You should see the illustrations in one of the books I have in the workings of Steam Engines and Injectors I have 2 books of the set of the books from a class on Railroad Steam Engines by International Textbooks in Scranton PA From back in the days when classes where done by mail for some courses when people want to learn but did not have the time to attend a classroom-type of school
@@timsering9964 Took 3 years of drafting in HS along with 2 years of electronic, Love how people today CANT read a Blueprint. the classes were Vocation Education. BTW went in the field of computer repair
I ALWAYS use the Machinery's Handbook! My Milling Machine handbook was from the 1970s and was researched and printed in Germany; it had alot of very precise information on weird machining processes. Thank you very much Keith Very nicely executed but just as important, very nicely set up so you come out with a super nice part in the end.
I was a machinist for 46 years before retiring at age 62. I never made a bevel gear. Nice work. By the way, I still have a Bridgeport and South Bend with 3 phase power in the garage. The neighbors keep me busy fixing their tractors and lawn mower parts. I need a bigger garage and a surface grinder. Love your videos.
I’m not a machine shop guy but I love watching milling machines and people put their skills to work restoring things. When I saw you cut the initial casting I was hooked.
I like your teaching style, Keith. I don't have dividing head or horizontal mill, but I have a vertical mill and was mentally converting your setup to what I'd need to do in the other direction.
I wish there were something else, other than just the 'like' button, to show one's admiration for another person's skills. What I see here is a display of absolutely consummate professional competence, only possible when the operator is at the peak. Eleven-out-of-ten here, for mister Rucker. BRAVO Sir ! and thank you for sharing.
Saw someone on another channel asking for help printing a bevel gear. He couldn't stop it from binding. Now I can see why. Thanks for the great explanation of the tooth geometry.
Like every machinist, on occasion I get questions about what a machinist does. And I try to explain what it is that I've spent so many years of my life doing and I'll get comments from different people to the effect of, "well, that doesn't sound so hard, all you have to do is set the machine and it does the work!" From now on I'm going to send them to your channel and let them see for themselves just how much work and effort has to go into a machined part like this one you just did. Wonderful work Mr. Rucker, well done.
Awesome thanks for sharing Keith! I don't watch you because you are an "expert" I watch you because you strike me as an honest guy using what skills and experience has taught him. Keep up the good work :)
I appreciate the effort you made to explain what is necessary to cut the teeth of a bevel gear. I have never seen a discussion of this before and you explained it so I could understand it. Thank you very much.
Keith, one of the biggest things I love about you is your lack of fear to tackle things you have zero experience doing. It doesn't stop you, you just try. Even if you fail and your pride takes a hit, you chalk it up to learning. Thank you!!!
Keith, like you I've cut many spur gears repairing lathes and other machines. But bevel gears, ugh! I have a beautiful 1897 Flather lathe and a nice adjust-tru chuck that have been waiting for me to cut bevel gears so they can get back to work. Your "course" has given me what I needed! Thanks for your wisdom and insight. Can't wait to get back to the shop and get these two bevel gears cut!!
Very impressive video. I recently made my first spur gear reduction to replace a very awkward hand crank on the side of a vertical milling head machine. Gear reduced 96:15 ratio ...an estimated ratio ...and lucky me, the ratio turned out almost perfect. I simply attach a cordless hand drill to an input shaft and let the drill raise and lower the head. I planned ahead to reduce more if needed in the gear frame mechanism ...but it wasn't needed. As it was a first attempt, and spur gear was the "easiest". I was interested in looking into a bevel gear design to have the input shaft pointing forward toward the operator. Your video answered ALL the questions! Thank you very much for sharing your knowledge and time.
I didn't understand half he said at the beginning, it was to technical for me . But later in the video I understood more. When he actually started making it. But I never knew there was so much to making bevelled gears . A very well made explanation of a very complicated subject !
