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Tools, Glorious Tools! #10 (Part 3) - Shop Made Gear Cutters - Making Involute Cutters (Patreon)

Published:
2020-06-14 19:59:48
Edited:
2023-06-22 05:04:03
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Hi Folks,

Part 3 of the shop made gear cutter series is ready to go, covering the full process on making involute profile gear cutters - do please enjoy!

Cheers,

Chris.

Direct links to the video -

Vimeo: https://vimeo.com/428968967/22c3bffbf5

Youtube:  https://youtu.be/1sBU7GZNEJQ

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

Some top resources on Gear Theory:

John Stevenson 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 sharpening with pro gear, 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:

Starrett S828 Wiggler Center Finder With 3 Attachments - https://amzn.to/3hoAsK1

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

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

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

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

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 3) - Shop Made Gear Cutters - Making 'Involute' Cutters

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

Mark Hatchman

Hi Chris, been watching your videos for a long time ( brilliant ) and thought that it's time to have a go at the clock. I have a lot of questions but will try and work them out as I go. One question, is O1 tool steel the same as silver steel / drill rod?

Anonymous

Any updates on the research paper?

Markos Skoulatos

Hey Chris, very nice video, thanks as we anticipate more and more of these, LET THIS SERIES NEVER END! I have a question on the tool at the beginning, the one that finds the center of a hole(?). You first flick it with your finger, why? And then how does it work? Can you point us to some video describing this, and where to buy?

John Gentzel

Beautiful work, it always makes my day when I get the email that there is a new video.

Jeff Armstrong
>>38649030

It's a 'wiggler' type edge finder being used as a centre finder. The flick is to get it running true so you can get the drill accurately into the centre punch mark.

Anonymous

I feel sorry thumb nail.

Anonymous

OMG, Yet another great video with production of beautiful tools!

Iain Deas

Timing of this couldn’t be better!! I think I’ll be trying my hand at this on a count down f needing a one off gear 👍🏻

Kevin Reardon

I keep forgetting you put your primary content on Patreon. Good show. I have missed your content during this shut-in period.

Chris Schmedding

Hi Chris, fantastic, I didn’t catch what type of alcohol you mixed with the boric acid.

clickspring
>>38653007

Thank you mate - standard YT programming will resume once the paper is out - Cheers :)

clickspring
>>38654361

I use this stuff: https://www.bunnings.com.au/diggers-methylated-spirits-1l_p1560782 I've always assumed it to be a denatured alcohol, but the term might mean slightly different things in other parts of the world - Cheers :)

Spoons

I know it's only a little detail, but I really liked the little 90° indication again the part and the fly cutter for the rack. It was a nice little touch and really makes it simple to see and makes your videos pop. I love it. Thanks for making cool stuff!

David Few

Thanks Chris, demystifying another black art. Your videos are always so enlightening, makes you want to go out to the shop and give It a burl.

MrTridac

Your video description is a treasure trove.

Harri Haataja

Another glorious video, though I'll probably stick with premade cutters now that I can find them. I feel the background music is annoying at times. Not as bad as many channels, but still.

Harri Haataja

BTW the links in the post have a few duplicates like the scroll saw.

Anonymous

I am learning so much from these videos! It's completely fascinating. I have some of the reference books you mentioned, but your demonstrations really bring the concepts to life and make them easy to understand. Thank you.

Anonymous

Just perfect as always chris!

Justus Dehegovit

Excellent videos as always, Chris. I was super nervous when you were forming the cutter profile since it looked like the buttons were about to collide with the arbour. Which brings me to the question: How big can you make those cutters? I happen to have plans for the gearing of an astronomical clock (something I wanted to own for a long time) and some of the gears are quite big (module >1, with the biggest being 2,5)

Anonymous

Hi Chris, if we wanted to cut (broach) a ring gear for a planetary gear set, would we use the rack profile for a broaching tool or something else?

clickspring
>>38682275

Hello mate - if you were going to broach, then the appropriate profile in fly cutter form would do the trick. Alternatively, the method with which I'm familiar to sort out the ring gear issue is to run the cutter in standard rotary mode, on an extended spindle that has the ability to reach inside the diameter of the ring. Happy to elaborate if required - Cheers :)

clickspring
>>38680055

Thank you mate :) That sounds like a terrific project! Assuming you scale the tools appropriately, you can make and use the cutters to as large a module as you require. From the horological cutter standpoint, the tool drawings as published are intended for cutters of M0.2 up to around M1.0. I would guess that scaling up by approx 1.5 would be a good place to start to cover your upper limit of M2.5, but you will need to check for limitations to be sure. Use the calculator to see where the issues arise (eg optimum cutter blank thickness, button diameter etc) and then go from there - Very happy to answer any questions that arise - Cheers :)

Paul Busby

Another great video Chris. Really removes all of the cost and knowledge excuses of gear cutting. I was watching almost counting the many different ways I could ruin a rotary cutter while making it then you did the fly cutter which made it look so simple. Given the lack of complexity in making, I wondered if making 2 or more of the same fly cutters would still be faster than the rotary which would offset the higher wear during use. Would any of these approaches work for making pinion gears or would you still need HSS cutters for these?

