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Tools, Glorious Tools! #10 (Part 2) - Shop Made Gear Cutters - The Cutter Forming Tools (Patreon)

Published:
2020-05-10 23:44:59
Edited:
2023-06-20 22:45:00
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Content

Hi Folks,

Here is part 2 of the shop made gear cutter series - do please enjoy!

Cheers,

Chris.

ps Tool drawings to follow shortly.   [EDIT - Drawings now available below, at the bottom of the text]

Direct links to the video -

Vimeo: https://vimeo.com/417001842/7edec888da

Youtube:  https://youtu.be/AN0rYzOvMyg

-------------- Video Notes: ---------------

Some top resources on Gear Theory!

John Stevenson's Blog Post - http://metalwebnews.com/howto/gear/gear1.html

WO Davis – “Gears For Small Mechanisms”: https://amzn.to/2Yj2Ben

JM Wild - "Wheel & Pinion Cutting in Horology": http://amzn.to/2HI6ca9

"Gears and Gear Cutting", Ivan Law: http://amzn.to/2FKmaUI

Tony's gear videos:

https://www.youtube.com/watch?v=Q-XOM4E4RZQ

https://www.youtube.com/watch?v=ds6qZ7Ss2fA

Stefan on the subject of sharpening, and a discussion on profile error: https://www.youtube.com/watch?v=7sxq5khqeWI

Mr Pete's Gear Videos:

https://www.youtube.com/watch?v=JMhYuXx35Ik

https://www.youtube.com/watch?v=12sdMFr5CNU

https://www.youtube.com/watch?v=2lPNqn8LU4Q

https://www.youtube.com/watch?v=dQVUI1YhN0E

https://www.youtube.com/watch?v=mXU-URNdUFU

https://www.youtube.com/watch?v=Dipd0ohrYzg

Andy Pugh's Gear hobbing video's:

https://youtu.be/ZhICrb0Tbn4

https://youtu.be/xdE46yvckbM

"The Watchmakers' Lathe " Ward Goodrich - https://amzn.to/2Wijchr

Hugh Sparks - https://www.csparks.com/watchmaking/CycloidalGears/index.jxl

"The Clock & Watch Makers Guide to Gear Making" Porter - https://amzn.to/2xuFP7I

Online Gear Generator: https://geargenerator.com/

Alan Pinkus’s Gear Generator - http://www.micro-machine-shop.com/gears.htm#Gearotic_Motion

Matthias Wandels gear generator: https://woodgears.ca/gear_cutting/template.html

(Amazon Affiliate links)

Cameras:

Panasonic GH5 - https://amzn.to/2rEzhh2

Panasonic X920 - https://amzn.to/2wzxxdT

Books:

"Wheel & Pinion Cutting in Horology": http://amzn.to/2HI6ca9

"Solidworks 2013 Bible": http://amzn.to/2FObS1D

WO Davis – “Gears For Small Mechanisms”: https://amzn.to/2Yj2Ben

"Workshop practice Series": https://amzn.to/2WgeGh0

Tools & Shop Products:

Norton 1-by-2-by-8-Inch Fine/Coarse India Combination Oilstone, Red: http://amzn.to/2tTEPb0

Hegner Scroll Saw: https://amzn.to/2IhteVW

Digital Caliper 6 inch/150 mm Electronic Vernier Calipers: https://amzn.to/2EArNRU

Generic Dial Indicator 0.001": http://amzn.to/2FOFTyF

Interapid Dial Test Indicator: http://amzn.to/2FPInwH

Optivisor Headband Magnifier: http://amzn.to/2HFg1FU

Saint Gobain (Norton) - 4 Arkansas Stones + case: http://amzn.to/2HCOAMX

Dormer A190202 Jobber Drill Set, 1.0 mm - 6.0 mm x 0.1 mm Size: https://amzn.to/2DR5fdb

Dormer A190203 Jobber Drill Set, 6.0 mm - 10.0 mm x 0.1 mm Size: https://amzn.to/2ITfeTa

YG1 NC Spotting Drill 8% Cobalt HSS 1/8 to 1/2" 120 Degree 5 Pc Set CNC Machine: https://amzn.to/2G7ylv6

Hegner Scroll Saw: https://amzn.to/2IhteVW

Blazer GB2001 Self-Igniting Butane Micro-Torch: https://amzn.to/3f5Gzlh

Magnetic Base Adjustable Metal Test Indicator Holder Digital Level 14" - Tool Stand: https://amzn.to/2PkyoTV