Keith takes it to the next level !! You don't get a diploma or even a certificate for all this work, but you get something even better... a functional bevel gear.
Very interesting to watch. It just shows how smart people had to be in the past to make complicated objects with very basic tools. Nowadays with CNC machining many things have become much easier(faster/cheaper). It makes you appreciate the skills of workers/machinists in the past.
Keith, You did a great job hitting the high points of the 3 pass approximation method. A full detailed discussion is beyond the scope of this video. I made bevel gears on my K&T 2HL with the same setup but only had spur gear cutters as you mentioned. There are ways to "generate" a much more accurate bevel gear on the mill but they take a lot more passes with careful setups. The CNC has pretty much taken over and allows you to generate a good involute with constantly varying tooth pitch with a 4 to 6 axis machine. As you say the dedicated gear shaper is the way to do volume production generated involute bevel gears.
Fantastic Keith. Nothing simple for the one shot home setup. Getting it done and correct within means is always a win. Way to get after it and get it done. Thank you for sharing this and some of the issues you encountered. The math alone as you said isn't straight forward and while trivial is easy to mistake. Even the face angle can be mind blowing. Pitch angle is the rolling relative center angle between the mating gears allowing the resulting shaft angle to be in this case 45deg. Awesome to see you do this.
You did a great job explaining the process. i understood it perfectly. You would make a good instructor. I have only cut 1 spur gear back in tech school 40 years ago. It was a prime no, 89 tooth gear. I did it as a favor for a job shop. He was very happy with it .
Keith you are a Master of your craft, I could understand some of it (not being a machinist) but got lost about 3 minutes after you started explaining the angles of cut. It can out great, can't wait til it's finished. Thanks for sharing and stay safe.
Im not meaning to talk bad about other channels, but this channel consistently makes me feel like ive learned something new. Thoughtfully explained, wonderfully filmed, by a guy that is humble as the day is long. No wonder i get excited everytime i get a new video notification!! Best machining channel on UA-cam!
Keith....great job. I love these videos. I'm an engineer and I enjoy seeing the details of what goes on when parts are built by skilled craftsmen like you. Keep up the great work. Cheers. Also, you're presentation is really good.
Great Video! Makes me appreciate the effort needed over a hundred years ago, and just to think of the effort, and thought process, needed to start making any gear, not just those. What about the tiny ones in a pocket watch winder!! Mind blowing!!!!
I could have read and reread the information in the Machinery's Handbook multiple times without getting the insight that I obtained by watching this video. While not a comprehensive treatise on bevel gear cutting, Keith pulled together the essential elements that would make deeper study easier.
Nicely presented. As a non-machinist, I was able to understand you and appreciate both your explanation and the fine job you did with old machinery making what appears to be a very serviceable bevel gear. Good Job!
I went through this 30 years ago, using similar equipment like you did. You are right, to understand what and why you do it is more than half way. About 5 years ago I made a bevel gear on a 4 axis CNC using ball endmills - that was in comparison really easy.
Lots of magic sauce! Like most things in life, do your homework. Good demonstration on making intricate parts with what equipment is available vs ideal equipment designed for one job.
Keith, Never cut a bevel gear before, but also never thought it was any big deal. But watching you go through the steps I now realize that its a bigger deal than I thought. Thanks for sharing. And maybe its time for me to get one of those fancy machining hand books :) Gary
That's a pretty impressive result for your first time. Congratulations and I appreciate your honesty and sincerity as you explained this difficult operation. Well played.
