Building a Gear Shaper
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- čas přidán 28. 10. 2022
- I've tried to make internal gears by a number of methods in the past, but it's never quick, easy or reliable with normal hand or machine tools. The gear shaper is the perfect machine to do this, so I thought I'd have a go at building one.
- Věda a technologie
This has to be one of the best, if not the best diy machine builds I’ve seen on CZcams yet. Your use of the donor mill casting was a great idea. It retains the quill functionality to get your reciprocating motion (shaper motion) and you get the dampening properties of cast iron that all proper commercial machine tools are built from. Most diy machine tool builds I’ve seen are of the “built up” variety, with housings fabricated from steel plate and bolted together or a combination of bolted construction and weldments. The cast iron construction being more rigid and thus more ideal for machining.
Can’t wait for part 2!!
Thanks! The only thing I'm slightly concerned about is that the rack and pinion gears on the quill are not that big and probably not designed for this type of use. That's why I used the shear pin. I'm probably being over cautious though and it will outlast all the use I'll ever need from it.
@@AndysMachines I agree. The rack and pinion gears will probably wear out first (after a LOT of gear cutting). Maybe a bell-crank arrangement at the top of the spindle driven from your new reciprocating arm could drive the spindle up and down directly?
@@chrisarmstrong8198 Good point. Not sure how the bellcrank would be fitted, but I was thinking of a piston. Could you elaborate?
Amazing man, most content creators would have stretched this into a 15 part series. I love the high-level overview that shows the most interesting parts of the process in your style of filming.
funny you said this. I could watch this all day. a 15 part series sounds fantastic :D. Andy always delivers!!! TIA, Greg
Absolutely fantastic! can't wait for part 2! I love that you are re-using/re-purposing old item to make a completely new machine- that in turn makes other parts for other machines- Brilliant!
That moment when you wanted to make internal gears for a while now - and have a spare milling head... Looks like another project for myself down the road.
This is awesome! Thank you for sharing this!
Absolutely amazing work. I love seeing you take crappy chinesium machine tools and turn them into other machine tools with amazing precision. Can’t wait for part 2!
Simply the best. No other teacher, which he definitely is, can transmit so much information in such a precise and clear way. Learn from him and you will be a better machinist, his ideas for obtaining a very complicated process in a simple attainable way using available parts and new technology are outstanding. Congratulations 👏
Your channel is awesome and extremely underrated.
Very impressive, taking the old mill and converting it like this, so clever. I'm looking forward to part 2
Very Impressive! This 14 minute video must have taken 40 hours of real time to make.
You’re back! ❤
I never actually went anywhere, but time flies!
Wow! So keen for the next one!
I love your videos so much. The effort, skill, and knowledge are immeasurable.
What a great start to the weekend! Always a delight to see a new video.
FINALLY !!!! I HAVE BEEN WAITING FOR SOMEOME TO TREPAN SOMETHING FOR YEARS!
Incredible build and some amazing techniques. This really makes for an incredibly precise piece of equipment and endless possibilities well done!
BRAVO, Andy!
Astonishing vision, design and execution. Well done on such a brilliant build. 👏👏👍😀
Fabulous project, fabulous work, and fabulous explanations. Thanks for sharing this with us.
Regards Mark in the UK
Really neat stuff! One of the few channels I don't FF through at some point. Probably a combination of the overall length and not wasting a lot of time showing completely obvious disassembly in fast-motion. The subject matter is most important, of course, and I find this inspirational as I'm mostly an amateur hack machinist.
hahaha, you got me with "The two, in no way fit together"
Now that is a LOT of work.
WOW... a very impressive build!!!
Best part is when he said "gimmie dat, gimmie dat" while building his monster. KEEP SPEED! Ok ok oh god I could say so much. But the transition from CNC spot drill to HAND DRILL really got me. 😅Pure genius.
Fantastic work Andy, you certainly have a wide range of skills
Very impressive! You do such well thought out projects.
Simply brilliant! Looking forward to the math involved to get it all to sync.
Also hoping on more elaboration on inside gears, particularly, tooth profiles.
Very interesting project. Thoroughly enjoyed.
Absolutely amazing!!
Absolutely brilliant. I love it.
I am so impressed with your designs !! 👌👍👍It is a pity that I do not have such knowledge in the field of CNC. 🤥Greetings from Poland
Jestem pod wrażeniem twoich projektów !! Szkoda, że nie mam takiej wiedzy z zakresu CNC.
