Cutting Helical Gears for Mastiff

[ozzie46]

Well here is the Heilcal gear progress report.


The gears cutters arrived on Wed :ups: and I made an arbor for them on Thurs and started preparations for cutting the gears. I cut a couple of practice gears and called it a night as I was not happy with them at all.



I woke up at 1 am thinking about the problem I was having with the gears. :thinking: I tried to go back to sleep but gave up about 3:30 am. I got up, had some coffee and went to the shop about 4:30 am and started cutting again. Still no joy. :think1:



Here are my setups. The first is the 63 degree setup.


http://s661.photobucket.com/user/ozzie46/media/DSC03092.jpg.html][/URL]


Trying to get the cutters centered on the gear blanks was a real chore with the head set like this.


This is the 27 degree tilt.


http://s661.photobucket.com/user/ozzie46/media/DSC03094.jpg.html][/URL]


A shot of the 27 degree 16 tooth gear being cut.


http://s661.photobucket.com/user/ozzie46/media/DSC03095.jpg.html][/URL]


This is the 63 degree gear blank after one pass of the cutter. Sorry ,can't see much.
http://s661.photobucket.com/user/ozzie46/media/DSC03093.jpg.html][/URL]


These are practice gears that didn't survive.


http://s661.photobucket.com/user/ozzie46/media/DSC03097.jpg.html][/URL]




I found out you had to really make sure the aluminum angle was real tight against the disc on the fixture. Any play and it did weird things to the gear teeth. Also I had t make sure I had positive conrtol of the shaft as I rotated it into the cutter.



On the left are the “learning” blanks and the ones on the right are keepers. :thumbsup:



http://s661.photobucket.com/user/ozzie46/media/DSC03096.jpg.html][/URL]


Here is a real crappy video. Sorry but its the best I can do. :whiteflag:



http://media.photobucket.com/user/ozzie46/media/MOV03099.mp4.html][/URL]




Well all in all in was productive day as far as the gears went I'm really happy with them. But there is a down side as my lathe motor decided to give up the ghost. anic:anic: :angry::angry:



It started running loud and got real hot.


Anybody got an extra motor for a g0602 10x 22 lathe? Grizzly say it will be Aug before they have any.



Hope you enjoyed this.


Ron

 

[rhost]

Why not just buy a VFD and 3 phase 2 pole AC motor?

 

[Bill Gruby]

Looks like you are overcoming the learning curve on this one Ron. Very nice work. Got the file, thank you.

"Billy G"

 

[ozzie46]

Why not just buy a VFD and 3 phase 2 pole AC motor?

:nomoney::nomoney:

And no electrical knowledge or experience.

Ron

- - - Updated - - -


Thanks Bill, there was a severe pucker factor there.

Ron

 

[eightball]

very nice job

 

[ozzie46]

Thanks eightball.

Ron

 

[Metalmann]

I think you did a great job. All those tedious angles can get to a guy, sometimes.:thumbsup:

 

[ozzie46]

Thanks metalman. I was born in Lafayette by the way.

Ron

 

[rhost]

I don't know what size frame or how many poles the the G0602 uses, but you might try looking at automation direct. They have a 1HP single phase 110/220 TEFC 56C frame motor that might work and its about half the price of the grizzly replacement. You can find more info on it here.

http://www.automationdirect.com/adc...hase_Motors,_56C_(0.33_-_1.5HP)/MTR-001-1AB18

 

[eightball]

Ya'll are killing me. I am in awe at what you're doing. Many years ago I had a dirt track car. Built my own motors and loved it. Unfortunantly it just became too expensive of a hobby. Now years later, you inadvertantly are inspiring me to try and build one of these. I have a full time job, and im very active in my MC club. I just dont have the time. I would love to hear this little puppy run.