Having cut bevel gears on a horizontal mill myself, I can vouch for the attention to detail required to make these gears. Nice job. My take on this subject is don’t be afraid to take it on, just do your homework. I’m starting to sound like Keith. 😁 Thanks Keith, John
I only have a small vertical mill, but it has some degree of rigidity ...but certainly not a two ton Cincinnati. At least a box column. Very impressive video. I recently made my first spur gear reduction to replace a very awkward hand crank on the side of a vertical milling head machine. Gear reduced 96:15 ratio ...an estimated ratio ...and lucky me, the ratio turned out almost perfect. I simply attach a cordless hand drill to an input shaft and let the drill raise and lower the head. I planned ahead to reduce more if needed in the gear frame mechanism ...but it wasn't needed. As it was a first attempt, and spur gear was the "easiest". I was interested in looking into a bevel gear design to have the input shaft pointing forward toward the operator. Your video answered ALL the questions! Thank you very much for sharing your knowledge and time. ------ I am thinking I might like this new challenge!!
Fantastic demo on how to cut a bevel gear with limited equipment 👏👏 I can see how the addition of one of the electronic indexing kits with stepper servo attached to the dividing head would greatly simplify and speed up the indexing. Nice job,Keith.👍
Thanks for posting this video. There is a real dearth of information on bevel gear cutting and this helps a lot. Of the many things I learned probably the most important one is that if you can find an off the shelf bevel gear for your application it will probably be cheaper than trying to find the cutters and do all the work to make one, unless you're just up for a challenge. If you can't find a proper gear you don't have any other choice. Thanks again!
Wow🤔, probably the highest challenging task yet. Well done! Thanks for allowing us to look over your shoulder and the well though out description of the complexities.
Great 👍🏼 job Keith! I have cut a lot of different configurations never had to get really involved in gear cutting. Your general public has no clue what a machinist has to do to calculate completion of an operation. I have been blessed to work I. The manual machine side. NC machinist use to be what the industry was always looking for. I understand the logic for high speed production. But as soon as they know you have manual skills your gold and you get all the problem projects!! Keep the great videos coming!
Lee Klemetti very true! Growing up we always thought our parents were clueless! They had more cognitive thinking going on than we can imagine! My machinist handbook saved my butt several times! My dad was a carpenter, he also had what he called his carpenter bible. It had all types of calculations. Pitch and rise, footings and foundation load calculators tons of structural formulas. Even though the engineer has already done it. The old timers validate everything! Be blessed!!
I suppose the next learning step is to make a rear axle for a car (both crown AND pinion)? - OK maybe not. But makes you appreciate the minds who worked all this out - with no computers, only slide rules and log tables!
Thank you my friend. I've been intimidated by cutting gears and didn't have tooling needed to cut them so no need to learn. After watching your process, your studying, your abilities I would entertain cutting a gear now. Still no guarantee it would be right but I'd try it with more confidence than I had. Hope that makes sense Keith. Thank you for enlightening me.
This was super interesting. I guess I never thought about the fact that a bevel gear tooth had tapered faces. Well done Keith for a great explanation and some good footage of the cutting stages.
Nice ! I never had to make a bevel gear so I didn't realize there was so much to it. So I'm happy you did this demonstration as it was something new to learn about. Thanks. I hadn't watched your channel for a while but I have to say your shop is looking great! That's an impressive collection of too boxes in the background - especially the Gerstners!
Gday Keith, you did a great job explaining the makings of a bevel gear, I really need to get a machinery’s handbook, there is a lot of maths that goes into this and sadly mathematics and I don’t tend to mix, I appreciate the effort you go to to help people like me understand how things work, thank you, Take care. Matty
Amazing work! I have a weekly lunch with a great friend, and we discuss many YT channels... the Bevel Gear Project caused much musing: This musings are now answered. Again Great work!
What a saga! Bravo for seeing this through. I do have to pile on whomever is complaining about the runout on your mill. To recap: - You commissioned a custom iron casting - You did the lathe work to create a gear blank from the casting - You wrangled an antique bevel gear cutter - You handmade a custom 27mm arbor to mount the antique cutter - You worked out a dizzying amount of 3D trigonometry including extensive book research and a custom spreadsheet - You made a delrin mockup to practice the job - You tolerated (I'm guessing) 35 thousandths of runout on the horizontal mill, tearing up your antique cutter, messing up your speeds and feeds, and probably compromising on the part's tolerances and finishes, because meh Again, I like you, I get your notifications, and I'm gonna keep watching this project. And I also develop blind spots when my perfectionism kicks into high gear and I fixate on my favored part of a big system. But it's easy to see how a reasonable person might suggest that you skip some extreme-precision scraping on your planer and repair your mill!
