What tools to use for Gear making?

[mooreaa]

Hello,

I am interested in cutting custom gears and was wondering if someone could give me some advise on what tools would be best for cutting them.

I want to be able to cut either aluminum, nylon, or similar plastics. The gear types would mostly be bevel gears, face gears, regular pinion/spur gears.

I am in the market to buy a new CNC machine but I am not sure if a CNC mill itself is sufficient in cutting gears. I am looking at a Tormach to fill my flat plate milling needs. I am not finding a lot of info about how to cut bevel gears with a CNC.

Any advice/recommendations would be appreciated.

[RICHARD ZASTROW]

mooreaa, Milling machines, both manual and CNC, can cut gears. Not all gears, but many types of gears. Straight bevel gears yes, spiral bevel's no.

Straight bevel gears are cut on a milling machine with a form cutter and the workpiece held in an indexing device, positioned at an angle if a manual mill. Spur gears require an indexing device with appropriate form cutters.

Volume of production and cost determine justification unless it's a hobby thing. If it's a hobby decision, no logic need be applied. LOL

Dick Z

[mooreaa]

Thanks Richard.

Thats good to know that I can cut straight bevel gears with a mill.

Where can I find more information on this? I have seen a lot of info on how to cut spur gears, but not straight bevel gears.

Can you recommend any tools or sites?

I have been playing with Rhino trying to design a bevel gear, but I am having difficulty getting the gears to mesh well. If you could recommend some reading on bevel gears I would greatly appreciate it.

This is for prototyping, not production so volume production isn't a factor at this time.

[RICHARD ZASTROW]

mooreaa, The source for how is "Machinery's Handbook"(spelling is correct) and cutters described there are available from many sources including Ash

There are many "how to" books, but mine (I'm old) is The Cincinnati Milling Machine Co.'s "A Treatise on Milling and Milling Machines" for conventional machines. This will supply the basics. Others on the Zone can provide the CNC "how to's". I would consider linear interpollation for the bevel angle with an indexer to provide tooth spacing. The indexer could be a simple indexing fixture as in the manual method or a 4th. axis.

Dick Z