Cool build Andy, looking forward to the rest of the series.
Cheers
Spent most of a day researching how I was going to do this for the ring gear of a planetary setup last week... Then presto! Andy beat me to it. Kudos.
Wow , best explanations on gears ever , thank you 🙏
impressive work
thank you for sharing your experience
Excellent video!
I’m loving all the gear making videos, keep up the good work!
totally brilliant. Inspiring!
You sir are a mechanical genius. I loved watching that!
Excellent work and video, thanks!
Your videos are very impressive, Thank You very much for sharing them.
Good work. We shared this video on our homemade tools forum this week 😎
Always exciting, interesting, educational and entertaining content that I eagerly look forward to watching. Thank you 👍👍😎👍👍.
Brilliant idea 👍👍
That is so cool. Once you have enough tools you can make so many other tools!
Brilliant, enjoyed watching. Tony
Impressive!
Cheers and thanks for sharing Andy,, 🍻😎👍👍
Legend !! Who would have ever thought about doing that !!
Nice work. Thanks for sharing
Can't wait!
Технари друг друга всегда поймут. Шикарная работа!
Interesting. Very nice work
Just pure awesomeness
Thanks for sharing.
WOW! Your video production is always so well done. Your engineering and clever design ability (i.e. talent) is exemplary.
This is not applicable to your implementation, but I turned a motor shaft down a few years back, on a new 3 phase motor I was fitting on my lathe. In my case a V-belt pulley. I didn't think about it at the time, but I left a sharp corner on the reduced shaft. Within 20 hours of running, the vibrations of the motor caused a crack to develop at that corner and the shaft with the pulley went rolling down the shop floor. Big lesson learned. Never thought that small vibration and radial load would do this on a 19mm shaft, at least not in my lifetime.
This is excellent, cheers.
Very cool upcycling
This channel covers so many different topics I'm interested in, and I really have a limited interest in gears. Just became a patreon supporter.
Help me a lot. Thanx brother
Thanks a lot!! 👏👏👏👏👏👏👏👏👏👏👏
Great video! The only thing that I would change is to make the worm taper , but your system works good as well…keep up the good work!
Part two? really. I hate suspense. Anyway, this just looks like another awesome build. Top notch build for a difficult challenge. Great jOB.
Brilliant.
Spectacular! That has money maker written all over it! ;)
Thanks, Andy! A new machine to obsess over! I happen to have an old XLO mill head….hmmm.
Your videos are amazing; thanks for making them! Cheers from across the pond.
Love the fact you are sinking your teeth back into the whole gear topic. I believe its somewhat of a black art for most machinists s its great to learn about it.
Phenomenal.
The information I wasn't aware of is the blank also rotates with cutter
I love this
Good job c'est une idée géniale
6:30 'They call me Dr Worm... I'm not a real doctor, but I am a real worm'
Brilliant stuff :)
Well done Andy! From your last video I inferred the finish would be due to the rotary head not being in perfect sync with the spindle, as in something you could solve somewhat easily, but great build otherwise!
I don't personally like much the fact that quill's rack and pinion are taking all that intermittent load, but (as originally intended) the mechanism seems able of handling moderate loads, so as long as you don't give it too much depth of cut I guess you should be fine. And if that fails at anytime you've got more than enough skills to find a suitable solution. All the best!
Awesome!!! It’s like my maker Channels know I’ve been tooling up to make gears!
I have made a planetary gear set 8mm. Tick using a a laser cnc cutter and it's working perfecly
Awesome.
o yes!Dont forget the relief on up strokes!Somebody with your calibre can easily program that in.Cant wait to see Andy...
Good idea
So much garbage on youtube that gets millions of views. Content like this is why I watch youtube, I'm rooting for you that your channel will blow up big, you deserve it.
Amazing transformation and very good machining 👍
Just a little upgrade tip add another stepper motor to bed horizontal movement you will get rack shaping machine too 🤑🤑
Awesome build. When I do projects they keep getting interrupted by 100 other tasks and months later my project may get completed😊
Nicely done! Thinking outside to box here. 🤔
cool amazing skill
impressive it is my first time to see that 😍
inspiring to say the least 👍
Amazing!
But have to wait for part 2… 😬😉
Very nice. See you in Part2D2. :)
You are mad but genious !
Merci infiniment!!!
