This is the third part in the series on the gear cutting attachment for the Elliott 10M shaper. In this part I configure the shaper to cut a 20 tooth, 12DP spur gear and cut the gear.
I am an another 10M shaper owner. I really appreciate your work! I know that it's beyond my "math anxiety" (an American, which I'm not, which I describes very well my reaction to seeing calculations!). I haven't tried it yet, but the two posts and wire drive is also an amazing shaper application. Thank you for this great video! All the best, Matthew.
Excellent video. I finally understand how it all works 🥳 I can now also really appreciate the effort you had to go through to cut me the custom 12.27 DP 22T and 74T gear to replace the broken helical gears. Thanks again for that, the old Warco lathe would have never ran again with all the speed ranges without your help!
This is the coolest setup I've ever seen. Just watching it work away is therapeutic - a marvel of engineering, tooling and geometry. The over hang on the clapper box tool hold down would bother me but that is a work of art.
Thank you! I agree the tool stick out is a bit much but is needed for clearance. However, I have an extended toolholder that I'll try and use for the next video which should increase rigidity.
Fantastic series, we have a similar system where a Bridgeport slotting head is mounted on the Z of a CNC mill, stroke in the x axis, the rotary axis holds the blank. It will cut any pitch and any helix angle gear you want, we make our cutters the same way, but with a surface grinder and a jig to achieve the angle. recently we provided a 17dp helical gear for a 1920's Fay and Bowman T head engine oil pump drive. Kudos on the math, at least here in the states the concept of pitch diameter seems to be elusive.
Thanks for watching! Thats the beauty of a setup like this, not being tied to standard DPs or modules. As for helical gears, thats coming in the next video!
@@ThePottingShedWorkshopAnd the tooling is very economical vs hobs or even single milling cutters! I found a short video of the slotting head cutting a rack, I'll see if I can figure out how to send it to you
Thank you! I made the video in the first place as, having worked out how to make this attachment, I thought I'd share the knowledge. So, thanks for helping to publicise it.
This is a fascinating series to watch. It's a long process and I wondered how long it actually took to produce the gear in total. And I mean from the start of cutting the gear on the shaper, not making the blank as well. I'd imagine it was at least two hours the machine was running, if not more. Now I can understand why machinists say it was far quicker on the horizontal milling machine running a multi toothed involute cutter. You could do that in one pass per tooth in a production setting especially if the gear was aluminium. In steel you'd probably have to do it in two passes, but that's one or two passes under the cutter, whereas god knows how many strokes of the shaper ram there was per tooth multiplied by the number of teeth. The industry bean counters must have been in ecstasy when the involute cutters came in for the horizontal mills lol. That said the shaper is a very cool machine and can do some excellent work. I've watched Abom79 and Steve summers do some really cool and interesting projects on their shapers. I've only just found your channel and have subscribed after first video of this series. Now I will binge watch your videos!
Thank you for watching! Yes, it is a long process. Each pass takes approx 2 minutes per tooth, 11 teeth and 5 passes per tooth to get to depth and you're not far off 2 hours. That assumes you can concentrate for that long (I showed you the results of a loss of concentration! 🤣). For spur gears in steel the process can be speeded up by gashing the teeth with a slitting saw (or an involute cutter that leaves material to be removed) followed by final machining on the shaper. The big advantage of the shaper is the DIY tooling. Of course in industry a hobbing machine is even quicker than involute cutters. I still watch Steve Summers but stopped watching Abom79 after it degenerated into either promoting products or trying to learn CNC. Thanks for subscribing and watching!
Thank you! I don't think I'll take up your suggestion though as I'd never make any money from it🤣. It's far too slow, but it is cheap tooling in a home workshop.
@@ThePottingShedWorkshop The speed is just a matter of percpective. It is much faster than you think. Have you tried to ask a machine shop to make a gear? They would say ohh my friend…. come back two week later, because we are doing a serial job. When you go back to the shop they say ok, we can do it. Come back for the gear a week later. Unfortunately that is the thruth. So, your solution is pretty fast.👍👍😊
only just found you,, what a setup!( subscribed) i own an Victoria milling machine and have the dividing head assembly but not the banjo and gears so i was really glad to see your set up. what country are you in ,, England?? great vid and now i have to look at your previous ones!!!
I got lucky when I bought my universal dividing head in that it came in almost unused condition in its original shipping crate, with all the accessories that it would have been supplied with. Gears and banjo, tailstock, machine jack, dividing plates, dead centre on an ISO40 taper arbor with drive dog for driving the work. It wasn't cheap though.
Rust: Try setting up a commercial gear hobbing machine with mechanical indexing gear box. One needs a boxful of gears to cover every tooth count. A friend of mine and I designed and built an electronic gearbox to take the out tedium of gear changes for every tooth count. For one-offs the gear changing was enough to drive you to drink:-))
