Gears for Gary

[lane]

Needed a project this week end .So i set up and made 5 gears for one of our members. who needed the for a 1909 lathe he is restoring. Here are some picthures.
Turning gear blanks.
Parting off blanks.
Stack of un cut blanks.
Cutting 20 tooth gear.

[lane]

More cutting.

Finished stack of 14 DP gears Five gears 20 tooth 24, 28 , 32 , 60 tooth .
Boxes them up to mail this evening Merry Christmas or Happy birthday Gary . Don't worry NO CHARGE. Hope these get you going. Return the favor to some one some times. What goes around comes around. Lane

[sidegrinder]

Hats off to Lane for setting a real good example for the rest of us derelics That's a real nice gesture there and it does feel good to help another out like that--good for you, your momma would be proud!

[ProGunOne]

Ditto! Bravo.............

[j king]

What a generous deed Lane.Very nice job.Also looks like you have a nice shop. Jim

[garyphansen]

Lane, I do not what to say but Thank You! The people on this board are some of the nicest to be found anywere, and you are up there at the top. Thanks again, and if there is anything I can do to return the favor please let me know. Gary P. Hansen

[dp]

I gotta agree with Gary - that was a fine thing to do, Lane.

[Joel]

Heck of a nice thing to do Lane. Thanks!

[Mike Burdick]

Lane,

What a gift! That's a lot of work and represents quite a bit of money.
Like others have said..."What a generous deed."

You're a good example of what we all should be!

Mike

[BadDog]

You are a prince among men and an amazing craftsman as well. Nicely done, in every way...

[darryl]

Way to go, Lane, and beautiful job on the gears!

[Your Old Dog]

Ah it just another sensless random act of kindness!! I would have done it for him when I got done working out the math in my check book (that gear project is so far overy my head my neck hurts just thinking about it)

[pcarpenter]

Lane-- I'd have to say that goes above and beyond the call of duty. It was certainly nice of you to do that for him...much less without even a modest charge. Gears hold a lot of (perhaps unnecessary) mystique for a lot of us home shop types, but even for a trained machinist with the right tools at hand (love your Van Norman mill by the way), they are a good bit of work.

I am a way off from cutting gears, but if you could tell us a bit about this then maybe it can be a bit of a tutorial for the rest of us as well as a great gift for Gary.

I have a couple of questions that I would like to know about for example. I would probably use a shaper to cut gears even though I have a horizontal mill. I say this because I don't have a bunch of the involute gear cutters around. If, however, you are using a mill, do you take several passes on each tooth or cut at full depth, slowly? If you can do the latter, it has to be *much* faster than a shaper ever would.

I see you use flood coolant on the lathe and mill. What do you use and do you have problems with rancid stagnation that are so common? As a home shop type, I have shyed away from it even though my lathe came with a pump as my coolant would sit more often than not. I would think that would promote it going nasty sooner than if it were regularly aerated. Someone on the PM site recommended a UV bulb as a way to avoid this but I have no firsthand experience. How about rusting where two way surfaces can trap water? Cutter life is a concern, but cutters are cheaper than new machine tools.

Good on you, Lane!

Paul

[lane]

Pcarperter I will try to answer some Questions.
Gears scare a lot of people but they are fairly simple. most good machinist books have all the formula`s for figuring out what info you need. Yes I have a set of 14 diametral pitch gear cutters . their are 8 cutters in a set.
Cutter # 1 cuts 135 teeth to a rack.
cutter # 2 cuts 55 - 134 teeth.
" # 3 35- 54 "
" # 4 26 - 34 "
" # 5 21 - 25 "
" # 6 17 - 20 "
" # 7 14 - 16
" # 8 12 - 13
You can`t cut any thing less than a 12 tooth gear. I needed a 20 tooth ,24 , 28 , 32 , and a 60 tooth gear. 20 tooth cutter # 6 24 cutter #5 28 cutter #4 , 32 cutter# 4 and the 60 was cutter # 2.
The cuts were made in one pass .154 deep 130 RPM at feed rate of 2 inches per minute. On a large gear 8 DP are less I would cut around twice a roughing cut and about 10 -20 thousand to finish. You can hand grind a bit to make one or two gears but too much trouble . gear cutters are cheep if you know where to get them. I have 2 complete sets and a bunch of different ones in different pitches.Years ago at a place i worked we fly cut gears for one of a kind jobs ,but you spend too much time trying to get gutter ground.
It took 2½ hours to turn the blanks about 30 minutes to set mill up and from 12:00 - 7 :30 to cut gears and clean up shop.
While the gears were cutting I was fooling around with other stuff. Just back out cutter index and go again.
As far as coolant I justed rigged up the coolant on the mill 5 gallon bucket with Little Giant submerged pump I use bio cool a synthetic coolant that wont go bad. I have had it in my lathe and surface grinder for ever the water will evaporate out some times just add more and go. It clean`s the machine and it wont rust things best coolant i have found any where.
As far as the info I needed Gary told me the number of teeth and the Diametral pitch of the gear`s. 20 tooth gear = outside dia. add 2 to the number of teeth = 22and divide by diametral pitch which is 14 20+ 2= 22 / 14=1.571 diameter easy. as pie

[Bill in Ky]

That was a very nice thing you did. Great work too!!