Nice work 👏 💞💞🌺😘
I'd be interested in power skiving, I'm doing quite some gear hobbing myself.
gear skiving is more interesting , keep going on that bro
It is! The problem is it needs a specific cutter for each number of teeth, and the geometry is much more complicated. A shaping cutter (which looks very similar) will cut any number of teeth, like a hob.
Technically speaking you can do away with form invole cutters.Cnc grind a perfect involute 1 tooth cutter from proper hss and still shape with it while indexing for all teeth to be cut.Away with expensive disc type shaper cutters.Damn your content makes me so excited.Having shapers myself i always wanted to see a setup like yours.Im very interested on the span measurements accuracy after you finished.
Yes, that method would be similar to using a regular gear cutter on a milling machine and indexing the blank, whereas the pinion cutter is more like cutting a gear with a hob. The pinion cutter is more complicated to make, but has the advantage that it will cut any number of teeth. The one-tooth cutter might be better for larger module sizes, as only one tooth is being cut producing less force on the cutter compared to multiple teeth being cut at once.
@@AndysMachines ja
Yes!That idea you are moving to now is way more professional. It ticks a lot of boxes. One is practical setting up the gear for runout before starting. You only have to deal with one plane instead of milling which has three. Two, overall rigidity. Instead of cutting something on a abour you are cutting into the table. 3, by setting feed rate slower (more cuts per tooth) equal less force and better accuracy. 4, cutter runout becomes neglectable for generating with 1 tooth cutter. 5, you will always get close to perfect involute profile instead of form cutters that's involute is only correct for 1 count tooth for that specific range. That alone in itself is why one doesn't cut professional gears on milling machines. 6 form cutters involute profiles typically vary from standard generated gears so it's not a good idea to mesh milled gears with 99% of all gears found in a gearbox. 7. now you can start experimenting with complex internal generating profiles like internal square with almost no radius. You're making the gear cutters jealous now. Actually generating with a mill wow!!! Cant wait to see more
I have made and generated with single point cutters if you are interested to see how good the results are? Its totally worth it for various reasons.
Super
great job andy!!! I'd love to know how much force it takes to cut a chip with that setup. I did a small experiment on a 9x30 lathe and it didn't seem rigid enough. Also, why not just drive the cut with your Z motor? Would it stall or were you just worried about ware?
Thanks! It's actually capable of applying a downward force on the cutter of around 6000N (~600Kg) in the middle of the stroke. This would possibly be enough to strip the quill gears but hopefully the shear pin would go first. I don't know how much force it actually takes to make a cut, but considerably less, even when cutting steel the motor doesn't appear to be under much load at all. Using the Z motor (Nema 34 stepper) would be much slower, have less force, and also there would be more backlash as when using the quill I lock the head to the column.
you are awesome
I run a Liebherr LFS 380 gear shaper at work and would recommend taking another look at skiving. Gear shaping is one of the most soul killing machining strategies to get dialed in perfectly (assuming numerical control).
Looking at your results for skiving i strongly suspect the defects you got on your attempts is down to the synchronisation of the two spindles. A properly tuned PID curve and backlash free servo drive would probably remedy that.
That's an interesting opinion, most people tell me to give up with skiving as I'll never get good results with home-made equipment!
The main problem I have with skiving is making the cutters to the correct geometry, there's much more to it than a hob or shaper cutter, plus with skiving you need a different cutter for each tooth count whereas with hobbing/shaping it only takes one cutter. So far the results I've got from shaping are much better, though the cuts I'm taking seem to be consistently shallower than expected, due to rigidity/ deflection issues.
@@AndysMachines Yeah, i can understand the issue with grinding your own skiving cutters.
I've just never had an easy going experience with gear shaping so i would rather put in the time to research, reverse engineer and calculate a parametric formula for the geometry to make my own skiving cutters than to work anymore than i absolutely have to with a gear shaper
Thank you! You are such a great resource for all things "gears" ! Home shop engineering is so enjoyable. Thanks for all of your great videos! PS: Consider creating an email address and adding it to the "About" section of your CZcams channel for direct communication. Regards.
Another fascinating build! No need for adjustment on the stroke length? Or does that add a level of complexity not warranted in this design?
I chose a stroke length to suit the type of gears I want to make, I probably won't need to change it, if I do the only way is to shorten or lengthen one of the lever arms.
The greatest thing in today's world is knowing the ledge if you don't know then it will cost you a lot of money that you don't have
Cool
A constant oil supply will be a must