Repairing a Broken Gear Tooth Part 1 - Milling a Dovetail Slot on a Horizontal Milling Machine
Vložit
- čas přidán 8. 09. 2024
- The process I used to repair a broken gear tooth. Includes making a holding fixture, turning a custom tool holding arbor, and milling a dovetail slot on a horizontal milling machine.
Music License for Intro/Outro Music - "Better and Better", by Joel Hunger:
I'm Joel Hunger, as an author of 'Better and Better'
www.melodyloops.com/tracks/better-and-better/, grants Melody Loops and its licensees, including Keith Rucker owing CZcams channel Keith Rucker, permission to use this Music.
This Music may be used in commercial and personal projects and in monetized videos (such as CZcams or Vimeo) without paying additional fees or royalties to author. The Music must be used in accordance with the Melody Loops End User License Agreement
www.melodyloops...
License #: 42949643994
CONFIRMATION SUMMARY
Here are a few details of this Grant and Permission:
It is conditional upon full receipt of payment; The Music may be used in various multimedia applications including as video games, educational software, powerpoint and keynote presentations, television advertisements, radio spots, documentaries, institutional and corporate advertising, hold on, jingles, websites, flashes, banners; The Music may be modified but may not resold or redistributed outright by licensees of Melody Loops, although it may be included as part of a production; and The Music is being licensed not sold. 'Melody Loops' referred to above means Melody Loops Inc., operators of www.melodyloops.com (the 'Site').
Joel Hunger
2014-11-27
I spent 35 years as a machinist I always found the greatest pride came from just finding a way to get it done right. Making your own fixtures and tools is the best part and often the only way.
I just like the fact that there are people out there who see more than scrap metal when they find an old machine that's so rough and rusty. Its definitely not easy, or just a little work to get it going again, lots of work went into this for sure.
Thank you - I just love to bring pieces like this back from the dead and give them new life!
compactc9 up lore
Hi Keith,
Love hearing that train whistle!!!!!!!
Thank you for the video.
George
May I apologise for some of us viewers who think we know better. We haven’t done it or videoed it as you did and am thinking not qualified to judge your workmanship. Pls keep it coming
Love the way you do it. When I worked in the Oldsmobile factory, decades ago, I saw the skilled-tradesmen repair a broken tooth like that. But they did it by welding onto the broken tooth, and then machining the weld into the shape of the tooth.
I love watching these videos of old manual machines. I am a cnc machinist/programmer and I am often humbled by the amount of skill and patience it takes to do a job like this. Thanks Keith, keep up the good work!
i watched it about 2 years ago and still watching it,,,love these videos
excellent...
Thank you sir!
Keith Rucker - VintageMachinery.org
your more than welcome
Keith, I'm blown away by your talent. Amazing!
+Glenn Martin Thanks for the kind words Glenn!
Didn't even have to finish the video to realize I have to subscribe . Your an artist that I can learn to utilize every tool I have at my disposal .
I'm new to machining, going to school and learning. Your videos are so very helpful in opening my mind to "thinking outside the box" the experience and knowledge you share are invaluable. Some of the set ups you use are extremely simple yet I would never think of something like that, and it makes me feel dim. These things weren't come up with over night, they are tried and tested methods that have been passed down. I'm just at the bottom of the mountain looking up.... So much to learn. Thanks for your videos Keith.
Thanks Brandon. The main way to learn is to get out in the shop and just start doing things. Try things out and don't be afraid of making a mistake. Experience is a great teacher! But always try to learn from those who have already been taught some of the really tough lessons. And work around as many different machinist as you can - they will all do things differently and you can learn from each and every one of them!
You're a true artist and I loved seeing you at work. Thanks for the great video. I'm off to see part two!
Outstanding job. It utilizes everything a true machinist should be able to do, from problem solving and invention to executing the actual production of the piece. A dying breed we are, a true shame, I fear for the future when know one knows how to fix or build anything. Great video.