Anytime Tools Angle Block Set 1°, 2°, 3°, 4°, 5°, 10°, 15°, 20°, 25°, 30° Precision +/- 20 Seconds, Machinist Tool, 10 Piece Set: https://amzn.to/2QFqM2Y

Jewellers Bench Block - https://amzn.to/3clHQD2

Consumables:

Super Pike Saw Blades Size 3/0 pkg of 144: https://amzn.to/2uI0QdT

Blue Matador Abrasive Paper: https://amzn.to/2IAFiBT

Bergeon Professional Cleaning Rodico: https://amzn.to/2NwcM6y

Files

Tools, Glorious Tools! #10 (Part 2) - Shop Made Gear Cutters - The Cutter Forming Tools

A very special thank you to Patrons: Sinking Valley Woodworks (http://www.sinkingvalleywoodworks.com) Glenn Trewitt Mike Manfrin Christopher Warnock Guy Loughridge Charles Frodsham & Co. Peter John Richardson Adam Slagle Tim Bray Dan Keen Samuel Irons Sean Kuyper Matteo Neville Daniel Cohen Larry Pardi Olof Haggren Stassinopoulos Thomas Florian Ragwitz Andrew Smith Bernd Fischer Sam Towne Jack Cause Jeremiah G. Mort Andre van Soest Matthew Middleton Thomas Veilleux Dave Seff Robin Haerens L'Enfant Watch Company C. A. Patrick Voigt Mark Coburn Bogdan Dan Steven R. Crider Gary Levario Pete Askew Jeff Armstrong Rudolph Bescherer Jr Robert Petz Ralph McCoy Jim Popwell Kaedenn Bradley Pirtle Alan Carey PaxAndromeda John A McCormick Thomas Eriksen Michael Hardel Tim Ball Dominik Rogala Xanadu-King Eric Witte Peter Grant Michener Jonathan Teegarden Steve Hossner RuKiddin06 RobinP556 -------------- Video Notes: --------------- File Downloads (Be sure to COPY/PASTE the links): Cutter Sharpening Tool Metric: https://www.clickspringprojects.com/uploads/3/8/2/2/38221101/clickspring_cutter_sharpener_-_metric.pdf Cutter Sharpening Tool Inch: https://www.clickspringprojects.com/uploads/3/8/2/2/38221101/clickspring_cutter_sharpener_-_inch.pdf Clickspring Universal Gear Calculator: https://www.clickspringprojects.com/uploads/3/8/2/2/38221101/clickspring_universal_gear_cutter_geometry_calculator_v3.7.3.xlsx Cutter Forming Tools Metric: https://www.clickspringprojects.com/uploads/3/8/2/2/38221101/clickspring_cutter_forming_tools_-_metric.pdf Cutter Forming Tools Inch: https://www.clickspringprojects.com/uploads/3/8/2/2/38221101/clickspring_cutter_forming_tools_-_inch.pdf Cutter Blank Metric: https://www.clickspringprojects.com/uploads/3/8/2/2/38221101/clickspring_cutter_blank_-_metric.pdf Cutter Blank Inch: https://www.clickspringprojects.com/uploads/3/8/2/2/38221101/clickspring_cutter_blank_-_inch.pdf Some top resources on Gear Theory: John Stevenson's Blog Post - http://metalwebnews.com/howto/gear/gear1.html WO Davis – “Gears For Small Mechanisms”: https://amzn.to/2Yj2Ben JM Wild - "Wheel & Pinion Cutting in Horology": http://amzn.to/2HI6ca9 "Gears and Gear Cutting", Ivan Law: http://amzn.to/2FKmaUI Tony's gear videos: https://www.youtube.com/watch?v=Q-XOM4E4RZQ https://www.youtube.com/watch?v=ds6qZ7Ss2fA Stefan on the subject of sharpening, and a discussion on profile error: https://www.youtube.com/watch?v=7sxq5khqeWI Mr Pete's Gear Videos: https://www.youtube.com/watch?v=JMhYuXx35Ik https://www.youtube.com/watch?v=12sdMFr5CNU https://www.youtube.com/watch?v=2lPNqn8LU4Q https://www.youtube.com/watch?v=dQVUI1YhN0E https://www.youtube.com/watch?v=mXU-URNdUFU https://www.youtube.com/watch?v=Dipd0ohrYzg Andy Pugh's Gear hobbing video's: https://youtu.be/ZhICrb0Tbn4 https://youtu.be/xdE46yvckbM "The Watchmakers' Lathe " Ward Goodrich - https://amzn.to/2Wijchr Hugh Sparks - https://www.csparks.com/watchmaking/CycloidalGears/index.jxl "The Clock & Watch Makers Guide to Gear Making" Porter - https://amzn.to/2xuFP7I Online Gear Generator: https://geargenerator.com/ Alan Pinkus’s Gear Generator - http://www.micro-machine-shop.com/gears.htm#Gearotic_Motion Matthias Wandels gear generator: https://woodgears.ca/gear_cutting/template.html (Amazon Affiliate links) Cameras: Panasonic GH5 - https://amzn.to/2rEzhh2 Panasonic X920 - https://amzn.to/2wzxxdT Books: "Wheel & Pinion Cutting in Horology": http://amzn.to/2HI6ca9 "Solidworks 2013 Bible": http://amzn.to/2FObS1D WO Davis – “Gears For Small Mechanisms”: https://amzn.to/2Yj2Ben "Workshop practice Series": https://amzn.to/2WgeGh0 Tools & Shop Products: Optivisor Headband Magnifier: http://amzn.to/2HFg1FU Norton 1-by-2-by-8-Inch Fine/Coarse India Combination Oilstone, Red: http://amzn.to/2tTEPb0 Hegner Scroll Saw: https://amzn.to/2IhteVW Digital Caliper 6 inch/150 mm Electronic Vernier Calipers: https://amzn.to/2EArNRU Generic Dial Indicator 0.001": http://amzn.to/2FOFTyF Interapid Dial Test Indicator: http://amzn.to/2FPInwH Saint Gobain (Norton) - 4 Arkansas Stones + case: http://amzn.to/2HCOAMX Dormer A190202 Jobber Drill Set, 1.0 mm - 6.0 mm x 0.1 mm Size: https://amzn.to/2DR5fdb Dormer A190203 Jobber Drill Set, 6.0 mm - 10.0 mm x 0.1 mm Size: https://amzn.to/2ITfeTa YG1 NC Spotting Drill 8% Cobalt HSS 1/8 to 1/2" 120 Degree 5 Pc Set CNC Machine: https://amzn.to/2G7ylv6 Hegner Scroll Saw: https://amzn.to/2IhteVW Blazer GB2001 Self-Igniting Butane Micro-Torch: https://amzn.to/3f5Gzlh Magnetic Base Adjustable Metal Test Indicator Holder Digital Level 14" - Tool Stand: https://amzn.to/2PkyoTV Anytime Tools Angle Block Set 1°, 2°, 3°, 4°, 5°, 10°, 15°, 20°, 25°, 30° Precision +/- 20 Seconds, Machinist Tool, 10 Piece Set: https://amzn.to/2QFqM2Y Consumables: Super Pike Saw Blades Size 3/0 pkg of 144: https://amzn.to/2uI0QdT Blue Matador Abrasive Paper: https://amzn.to/2IAFiBT Bergeon Professional Cleaning Rodico: https://amzn.to/2NwcM6y

