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Tools, Glorious Tools! #10 (Part 5) - Shop Made Gear Cutters - Tooth Fillets & Edge Cases (Patreon)

Published:
2020-09-06 00:03:23
Edited:
2023-06-24 20:57:55
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Content

Hi Folks,

In this final episode of the 5 part mini-series on shop made gear cutters, I look at how to include fillet geometry into tooth profiles, and investigate a couple of the module and tooth count edge cases - do please enjoy!

Also, you have a standing invite to the weekly Clickspring Discord chat. Come along and say G'day, show some pics of what you've been up to for the week, ask a few questions and maybe give a few answers. Its on every Sunday evening/Monday morning at 2200 UTC (6pm Sunday EDT, 8am Monday AEST).

Cheers,

Chris.

Connect to the Clickspring Discord: support.patreon.com/hc/en-us/articles/212052266-How-do-I-receive-my-Discord-role-

Direct links to the video -

Vimeo: https://vimeo.com/455108809/da83909257

Youtube:  https://youtu.be/nE2GacSN3Qg

-------------- 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:

Sherline Lathe: http://amzn.to/2pnXM19

Sherline WW collets: http://amzn.to/2FYZ7F8

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

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

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

Dykem 80300 Steel Blue Layout Fluid, Brush-in-Cap (4oz): http://amzn.to/2HGPaJJ

Files

Tools, Glorious Tools! #10 (Part 5) - Shop Made Gear Cutters - Tooth Fillets & Edge Cases

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

Clifton Ballad

The way the loctite magnified the surface it was on ( 3:19 ) was visually amazing

Anonymous

Sir, you are a true master. Thanks for this deep dive, I learned so much. Now let try it myself.

Brian Boccia

I watch an unreasonable amount of videos of people making things. Your videos are easily the most satisfying of all of them. What was that tool holder you were using for the drill rod at the beginning?

Anonymous

Chris, why is your belt sander jerking the belt to and fro? Is the tensioner setting is too low or is the belt not up to par?

Justus Dehegovit

"These gear cutters will be a key element for the upcoming projects." Well, time to up my patreon tier! In all seriousness, I really enjoyed this mini series and I cant wait for the continuation on the AM project. I honestly have no idea what future project will be able to top the AM, I personally hope for an orrery, but only time will tell, I guess.

clickspring
>>43547877

Very pleased you're enjoying them Brian - That is a pin vise, a bit like this one: https://www.micromark.com/Double-End-Pin-Vise - Cheers :)

clickspring
>>43548961

Its the belts, they're made from cutting wider belts into 1" strips, so the edges end up a bit ragged. Cheers :)

clickspring
>>43549886

One thing I can say, its going to have gears cut with shop made cutters!! Cheers mate :)

Phil Sydor

Another excellent series which I really enjoy watching, thank you.

Duncan Luddite

A very nice Fathers Day present :) Thank you. I hope you had a good one too Chris.

Graeme Brumfitt

Chris, That was bloody magical. TFS, G :)

John S Dilsaver

Excellent. You are an inspiration.

Iain Deas

So. Any hints as to what the next project will be?

Mike Michelizzi

Excellent demonstration and beautifully filmed/edited as always. Thanks!

Anonymous

Why don't you post on normal youtube? I so rarely check patreon, so I miss most of your content. Your unlisted videos have fewer views than you have patrons; so I'm guessing many others are the same. Maybe create a youtube channel I can sub to which tells me to go check patreon? Or just have public videos like you used to. (none of my other patreons have unlisted videos or any "perks" I care about)

clickspring
>>43584534

I have a couple of 'next projects' on the board, but not sure which one will happen first yet, both are geared mechanism, but of quite different character to each other. First things first tho, I have to get back to work on the AM project - Cheers :)

clickspring
>>43599156

G'day Ray, things on YT have been interrupted due to the research posted 2 below this one. Normal programming will resume as I spin up the AM project again. The TGT's that have been accumulating here will also make their way onto YT in due course - Cheers :)

Iain Deas

Hey Chris. Question for you on commercially made cutters, you mentioned the PP Thornton cutters being in the £70 region in another video and I know that generally speaking you get what you pay for, but, If you’re only looking at low volume use why wouldn’t you just look at the Chinese made cutters? For example I purchased a set of ER32 collets from CTC tools for about $120 Aussie dollars including shipping, they’re based in Europe but it’s all obvious Chinese made, but they’re manufactured to the same DIN standard and when I’ve chucked them up with an indicator they run true and have no obvious runout. Assuming the same can be said for the cutters is there some less obvious reasons to avoid the Chinese made stuff? This set of 8 cutters is only $80 bucks freedom.... Here’s the link to them http://www.ctctools.biz/hss-involute-module-gear-cutter-set-8pcs-h97/