No, I have a real job that pays the bills - the museum is where I go to have fun! I worked there 20 years ago when I was a student in college as a part time job to help pay for school and loved it so much that when I got out of school, I just continued to volunteer. I learned most of my machine shop skills when I worked as a machinist for several years before I went to college while I was saving up money to go. I love to make, build, and fix things, and the museum gives me that outlet!
Great job keith.I learned alot from you.I remember making a gear for a debarker machine for a sawmill out of T-100 plate.We used a new one as a template,free hand cut out teeth with a acetylene torch and finish with bluing and a grinder to fine fit.lol.Then bored out for a 3 inch shaft for mounting.It was an idler gear and we didnt want to mismatch a new idler with old worn gears without replacing them all as a set.It lasted for a few months before teeth started to crack and sometimes break.Then a single tooth was cut and re welded in.Just a funny story of what we can do to keep old machines running.Thanks for the vid.
Amazing job, it brings to mind that old saying , Where there is a will there is a way !
I Love how you take the Time to make the Tools to do the Job. I World Not have thougth, that this much effort wents into the preperation of such a Job. Thank you for the Video.
If it were me I would have replaced the bushings first, and then made my fixture to fit the right sized bushing. That way if you ever needed to do work on it again you could, and if you needed to use it on a slightly worn gear you could shim it a bit.
Nice work i miss those old machines.
I like your custom arbor too.
I've never seen an overarm support used to support a cutter like that, bloody ingenious
Always interesting watching a master machinist work. Damage like that would be a real problem for a kid with a CNC mill to repair.
With CNC you would just make a new part....these days you can laser scan the old one. The part is symmetrical so the g code would be easy
Thankyou. Love what you can do and your patience letting us in on your journey.
wow - highskilled machining right here!
Very nice video!
Thanks
Stephan
Wonderful job in explaining the beautiful logic of machining! Thanks so much.
I had a great time here today, and I'll be back for more.
+James Monahan Please do stop back by!
Nice work! Old school. Thank you.
Excellent. Great machining.
I can smell the foundry just looking at that beautiful gear.
Thanks for sharing. I just got a Horizontal Mill and this motivates me!
There is always time for learning something new, Thank you Keith.
Thank you for a very well made and educational video. Your explanations during each step was above and beyond most. The explanation of why and how leads to a better understanding and judgement of application..
Great video! This isn't my trade, but I always enjoy seeing a good craftsman at work!
Excellent setup Keith
I enjoy your videos. I spend way too much time doing electrical and automation this days, and I miss machining sometimes. The problem-solving aspect of your job would make it a very enjoyable one to have. When I thought to myself "Why is he using a 3-jaw chuck? Why isn't he boring the hole for the tool bit?" you turned between centers with a dog and my questions were answered. Very nice.
One thing, though. That tap you were using is a spiral-point tap. You don't need to break the chip. It pushes the chips ahead of it. Since you were threading a through hole you could have put it in the machine and run it right in under power without a tapping head (as long as you can stop it before it hits the far side of the hole, that is...). Turning the tap backwards to break the chip just invites chipping the leading edges of the tap. Buy hey! I understand. Old habits die hard. :) Actually, another thing. You were using dark thread cutting oil as a lubricant on the late (believe me... I could smell the sulphur in my mind) but you used clear thread cutting oil for actual thread cutting. You prefer Tap Magic to sulphurized for hand tapping?
Mike
Great job from a fellow owwm'er. Looking forward to part 2.
Always great to see a metal working machinist do a good job, these skills are being lost.
Hi Keith,, thanks for the great videos, I enjoy watching them and I learn some new techniques. Please keep them coming,
Seems to be a lot of secondary work before completing the primary work. Who would have thunk it. Good work !!