Anonymous

An absolute delight to watch, as with all of your work and videos. Very much enjoyed, cheers!

clickspring
>>38736223

Thank you mate! Yes in some circumstances it might be the way to go, although it does raise the issue of registering the cutter mid cut - not insurmountable, but worth keeping in mind. Yes this process will give you pinions, I will cut some typical steel clock pinions in the next episode - Cheers :)

Stubbs

If Chris ever uses his powers for evil, we're all screwed

Trevor

Incredible work! Very much looking forward to your next videos :)

Matt Tester

After all these years of heat treating this way, have you ever considered building or buying an induction oven for ease and accuracy?

Anonymous

Well this is just the way to remind myself that I have too much to learn and not enough time to learn it!

Anonymous

I will never cease to be amazed by your skill at not only machining, but in planning, order of operations, and in adding in multiple uses for the tooling you have to build. I can't imagine the pile of discarded mistakes and single function tools I would generate in trying to do something like this. I love watching these, as I always find myself learning as much or more about those aspects as the actual project you're making.

Anonymous

I’ve been watching you for years but wanted to share with you a bit of a story about your channel that probably is a bit out of the ordinary for you. About five years ago I went through a divorce - nothing rough about the divorce (no kids luckily), but I was pretty heartbroken that my wife had been cheating on me and that I was starting my life over. Then I had a minor accident on a dirt bike that resulted in a major surgery on my brain and massively took a toll on my everyday ability to handle difficult situations; which, in turn, resulted in a highly depressive state for several years until my brain started to recover. I apologize if that is sharing too much, but I assure you it is relevant. During my first month or two post surgery I was (obviously) at home recovering and discovered your channel at the recommendation of a friend. Watching your videos of these machining processes relaxed me into a state where I could genuinely be comfortable even when my mind was struggling. Being able to not only see the work getting completed, but learning HOW it is done and soaking up the knowledge is extremely rewarding for me. I’ve literally watched every single video, many multiple times, and to this day they still are an excellent coping mechanism when I am not okay. Since then I left my desk job as a software engineer and have pursued automotive performance fabrication (as I had always wanted) and have spent my own time experimenting with machining to hopefully expand into more complex parts to begin to manufacture in small batches. Not only have I seen your own skills expand massively and your capabilities exponentially skyrocket over the years, but your channel has had a massive impact on some viewers’ lives - even if it has just been in the form of providing high quality, relaxing, and educative content. I’m remarried now with a year and a half old son, and he is absolutely intrigued by tools and electronics and building stuff - and I am looking forward to many more years of enjoying your content while I take on more challenging tasks myself and share that knowledge with him. Thank you for being a very consistent creator, and I hope you continue to be able to do what you clearly love to do.

clickspring
>>40528149

Hello mate, I was so pleased to read your post, in particular the happy ending! Thank you so much for sharing it with me, and also very happy to hear that your young lad is taking an interest. Should you find yourself with some spare time on a Sunday evening, do come along to the regular Discord chat - we could do with the performance auto engineer POV! Cheers :)

Anonymous

This question isn't about the gear cutting tool, but more about your lathe tooling, so I guess it's tooling related. I've noticed a lot of your turning tools have a sharp point, do you radius them at all or do you leave them sharp? I know this sounds a bit like a silly question because every machining handbook suggests radiusing the tips of tooling but I am curious if the practice is different when it comes to timepieces/precision instruments.

clickspring
>>41053645

Its a great question - my personal observation is that the rounding of the tool tip is not necessary. I almost never do it, unless I need the rounded geometry imprinted in the part as a fillet for example. I do give the tip one or two strokes with an arkansas slipstone to remove the burr from the grinder, but that's it. Cheers :)

Anonymous

I don't watch your videos as often as I would like (I always forget about patreon) but every time I do come back I am always amazed by the work you do. Even with something simple and inconsequential as the lettering stamped on a shop tool you put the effort in to make it straight and even.I also have to say thank you because over the years of watching channels such as yours, AvE, This old Tony, and Abom79 I have been able to (while not actually doing it myself) pick up on how to run machines such as lathes and mills and novel ways to overcome problems. This has helped me because just a couple months ago I started a new career in the hydraulic hose repair industry and running a lathe is actually fairly common to do and I was able to walk up to the machine with confidence on my first day and run it without issue.

Rickwest Sampaio

hi chris I've subscribe to your patreon today and your content is really AWESOME. I have a question. The profile of the cutter changes slightl as in a cut approximately in 45 degree in relation to the original radius that the relieve has been cut. How to compensate that? i'm planning to make change gears to my lathe IN MY LATHE. Very labourious work by the way

clickspring
>>72060411

Hello mate, terrific to have you on board! I'm not sure that I quite follow what you're describing, but generally, my observation is that the compromises and approximations inherent in the method I describe tend not to matter for the sort of work that most of us get up to in our home shops - Cheers :)