Anonymous

enjoying these videos. Much of it is very useful for my model making

clickspring
>>43633432

Glad you asked! Here are some of the reasons why you might want to make your own gear cutters: 1./ Cost. The horological gear cutters are approx £70 each, with several required for something like a standard clock mechanism (plus the escapement & ratchet cutters), and no readily available substitute that I am aware of. The shop made process makes this cost trivial, and removes a major barrier to starting a clockmaking project. 2./ Quality. While the Involute cutters can be found at a cheaper price than typical horological cutters, you do indeed get what you pay for. My observation is that the cheap cutters are of poor quality, particularly at the low module end of the scale. The cost of the good quality HSS involute cutters approaches that of the horological cutters. 3./ Availability. Commercial cutters are provided at specific sizes that may not meet your needs. Involute modules below 0.3 are likely to require an expensive custom order, and the same would apply if you need a one off pressure angle, clearance, bore etc. With shop made cutters you can specify all parameters and make it exactly to your needs. 4./ Protoyping. Despite the value of CAD, its often not clear whether the scale of a project is correct until you actually make it. I have a project in prototype at present that fits into this category, where the scale is quite a subjective thing and I really need to see it in use for a few months before committing to the final design. I've run through 3 iteratons so far, each requiring a distinct set of cutters, all odd modules. This would have been prohibitively expensive if going commercial, but its negligible for shop made, and encourages continued experimentation as opposed to 'that will have to do'. 5./ No Supply Delay/Disruption. In my part of the world (and I suspect this applies to many others), there is no option to walk into a store and buy gear cutters. Its all delivery by post with many weeks delay before delivery, and in some cases months. If you are working on a repair job, that means the device must sit in the shop waiting on the arrival of the cutter. No such delay for shop made cutters, knock it out, and get to work completing the repair all inside a day. 6./ Satisfaction. There is nothing like the feeling of achievement that comes from completing a demanding project, knowing that even the gear cutters were shop made! No doubt there are more reasons, but I'd reckon there's something for most of us in the list above - Cheers :)

Glenn Trewitt

I'm a stickler for documentation at work, so I have one suggestion for your gear calculator: generate a label for the geometry, suitable for stamping on the cutter or otherwise labeling it. Uh, and is the calculator publically available? It's nice to watch straightforward videos that make me realize how much I don't know. :-)

clickspring
>>43650825

Hi Glenn, yes the calculator can be downloaded from the link beneath each of the videos. I like your idea of a label generator. I'm not overly skilled at driving excel so open to suggestions as to how this is best done - Cheers :)

PeetieGonzalez

What an absolute delight to watch. I'm glad you've been posting this series to keep us entertained and educated. Now you have your research published I'm absolutely dying to see a continuation on the Antikythera mechanism. It will be interesting to see the research informing the parts making process. The final product will be fit for a national history/science museum!

Anonymous

Hey Chris, I have completely fallen in love with this channel. I just purchased a lathe and I'm a little apprehensive. I was wondering if you or people here could offer some educational places I could go and or some basic setup tools for my new lathe. A Grizzly variable speed 10X22.

clickspring
>>43831251

Hi Tim, so pleased to hear that! I'd suggest that you head on over to the Clickspring Discord. There are plenty of folks there that will offer some thoughts about where to start learning. More info on how to connect to Discord here: support.patreon.com/hc/en-us/articles/212052266-How-do-I-receive-my-Discord-role- The best time to come and say G'day and catch me and a lot of Patrons at the same time is Sunday evening/Monday morning at 2200 UTC (6pm Sunday EDT, 8am Monday AEST) Its a weekly chat, lots of sharing of questions, answers, what's been happening in the shop etc - Cheers :)

Anonymous

Thanks Chris, See you there 3 PM PDT for me. (Greetings from the Bay Area)

PJ

Wonderful Series Chris! Packed with info, practical application and your camera work (framing and lighting) on this last one is some of the best out there, especially with the tiny stuff, Bravo! Much appreciate and logged for absolute reference. Thank You!

Ralph McCoy

Chris, when you were engraving the card press can that be done with a cnc mill? Ralph

clickspring
>>44046801

As of right now, no. There are several ways to get a CNC machine to roughly approximate it, with a drag tool, and in some applications using a very small rotary tool, but its a different result to hand pushed bright cut engraving. Cheers :)

Ralph McCoy

Thanks, I am glad the machines do not win this one. Stay safe Ralph

Hogtown Pens

Makes me wish I had machining tools! I'm a woodworker but greatly enjoy your videos - this seems like it would be a terrific way to make one's own router bits for shaping and profiling wood!

Kirk Jensen

The round bottom cutters don't seem to cut on the return pass. im trying to verify that in my head with the square corner not passing down the tooth wall.

Karl Mansson

By presenting the circular cutter at an angle to the work, are you not really presenting an oval and not a circular cutter? Maybe I'm missing something here but it seems like it would produce a different tooth profile. Same would go for the button cutters I think.

clickspring
>>48385224

Hi Karl, yes that is correct. However it is a small variation when considered within the collection of other compromises already accepted as part of the underlying standards. The reality is that even commercially produced gear geometry is a compromise, balancing the 'ideal' against machining convenience - Cheers :)

Joshua Greer

Amazing! Learned so much from this series. Stayed up way past my bedtime, was so helpful.