Wow, every time I thought, ok, not too bad, then you'd add the next part to the plan. Good to be very methodical! I liked how you explained, or didn't explain! The spreadsheet! Well Done.
My Machinery's Handbook is a 1959, 16th Edition. I've always had it in my kit for all of 40 plus years and now I'm "retired", it sits beside me at my worktable at home.
" Old machines" make you think. They also make you work a little harder at what you are trying to do. Your set up has to be a little more thought out and refined. Old stuff is what I learned on. Young people can't seem to deal with it. They want everything new. I once ran an old long tabled mill that had so much wear if you tried anything longer than 12 inches from center you had to shim your fixture. Table had that much drop in it. But you learned these things and made your set ups to compensate for it. You still made good parts you just had to work a little harder to get them. I think Keith did a fine job. Like it when you sped it up. Makes it look like an NC machine......
Appears the spacers (left of cutter) ID could be a scoche oversize creating a ‘wobble effect’. Just speculative! But for all I know it could be bent like a banana! Enjoy your videos and thanks sharing them!
You owe me a new chair Keith. Every time you RAPID THE WORK TO THE SPINNING CUTTER I flinched. LOL! Every arbor runs out. Even new ones. This means that only 1/2 of the teeth are cutting. Keep this in mind when doing your feed formula. Anyway I think you went one notch faster than I would've. I gotta tell ya, I can't wait to see the first chips from this planer. Congratulations on the bevel gear! I'm a tad jelly.
The arbor isn't supposed to run out. Would you accept 1/5th of full productivity and even smaller fraction of the possible tool life in a production run which they were made for? If a new arbor would run out, it's 99% chance of user error and 1% of faulty product that slipped through inspection or something like that, lol
Arbor run out is just a fact we live with when using these horizontal mills. In this instance, Kieth is more like a job shop than a production shop. If I had a choice, I would not use these types of mills for production. Set up is too labor intensive.
@@Scooter-k1h for some jobs the horizontal mill is ideal, for example you can gang mill a lathe bed casting to be ready for grinding the ways in one pass. Lots of other similar applications as well but mostly if not all for production. The setup times matter the most in one-offs.
Keith, I’ve only ever cut spur gears, both involute and a different tooth form for clocks, and haven’t touched any machine tool since 1990 when I moved to a new workplace and lost access to workshops. Interesting to compare the cutting of this bevel gear to the helical gear which you did more recently. The helical gear was quite simple; it took a lot of time and different videos, but most of that work was in finding or making missing, broken or incorrect parts. There was also the need to use the universal head due to the large helix angle of that gear. Now you have everything set up cutting another helical gear would be a fairly simple matter. The bevel gear is more complicated to set up. I then thought about whether it would be possible to combine the two techniques to cut a spiral bevel gear on a horizontal mill without needing a specialised machine. Looked on UA-cam and there’s a video of somebody doing it; looks like they’re using a fly cutter. Amazing what you can get a horizontal milling machine to do. Have noticed that both of your dividing heads have two handles, the one with the plunger pin to fit the holes in the index plate and a plain handle. Obviously you couldn’t turn the plain handle while the pin was engaged in the plate, and it would be difficult to hold the pin out with one hand while turning the plain handle with the other. Is it possible to lock the pin back while turning the plain handle? This would seem like a good idea but I’ve never seen it on any devising head that I have used. Can either of your dividing heads do differential indexing? Might be useful on the k type with it’s 5:1 ratio where you might need to turn the handle by a small amount to index a large number of divisions. I had never heard of K&T until I watched your videos. Do you have a copy of one of their catalogues showing all of the various attachments they made? If you do it would be interesting to see a scan of it. Best wishes.
