How do I machine this efficently

[dmerrll]

I call this a rosette. I use them for positioning handles around an axis with the mating surfaces meshing usually in 6deg increments. My cam program (AlibreCam pro) chokes as I cannot chain. I am digging through my acramatic 2100 books to explore a macro rtp way of doing this. I would buy these parts if I could find them. It would seem to me that they would be sold to attach to mating faces for pivot lock. I could use them made out of 6061 or 2024 in several diameters and pitches 6, 10, 12 deg. I had made a few tests using with 6061 using a 6 flute .500 chamfer bit HSS final depth of cut .125 overall diameter 2.00" Not great. Used a 2 flute carbide vee router bit 5600 rpm 16ipm feed .08 doc, so so. Single flute engraver.Eh... could put on my highspeed spindle 35k rpm. Any suggestions. BTW larger diameters will be 4.00" 10 deg .187 doc overall.
Does anybody know a vendor that sells these as a fixturing aid? I have tried MSC, Mc Master,Reid and Jergens with no luck they all seem to think they have seen something like that in their travels but suggest they are proprietary.
I am enclosing jpeg and PDF.
Thanks, David

[RICHARD ZASTROW]

Look up "Hirth" or Hurth" couplings $$$$$$$$$$

Dick Z

[BobWarfield]

If I'm not mistaken, those are also called "Face Gears". They're used for example to lock rotary indexers. Put two facing each other, move them apart and the axis is unlocked. Push them together and the axis is locked in one of the positions the "teeth" line up for.

Presumably the difficulty is in machining those tapered teeth efficiently.

But what if you achieve the taper by using a fixed width cutter and just raise the cutter as you move inward? Sure the depth of the bottom will reduce towards the center, but that may be ok for your application. Sounds like it would be.

See what I mean?

Best,

BW

[dmerrll]

Well when I machine these I use a fixed width vee cutter. sop far I have only made large ones 8" dia with a 2 fl niagra HSS that I use for chamfering .375 fh screw heads. When i do this and mill straight across the taper towards center is a by product of the width of the cutter as it approaches center of radius. I usually have the center countersunk already to depth and this makes it look nice as well. when I get to smaller diameter I cannot have 10-20 thou nose on the cutter. So I am looking for advice on which would be best cutter. single flute carbide high rpm say 25k - 35k. Or multiflute countersink say 6fl 60 deg .375 fl len .500 dia.
Other thing is a macro for g code.Like enter dia or radius for length of cut 360/ teeth = deg for radian spacing. since my cam program will not do chain or path milling 3d roughing with finish pass generates totally innefficient code.
Any thoughts, thanks, David

[ctate2000]

Do you have an indexer or 4th axis rotary? If you can mount it verticaly you could use an arobor and form ground mill cutter. Make a pass, index 6 degrees make another pass, etc.

[dmerrll]

Good idea!
sometimes I just get married to a process.