protects drunks and stupid people I say that because I'm very aware that it should have could have if it would have grabbed the part and sent stuff flying like I say it never did and I never touched it I just stood there and held my breath, I must have made 20 ft of this material by this process.
the ominous music makes this feel like a strange horror movie with jump scares. im just waiting for a hideous goblin creature to jump out and make a wretched noise the whole time.
I just bought a universal milling machine and I'm still trying to teach myself how to use it. Your MUSICCC is very INTIMIDATING and I started to doubt myself :(
Die ganze Mühe die Ihr euch gemacht habt, nur um uns allen das verständlich darzustellen... Vielen Dank, das Video ist sehr nachvollziehbar! Grüße von der HS Osna
From an ordinary human (me) who was not blessed like you with infinite patience, incredible precision, and the true mindset of a maker that makes all this possible ... my respects, my admiration, your work is truly incredible, I saw the video Complete 2 times and ...I envy your skill. wonderful work Sr.
Great video. Thanks! I’m subscribed and looking forward to watching more of your videos. One comment though, leave more time for viewers to read the written text, before continuing.
Hopefully and finally I found what I was looking for,,, pretty awesome thanks for teaching us I will always be tuned for all new lessons. Thanks for sharing.
I know why you're making them in Module 2.5. Because *nobody* makes MOD 2.5 gears as stock gears. They had a period of popularity in the late 1970's through the 80's then the entire machine tool industry decided nobody was going to use MOD 2.5 gears on anything. The cutters are still available used, or new by special order. But if you have a broken MOD 2.5 gear you have to make it yourself. The exact same thing happened with 14 Diametral Pitch gears after WW2. Many smaller lathes and other machine tools used 14 DP gears, mostly in 14.5 degree Pressure Angle. But shortly after the war the whole industry decided nobody was going to use 14 DP gears. There is one company in the UK which claims to have stock 14 DP gears, but only in 20 degree PA. 20 PA was uncommon in the 1940's and earlier when most spur gears were cut to 14.5 PA. So if you need to replace gears of this pitch and these pressure angles, it's a DIY job. What makes this even more annoying is that 2.5 MOD's tooth size and profile is >thisclose< to 14 DP 14.5 PA. The machinery industry recognized a need for gears with that size tooth but instead of resurrecting 14 DP they created 2.5 MOD, only to have the size exterminated a second time. A similar tale is how the variable speed drive industry apparently unanimously decided some time in the late 90's that for 3 Horsepower motors they'd all quit using a single keyed shaft on the spring loaded split sheave on the motor and switch to a splined shaft. So if you need parts for an older single key sheave you have to make them yourself, or figure out how to retrofit the motor sheave to a splined version. I have an ACRA knee mill from 1990 and had to make the plastic bushings for the split sheave when the nylon originals broke.
although this is great machining, the drive system for the dividing head can just use a stepper motor and a controller to change any size gear you need
I must be missing the reason why the rotary chuck dividing plate is turning back wards ,would it not have to stay at the same position so that the next count for the amount of turns can be done for the next rotation for the next gear tooth. As very interested due to I have my rotary table chuck set up with a Arduino and stepper motor which allows me to get the right amount of turns every time , i also am using the free program called Gearotic which allows one to get the math done for you just by adding the numbers very handy for a dumby like me.
Very impressive skillset indeed. Are you going to make a new fifth gear ratio? I can imagine there is a huge demand in the car mod industry for your technique. Very impressive indeed.
Spoken commentary would make this a truly excellent video. I don't care if you speak with an accent. There is a lot of information to be unpacked from just watching and the music had to be muted. Someone telling me what they were doing and why would also have helped. I have copied a link to my library for future reference. Thank you. richtig schön und danke
In a mass production environment, cutting one tooth after another is way too slow. The process is called gear hobbing: ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-0rnTh6c19HM.html but you can image that alone the cutter costs a fortune ... but the method shown here can be done with simple machines.
A dedicated hobbing machine is like a screw maker. It's meant to spit out thousands a day. This is for the guy making custom transmission gears and the like.
awesome! looking at the geometry it appears that a longer helical gear could be cut with this setup, and then sliced into multiple copies afterwards, kind of like buying pinion wire, thoughts ? also you didn't show retracting the cutter while backing it up to return for the next tooth, but I suspect there's enough backlash in the drive to warrant doing so, thoughts ?
I absolutely loved your work. I am an aspiring mechanical engineer and this was very interesting. Could you please recommend some books so I can understand more in depth?
I can see that gears come out very nice but seem to still have steps. Is there a way to improve it or how bad it is on higher load applications like car differential etc. Wouldn't it make howling noises at higher rpm?
The topic is interesting. Narration would've been better than text displayed in a video. And the music makes me feel like I'm watching a video from Dark5.
Well done! Have you thought about using a 4 axis mill to shape helical gears by scraping/shaping? Yes, it would be slow compared to a dedicated machine tool like a fellows, but very handy for one-off prototypes.