Keith, well played. You did an outstanding job outlining the geometry and what is needed for cutting this type of gear. Nicely done!
Removing pet with an infrared head
Antonmursid🙏🙏🙏🙏🙏🇮🇩🇮🇩🇮🇩🇮🇩🇮🇩
I felt like I was in a class room with a very knowledgeable teacher that is very talented at teaching!!!
I respect your honesty, and admire your craftsmanship.
Outstanding work.
Take care.
I admire the draftsmen who made the illustrations in the machinery's handbook without 3D CAD
Life wasn't so bad with descriptive geometry
You should see the illustrations in one of the books I have in the workings of Steam Engines and Injectors
I have 2 books of the set of the books from a class on Railroad Steam Engines by International Textbooks in Scranton PA
From back in the days when classes where done by mail for some courses when people want to learn but did not have the time to attend a classroom-type of school
they didn't do it freehand, they used all sorts of mechanical devices for drafting, as well as tracing shadow boxes
Thats when people used there brain and not a computer
@@timsering9964 Took 3 years of drafting in HS along with 2 years of electronic, Love how people today CANT read a Blueprint. the classes were Vocation Education. BTW went in the field of computer repair
I ALWAYS use the Machinery's Handbook! My Milling Machine handbook was from the 1970s and was researched and printed in Germany; it had alot of very precise information on weird machining processes.
Thank you very much Keith Very nicely executed but just as important, very nicely set up so you come out with a super nice part in the end.
I was a machinist for 46 years before retiring at age 62. I never made a bevel gear. Nice work. By the way, I still have a Bridgeport and South Bend with 3 phase power in the garage. The neighbors keep me busy fixing their tractors and lawn mower parts. I need a bigger garage and a surface grinder. Love your videos.
You explain things so well. I'm no machinist, but I could understand everything clearly.
Keith , your the man , its been 48 years since i studied this method , you did great , you have patience , thank you !
Super video, very educational and insightful, bevel gears are so useful and undervalued. Really appreciate your take on making them.
I’m not a machine shop guy but I love watching milling machines and people put their skills to work restoring things. When I saw you cut the initial casting I was hooked.
This is great! I enjoyed the math and attention to detail. Your amount of homework put in is clearly evident. Thank you Keith!
I like your teaching style, Keith. I don't have dividing head or horizontal mill, but I have a vertical mill and was mentally converting your setup to what I'd need to do in the other direction.
I wish there were something else, other than just the 'like' button, to show one's admiration for another person's skills. What I see here is a display of absolutely consummate professional competence, only possible when the operator is at the peak. Eleven-out-of-ten here, for mister Rucker. BRAVO Sir ! and thank you for sharing.
Saw someone on another channel asking for help printing a bevel gear. He couldn't stop it from binding. Now I can see why. Thanks for the great explanation of the tooth geometry.
Like every machinist, on occasion I get questions about what a machinist does. And I try to explain what it is that I've spent so many years of my life doing and I'll get comments from different people to the effect of, "well, that doesn't sound so hard, all you have to do is set the machine and it does the work!" From now on I'm going to send them to your channel and let them see for themselves just how much work and effort has to go into a machined part like this one you just did. Wonderful work Mr. Rucker, well done.
Awesome thanks for sharing Keith! I don't watch you because you are an "expert" I watch you because you strike me as an honest guy using what skills and experience has taught him. Keep up the good work :)
No worries though, there are plenty of "experts" in the comments section. =P
I appreciate the effort you made to explain what is necessary to cut the teeth of a bevel gear. I have never seen a discussion of this before and you explained it so I could understand it. Thank you very much.
Keith, one of the biggest things I love about you is your lack of fear to tackle things you have zero experience doing. It doesn't stop you, you just try. Even if you fail and your pride takes a hit, you chalk it up to learning. Thank you!!!
