Gear cutting question

I don't know. Might have to do some study in machinery's handbook looking not at the tables but at the formulas. I've never had to make an unconventional gear (if there is such a thing) my 'experience' came when I was sloppy when making a gear blank and thought 'what's the difference if it's a little off'. I found out!
Aaron
 
The correct term for this is "profile shifted". It's a common practice; either to make the teeth larger at the root for strength, or to compensate for the centre distance not being quire right for the two gears in question if they were standard profile.
Explained brilliantly here:

Gear Profile Shift | KHK Gears

Profile shift of gear teeth is important topic, when we talk about gear related technical issues. In this page, KHK offers some information about it.
khkgears.net khkgears.net

I've never cut a profile shifted gear myself, but it should be easy enough to dig out some info on doing so with milling cutters. You'll need to cut the blank the correct diameter as well as get the DOC right.
 
Or maybe as @cathead said cut the standard gear and then if necessary take up to .030 off the OD to match. Even at that you'd only loose .015 of tooth height.
Aaron
 
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