Yes, I was running the same RPM with the dovetail cutter - 250 RPM. I ended up keeping the feed the same throughout the project as well - 1/2" per min. I probably could have pushed the feed up a notch or two, but it was cutting good and I was not in a hurry,
Is it just me but rusty steel becoming clean fresh steel again is just great
This video appeared on my play list. I watched it out of curiosity. I subscribed immediately.All I can say Keith, you sir are an artisan! Keep up the great work and videos!
+James Weber Thanks James - glad that you found the channel and I hope that you enjoy the projects I have going on in the shop!
Thanks, I spend my time with pleasure during watching your video. Perfect video to open mind and think like engineer :)
***** Thank you!
Very interesting. I'm anxious to see how you make the tooth.
Tried to watch this video with my ear buds in cause everyone was asleep, not a good idea, the hammering was about to pop an eardrum. Looks like an awesome project though. Thanks for posting
Nice video & great shape.
Pretty amazing work. Nice job!
Nice machining there.
You can also pin it then build it up using oxygen & acetylene with brazing rods. Takes a lot of heat but very strong repair. Infact the finished weld is stronger than the C.I no issues with the parent metal even near the welds.
Nicely done job.
Awesome, love how you make everything to fit that job too.
great method, wish I'd used it when repairing a broken gear tooth (not cast) I got a weld build up and had a profile of three teeth made and filed with hand file to tooth profile, hard monotonous work.
You certainly appear to know what you're doing. Nice work.
very nice work
Skilful stuff, Keith, compulsive viewing.
That's a cool mill vice!!
excellent video!
thanks for sharing your knowledge with us!!!
“Well Done Sir” As always, thanks’ for taking the time to make this video! ~M~
That was remarkably well done! You area superb machinist. It has been very well thought out as it should have.. Greetings from Arizona.
Wow, so much work that went into this!
+Alan Fox Thanks!
Keith Rucker - VintageMachinery.org The hammering at the beginning was a little annoying but the stream whistles add a wonderful ambience. How close do they get to coming though the shop? :-)
Alan Fox
gorillaau bof g
before I retired, I used to put Dykem on the dull end to remind me.
Impressive! Congratulations and good luck for future projects! Dan.
Fine Work - well done!
Awsome job ! Enjoyed the video !
Great video! If I could recommend a tip for a zero runout tooling arbor for the mill. Leave the cutter hole ID undersized at the lathe. Mount the arbor into the mill spindle and bore it out with a boring bar mounted to the mill's table. That's not nescecary for the big cast gear you had here, but you never know when you might need a more precise setup.
Excellent reminder of how to keep tolerances intent.
Wow,, thumbs up,, perfect video,, i Enjoy every minute,,,
I will either braze or silver solder the tooth in place, I have not decided yet. As to building up with weld and re-cutting it, I did consider that but chose not to go that route for two reasons. First, because of the flange at the back of the gear, it would be hard to cut the tooth because you can not cut all the way through, and second, because it is cast iron and welding to cast is not as strong as steel.
You make awesome videos--thanks!!!
Thank you Alex!
Two thumbs up Keith. Maybe try the Tom Lipton silicone bronze brazing sticks.
The lathe we have out at the museum is a Lodge & Shipley 16" Model X lathe. I have not been able to find a serial number on it to date it but suspect that it was probably built in the late 1940's or early 1950's. The museum acquired it in the early 1980's off of government surplus and it came from the Savannah River Nuclear Plant in SC. It has seen very little use over the years...
Keith Rucker - VintageMachinery.org ... Does that lathe glow in the dark?
I see the best of everything good about the usa in this video.
Using the upper and lower feed wheel feed,the momentum wheels 5 groups,5 groups simultaneously under strong feed and can be variable transmission.
Kool beans learned some stuff today Thank you
I am surprised that Keith didn't press out the badly worn bushings out and make the hold down tool fit the hole in the cast iron.
How far you have come in 8 years! AND you lost weight!
Thank You, I really learned a lot.
Frank Patti Sr.
+Frank Patti sr Thanks for watching!