I have seen a lot of bevel gears and not realize much is taken into account to cut them. Thanks for the explanation into the cutting, well done.😊
Keith, like you I've cut many spur gears repairing lathes and other machines. But bevel gears, ugh! I have a beautiful 1897 Flather lathe and a nice adjust-tru chuck that have been waiting for me to cut bevel gears so they can get back to work. Your "course" has given me what I needed! Thanks for your wisdom and insight. Can't wait to get back to the shop and get these two bevel gears cut!!
Very impressive video. I recently made my first spur gear reduction to replace a very awkward hand crank on the side of a vertical milling head machine. Gear reduced 96:15 ratio ...an estimated ratio ...and lucky me, the ratio turned out almost perfect. I simply attach a cordless hand drill to an input shaft and let the drill raise and lower the head. I planned ahead to reduce more if needed in the gear frame mechanism ...but it wasn't needed. As it was a first attempt, and spur gear was the "easiest". I was interested in looking into a bevel gear design to have the input shaft pointing forward toward the operator. Your video answered ALL the questions! Thank you very much for sharing your knowledge and time.
A neat exploration of something we commonly take for granted. Thanks for the great explanation and background, great shots and editing.
In the age of 3D printers, this video makes me appreciate the maths and tradesmanship behind the bevel gear. Thanks Keith.
This was the first bevel gear fabrication I have seen so this was a good subject. Well done Keith!!!!
Thank you Keith. I really appreciate the look over your shoulder to see such amazing projects.
I didn't understand half he said at the beginning, it was to technical for me . But later in the video I understood more. When he actually started making it. But I never knew there was so much to making bevelled gears . A very well made explanation of a very complicated subject !
Keith takes it to the next level !!
You don't get a diploma or even a certificate for all this work, but you get something even better... a functional bevel gear.
Very interesting to watch. It just shows how smart people had to be in the past to make complicated objects with very basic tools. Nowadays with CNC machining many things have become much easier(faster/cheaper). It makes you appreciate the skills of workers/machinists in the past.
Had no idea bevel gears had so much going on with them. Fascinating to watch, and very informative. Thank you for doing the video. 👍
Keith, You did a great job hitting the high points of the 3 pass approximation method. A full detailed discussion is beyond the scope of this video. I made bevel gears on my K&T 2HL with the same setup but only had spur gear cutters as you mentioned. There are ways to "generate" a much more accurate bevel gear on the mill but they take a lot more passes with careful setups. The CNC has pretty much taken over and allows you to generate a good involute with constantly varying tooth pitch with a 4 to 6 axis machine. As you say the dedicated gear shaper is the way to do volume production generated involute bevel gears.
Fantastic Keith. Nothing simple for the one shot home setup. Getting it done and correct within means is always a win. Way to get after it and get it done. Thank you for sharing this and some of the issues you encountered. The math alone as you said isn't straight forward and while trivial is easy to mistake. Even the face angle can be mind blowing. Pitch angle is the rolling relative center angle between the mating gears allowing the resulting shaft angle to be in this case 45deg. Awesome to see you do this.
You did a great job explaining the process. i understood it perfectly. You would make a good instructor. I have only cut 1 spur gear back in tech school 40 years ago. It was a prime no, 89 tooth gear. I did it as a favor for a job shop. He was very happy with it .
Keith you are a Master of your craft, I could understand some of it (not being a machinist) but got lost about 3 minutes after you started explaining the angles of cut. It can out great, can't wait til it's finished. Thanks for sharing and stay safe.
Im not meaning to talk bad about other channels, but this channel consistently makes me feel like ive learned something new. Thoughtfully explained, wonderfully filmed, by a guy that is humble as the day is long. No wonder i get excited everytime i get a new video notification!! Best machining channel on UA-cam!