Comments

David Paterson

I know this is an old project of yours, but, I am looking at the metric version of the plans and have a few questions> Can I assume the hole for the boss at 7.94 is simply an expression for 5/16 and can be replaced with 8mm (given the availability of 8mm stock in Aus). Is there any particular logic to the 7.64mm distance between the boss and the index pin? or can this be replaced with a more convenient 7.5? Question is related to not having the drawing to see it it has any impact on the relationship between the cutter shape and milling out the corners. Cheers David

clickspring
>>131685401

Hi David, yes you can adjust dimensions as required based on stock and tool availability; I use both interchangeably based on what I have available. The boss must be a precise fit, but no reason it can't be 8mm if that's the reamer size you have. As I recall, the index pin distance is how it basically came out based on all other design requirements, but I would expect you can modify just about all aspects to suit what you need. There will likley be consequences for each move, just keep your eye on it as you make the changes - Cheers :)

Chris Muncy

Where do I begin... First - Perfect ending to the day, thank you Chris. Second - I am guessing that the indexing of the buttons is not extremely critical or you would have keyed or slotted the button shanks? Last but not least - The button head finish... OMFG.... You need to talk more about that pixie dust you used. I don't think I have seen that in any videos yet. As always, thanks for another amazing video.

clickspring
>>36692444

Ha ha! Thank you mate! More on that pixie dust as soon as I have a good excuse! Yes not super critical on the button orientation in the button cutter holder, but certainly as close as you can get it by eye is fine - there are quite a few small compromises like that in the method that can be addressed if you add a bit more complexity, but as always its a trade off - Cheers :)

Anonymous

Hey Chris, I was wondering where you get all your raw stock? Also where do you get your quality files?