While I agree that my lathe can take bigger cuts than what I am cutting, my limitation is in some of my tooling, which is quite honestly a bit on the small size for this lathe. Right now, I am taking cuts that I am comfortable with based on my past experience and experiments. I am planning on investing in some larger tooling soon, which should allow me to hog off more material in a single pass.
great work love your channel
+Aaron Dixon Thanks for watching!
great work!!!
Very nice work, but geometrical, both nearby teeth will be much much weaker now. Expeecially from a force on the side of the teeth which faces the replacement tooth. It will pull the tooth out in some time. A better solution would be to smooth all the teeth into a round shaft, and installing a new gear as a bushing using high temparture on the gear and use a press. I bleave the right gear can be found and modified, but it seems this guy have also the skills to creat one.
I liked this.
Amazing repair work, passion and patience ! Congrats !
Man...a lot of extra work with the arbor, etc.....but sometimes it's better to take the long way 'round if you know you get good reliable results every time.
WAOO !
IS Incredible !
+Victor Noghea Thank you!
Nice seeing how much work goes into something like this.
How would this have been fixed back in the days when these machines were in commercial use? Would the same process of dovetailing a new tooth be used or the entire gear wheel replaced with a new casting ?
Very interresting to see, now I know it is called ducktale. :-)
+Mads Thorup Dovetail* not being a smartass just checking you now know
Brilliant !!!!
Interesting job you got there - I don't think there is too much meat left in to the bushing but the soldering maybe will add the strength back again ... or ?
Hi, Really interesting the way you've set about this problem. What are they going to do when they finally run out of skilled Machinists? Regards.
An easy way to tell the difference is the chip it leaves, if is a spiral its steel, if its dust it's cast
Великолепный мастер!!!
You can mark the bad side of a Center Point drill with Finger nail polish (red is good). That would remind you what side is bad
Yeah, I know. I am working on trying something different for the audio on these videos that will hopefully pick up my comments better.
The tooth, to the right of the broken one, as viewed from the top, is bent to the right. By a large amount. I wonder how it’s going to mesh? It was likely bent when the other tooth broke off. You can see where metal was scraped off when the problem occurred.
This is absolutely amazing work. I'm just curious if you considered sand casting another complete gear. I did sand casting in my early years. University foundries are a good place to have specialty items made.
Knott Reel Perhaps time was a factor. In order to cast another gear, you would need to make a pattern to create the sand mold. Metal shrinks when it cools.
Thank you for the video ...what sort of load does a tooth experience and is it shared
Keith, you are doing great work, this mecgine will be a great adition to the colection, my question is about how will the story of the planer matcher be told, live or staticly and will you adress the restoration too
Very impressed with your technique and your expert machining, Your comments are helpful for those who may be unfamiliar with machining. I'm subscribed- keep up the good work! I'd like to know the name and location of that RR museum. Thanks,.
Thanks for the sub - the museum is the Georgia Museum of Agriculture in Tifton, GA
I also learned that in your very next installation! It has a nice website.
you should get more views dude
I have to say the good thing about your video, is it shows how versatile the horizontal milling machine can be. I have one and find it great for removing lots of metal quickly. Also how do you intend to hold the new tooth in ? Brazing ? Did you consider building up the broken tooth with weld and recutting it ?
Just wondering how you aligned the rotation of the gear wheel/broken tooth to the arbor/mill axis. Was it just eyeballed? It is skipped in the video.
Clever idea dovetailing it like that, will it be strong enough do you think ?
i love your work mate but surely welding the tooth would look more authentic and save days of work
Very clever use of the horizontal mill with your improvised extended tool holder Keith. I love the old K&T mills! Next time if you want a cutter arbor to run true, drill undersize, indicate the arbor concentric, then single-point bore the hole. I guess it didn't really matter that you had runout in your extended holder since you got the job done handily. What brand is that stout old vise on your vertical mill? I like the simple reversible v-block jaws.