That was brilliant kieth thanks for posting all your films it learns me a hell of a lot and I’m 64
Keith....great job. I love these videos. I'm an engineer and I enjoy seeing the details of what goes on when parts are built by skilled craftsmen like you. Keep up the great work. Cheers.
Also, you're presentation is really good.
It's now easy to see why gear hobs are used to form gears like this. An excellent job, Keith. Many thanks.
Bevel gears are actually not hobbed. Each tooth is cut individually like this ua-cam.com/video/QTlo6bIIieE/v-deo.html
Great Video! Makes me appreciate the effort needed over a hundred years ago, and just to think of the effort, and thought process, needed to start making any gear, not just those. What about the tiny ones in a pocket watch winder!! Mind blowing!!!!
I could have read and reread the information in the Machinery's Handbook multiple times without getting the insight that I obtained by watching this video. While not a comprehensive treatise on bevel gear cutting, Keith pulled together the essential elements that would make deeper study easier.
Great explanation, actually wrapped my head around it. Well done.
Nicely presented. As a non-machinist, I was able to understand you and appreciate both your explanation and the fine job you did with old machinery making what appears to be a very serviceable bevel gear. Good Job!
That was a blast watching The Doctor of Machining in action!
Great Job. Thanks
Thanks Keith. Appreciated the step-by-step explanation and good shots in the mill.
Keith, a privilege to witness your first bevel gear cut.
I went through this 30 years ago, using similar equipment like you did. You are right, to understand what and why you do it is more than half way. About 5 years ago I made a bevel gear on a 4 axis CNC using ball endmills - that was in comparison really easy.
Keith, you sure made that look easy! Great job!
Lots of magic sauce! Like most things in life, do your homework. Good demonstration on making intricate parts with what equipment is available vs ideal equipment designed for one job.
Keith, Never cut a bevel gear before, but also never thought it was any big deal. But watching you go through the steps I now realize that its a bigger deal than I thought. Thanks for sharing. And maybe its time for me to get one of those fancy machining hand books :) Gary
That's a pretty impressive result for your first time. Congratulations and I appreciate your honesty and sincerity as you explained this difficult operation. Well played.
Keith, you are The Best Teacher on UA-cam.
I have much respect for the effort and talent you put into this rewarding project. Thank you for sharing this.
Gearing is a world all it's own.
I really wish I was younger and learning/ memory was still part of me.....
Great work Kieth.
Having cut bevel gears on a horizontal mill myself, I can vouch for the attention to detail required to make these gears.
Nice job. My take on this subject is don’t be afraid to take it on, just do your homework. I’m starting to sound like Keith. 😁
Thanks Keith,
John
I only have a small vertical mill, but it has some degree of rigidity ...but certainly not a two ton Cincinnati. At least a box column. Very impressive video. I recently made my first spur gear reduction to replace a very awkward hand crank on the side of a vertical milling head machine. Gear reduced 96:15 ratio ...an estimated ratio ...and lucky me, the ratio turned out almost perfect. I simply attach a cordless hand drill to an input shaft and let the drill raise and lower the head. I planned ahead to reduce more if needed in the gear frame mechanism ...but it wasn't needed. As it was a first attempt, and spur gear was the "easiest". I was interested in looking into a bevel gear design to have the input shaft pointing forward toward the operator. Your video answered ALL the questions! Thank you very much for sharing your knowledge and time. ------ I am thinking I might like this new challenge!!
Fantastic demo on how to cut a bevel gear with limited equipment 👏👏 I can see how the addition of one of the electronic indexing kits with stepper servo attached to the dividing head would greatly simplify and speed up the indexing. Nice job,Keith.👍
"Something I've not done before"
"Excellent" says Keith with a gleam in his eye!
I admire your sense of learning and your persistence.
One step closer Keith. Cant wait to see it all finished.
