A couple to try.
Does anybody have a favorite place to get gears specifically worm gears?
McMaster seems expensive.
A couple to try.
MSC had them as a non-catalog item. Not sure about the pricing, but maybe you can use one of their 30% off, etc. promo codes
I have had decent luck with these guys:
Quality Transmission Components - Your Source for Quality Power Transmission Components
They seem to be less expensive on many things. Finding the non-metric parts can be a little tricky. They mostly do metric.
Thanks everybody. I couldn't get sdp-si.com to bring up anything but it looks like Boston gear is the main supplier behind the scenes.
Not that I want to do it but does anyone know what the form tool looks like for cutting a worm gear and worm? I know a standard gear cutter looks like a slitting saw but how are helical and worm gears done? It seems like it would be done vertically with some sort of special end mill.
It's done with the same kind of cutter. The 4th axis is inclined to the angle of the helix, and the path is programmed to the same angle. That should work anyhow... I've only actually done helical gears on a horizontal conventional mill with a universal table geared to the dividing head, but the above should acheive the same effect.
ETA: You can thread worm gears on a lathe.
I was surfing Youtube and found this:
http://www.youtube.com/watch?v=fps0OR1eF_s]Cutting helical gear - YouTube
This might just be some guy with a v-bit but if this has an involute profile to the bit you could do gears with complex curves. Just knowing what these bits are called could answer lots of questions.
Art Fenerty The guy who came up with Mach3 has a pretty cool program called Gearotic for making gears. here is a link to a discussion here at the Zone. And a link the the gearotic page as well. As I recall it is designed to use regular endmills as long as they can get into the root.