I want to try something similiar with module 1 gear cutters on my vertical mill. But using steppermotors instead. Ideally I'd keep the 90 degree tramming of the head as well, but that will complicate things a lot.
No puedo expresar en ingles lo intersante de este video ya que no domino muy bien el idioma ingles pero es importa y me gusta este arte, esta profesion y todo los conocimiento que hay en esteoficio . Me gustaria conocer mas sobre algunas informacio que es de gran utilida para el uso de esta profesion .
Guten Tag, woher haben Sie die Modulfräser, wenn ich fragen darf? Sind das die chinesischen, die man auf ebay, banggood etc. Bekommt? Falls ja, halten die länger durch?
In my opinion the whole video could of used more machine shop sounds ie. Grinding, milling, bitching at the bandsaw guy for not cutting straight.. and less of the Xfiles themed music where I feel like I was being abducted the whole time amd about to get probed, but on the plus side of things.. Great video. Enjoyed the whole process and seeing your skill level. It was interesting to watch. Thanks for sharing.. 😎
Hai I am a beginner for gear cutting . I have a Grizzly milling machine go755. Can you do a video how to attach the universal dividing head to milling machine. Please it will help for all of us..
I watched the whole video and it's amazing to see your creativity doing the mechanism for the spining table(makes me wish and want to build one in imperial measurements) Professor would you recommend me the same type of book in english?( Estudie en español elementos de maquinas,pero en ingles es un universo mas facil de alcanzar)my humble congratulations for your engineering creations, my best regards!!!
Thank you very much for your kind comments! However, I can't give you recommendations upon books in English, please consult Amazon and book stores with Internet representation.
@@prof-riegas i understand the difference with spur gear cutting is the work will rotate constantly to the the helix featured teeth. to accomplish that there is an extra setup that make the dividing plate to rotate which in turn rotate the work. so how do you make that setup? is that pre built from the company or you just created it??
Same tools (cutters) for spur and helical gears? Only helical is cutting under angle. But then parallel cross-section is not equal on spur and helical gears (because of that 20.7° or 29.4°rotation of the profile). I thought they should be equal.
Yes, indeed, sane cutrers for both spur and helical gears. In fact, with increasing helix angle an very small error arises but this is tolerable up to helix angles under 30 degrees. Hope that answers your question.
Not a video to watch when your tired, LOL. I have cut a few Spur Gears but not any Helical Gears. Never really had the need to as yet ?? Interesting video to watch for sure
I watch the video till the end... (at least untill my phone giving low bat notification) Not knowing anything But I watched it anyway Was it because I watched something spining? Or the BGM...? Or both
@@prof-rieg seems to be a very good machine ! have u ever heard that there is a manufacturer in lithuania wich actualy makes the castings fro mr. prechtl ( golmatic seller ) have u perhaps ever seen one for these lithuanian machines aswell ? i am interested if those from lithuania have the same good finish on them
Now you know why you want to avoid having to cut a gear like this if there is any alternative available. A gear cutting shop (if you can find one) is your friend. It is also a reminder if you have any machine tools with helical gears you must take very good care of them. Breaking a couple of teeth off is a first class disaster.
In the shop I worked at for most of my machining time gear cutting training was replicating the years in the shops hear driven !achines. Always thought that was quite clever of the bosses.
Indeed, that is a very complicated manufacturing process. One needs a relieving lathe for the gaps between the cutting teeth either and for cutting the relief angle. Please refer to the according literature upon machine cutting tools.
The cross slide is fixed upon the helix angle. The helical movement is made by an independant electric motor which turns the dividing head and the spindle of the cross slide for forward movement . Hope that helps.
@@mikemakuh5319 yes, that works if you can turn the milling table around the Z axis. My machine and most modern hobby milling machined do not have this feature.
These gears were made from aluminium alloy. Such gears made from steel should work, especially if they are hardened and temperes after mechanical treatment.
1 rev of the Work piece x Index Head Ratio (usually 40) x A/B x B/C = GearHelixLead / PitchoftheFeedScrew 1 x 40 x A/B x C/D = Lead/ScrewPitch A,B,C and D are your Gear Teeth Numbers.
Bien sûr, vous êtes les bienvenus ! Le diamètre extérieur est de 77 mm, la largeur de l'engrenage est de 30 mm, le module est de 2,5 mm et le L'angle d'hélice est de 29,4°. L'engrenage monte vers la droite. De la Le diamètre intérieur est de 22 mm, la largeur de la clé est de 6 mm. De nombreux Salutations.
@@prof-rieg Great video! Thanks for making it. I'll probably never make a helical gear, but I like knowing that I could do it if I have to. Of course I'd need to rewatch this video a few times just to get started. I agree about the music, though. I would have loved to hear any audio you had from the machining, but silence was better than the music.