Myles Farrell

As always you know you're doing incredible work when people are excited about long videos. Thanks for you time, incredible production value, and of course the incredible knowledge.

clickspring
>>36693867

Hello mate - I get all of my files from www.artcotools.com For the raw stock, its a mixed bag. I have copied the text below from another post that pretty much covers it - Cheers :) "Gage plate: www.hales.com.au - A good range of high carbon steel plate stock, will do over the phone and post orders. Silver Steel (drill rod) - Visit your local Blackwoods to put in the order, they carry everything from 1/8th inch up to about 1.5 inch (and metric equivalents) and ship fairly quickly for an instore pickup Brass: www.georgeweston.com.au or www.georgewhite.com.au - Very expensive material and very expensive shipping from either BNE or MEL, but they carry everything you could ever want including bronze, copper etc Mild steel: www.mesupplies.com.au - Wayne is excellent for the small MS rod stock, small plate stock and other model engineering sized stock. Exotics like Invar etc: www.iantcobb.co.uk - Ian is excellent to deal with, carries a lot of the clock only stuff too like pivot steel, silvering compound, dial wax etc The other thing is to hit the local machine shops to see what they have sitting on their offcuts shelf or scrap bin. If you turn up with some folding, they often will let you have some of the best stuff for very little, particularly if you let them know you're a home machinist. Also find the local aluminium fabricators (boats builders, trailers etc) and do the same. Al is excellent for making adapter plates, stand offs etc as well as simple practice items, and its way easier (and cheaper) to source in our part of the world than steel. And lastly find the local sheet metal shop (ie the folks who work exclusively with sheet metal using a magna bend, spot welding etc to fabricate from sheet metal, not a general machine shop) You will get the 0.7mm to 4mm sheet stock very cheaply for making more substantial structures."

Anonymous

Hey you make it all look so easy Chris. Thanks for the time in your world.

John Gentzel

Beautiful finish on the buttons, you just make it look so easy. :)

Thomas McGinnis

I really enjoy the videos .... always a bit of a let down when they finish .... I've gotten into the habit of watching them twice in a row just to see if I missed anything.

Paul Busby

Always great. How do you go about degreasing your parts after heat-treat, sharpening or mill/lathe operations? I can imagine a huge oily mess if not done properly.

John Creasey

Hi Chris, do you use borax for your boric acid?

clickspring
>>36772766

Hi John, I use this stuff here: https://www.jewellerssupplies.com.au/product/26105-boric-acid-powder-500g - Cheers :)

Anonymous

Hi Chris! Really like your work in general and this series is particularly interesting. Making tools is fun and can (sometimes) help save money. Do you think that a set of eight gear cutters would be enough to cover the making any gear from smallest to rack? It seems like professional gear cutters typically come in sets of eight cutters. Or would this slightly more "approximate" style of cutters require a larger set?

clickspring
>>36896700

Hello mate! I think the general answer is yes, given that the error is quite small. Although its somewhat difficult to quantify since were talking about deviation from a curve. For the majority of the acting surface near the pitch circle the deviation is small, and so I would think it reasonable to say that the difference is negligible. The error tends to be greatest at the tooth tip and root where it is less consequential (assuming adequate clearance maintained), and becomes progressively smaller as the tooth count increases. Certainly adding a few more cutters to the standard 8 would be satisfactory I think, but then of course you can always zero in exactly on the tooth counts you intend to use for a given project with this method and get it as close as possible too - Cheers :)

Anonymous

Hi Chris - I am increasingly tempted to make a Wilding clock, though I would attempt the beginner's model... Did you cut your wheels with involute or cycloidal teeth? There's a significant price difference between the two! :) Also, does a "Module No. 1" cutter size = M 1.0? Thanks for the advice and inspiration!

clickspring
>>44898550

Hi Scott, I use the cycloidal square bottom profile, and yes "Module No.1" and "M 1.0" are two ways of saying the same thing. The cutter costs are a massive part of the project cost, hence this short series! If you decide to have a go at your own cutters, I'm here for advice should you need it. There are also a couple of guys active on the Discord who are making their own clock mechanisms at present using this process to make their own cutters - Cheers :) - edit - typo: the profile I use is cycloidal