Thanks for posting this video. There is a real dearth of information on bevel gear cutting and this helps a lot. Of the many things I learned probably the most important one is that if you can find an off the shelf bevel gear for your application it will probably be cheaper than trying to find the cutters and do all the work to make one, unless you're just up for a challenge. If you can't find a proper gear you don't have any other choice. Thanks again!
Fascinating engineering.. probably the best video I’ve watched this year. Thanks for the insight into the complexity of this task. Really enjoyed it.
Wow🤔, probably the highest challenging task yet. Well done! Thanks for allowing us to look over your shoulder and the well though out description of the complexities.
Great 👍🏼 job Keith! I have cut a lot of different configurations never had to get really involved in gear cutting. Your general public has no clue what a machinist has to do to calculate completion of an operation. I have been blessed to work I. The manual machine side. NC machinist use to be what the industry was always looking for. I understand the logic for high speed production. But as soon as they know you have manual skills your gold and you get all the problem projects!! Keep the great videos coming!
Remember those calculations are very OLD! Those old machinists really did their homework way back in the day. No CAD or computers either. LOL
Lee Klemetti very true! Growing up we always thought our parents were clueless! They had more cognitive thinking going on than we can imagine! My machinist handbook saved my butt several times! My dad was a carpenter, he also had what he called his carpenter bible. It had all types of calculations. Pitch and rise, footings and foundation load calculators tons of structural formulas. Even though the engineer has already done it. The old timers validate everything! Be blessed!!
I suppose the next learning step is to make a rear axle for a car (both crown AND pinion)? - OK maybe not. But makes you appreciate the minds who worked all this out - with no computers, only slide rules and log tables!
Very good explanation and demonstration on cutting bevel gears. One of your more interesting videos.
Nice one Keith I learnt a lot mostly how I need to read my machinist's handbook
Thank you my friend. I've been intimidated by cutting gears and didn't have tooling needed to cut them so no need to learn. After watching your process, your studying, your abilities I would entertain cutting a gear now. Still no guarantee it would be right but I'd try it with more confidence than I had. Hope that makes sense Keith. Thank you for enlightening me.
This was super interesting. I guess I never thought about the fact that a bevel gear tooth had tapered faces. Well done Keith for a great explanation and some good footage of the cutting stages.
Nice ! I never had to make a bevel gear so I didn't realize there was so much to it. So I'm happy you did this demonstration as it was something new to learn about. Thanks. I hadn't watched your channel for a while but I have to say your shop is looking great! That's an impressive collection of too boxes in the background - especially the Gerstners!
Very interesting Keith. I had no idea how this would be made so watched it with great interest.
Gday Keith, you did a great job explaining the makings of a bevel gear, I really need to get a machinery’s handbook, there is a lot of maths that goes into this and sadly mathematics and I don’t tend to mix, I appreciate the effort you go to to help people like me understand how things work, thank you, Take care. Matty
That’s a good result Keith. I feel like I could do it too. Thanks for sharing.
Another great video. You did an excellent job explaining a very complex topic in an easy to understand way. Well, maybe not easy but clearly.
Keith you make great...Videos l could watch you work for hours....Thank my friend....Blessing you way for sure....!
Our Mr Keith always keeps us interested in the "Gems" he does. Mighty fine man indeed.
Amazing work! I have a weekly lunch with a great friend, and we discuss many YT channels... the Bevel Gear Project caused much musing: This musings are now answered. Again Great work!
Nice job and excellent explanation! And as the saying goes the parts just need to get used to each other. Thanks for all the videos.
Wow, quite an involved process.. Great work Keith..
Excellent video, Keith. Thanks for taking the time and showing it.
What a saga! Bravo for seeing this through.
I do have to pile on whomever is complaining about the runout on your mill. To recap:
- You commissioned a custom iron casting
- You did the lathe work to create a gear blank from the casting
- You wrangled an antique bevel gear cutter
- You handmade a custom 27mm arbor to mount the antique cutter
- You worked out a dizzying amount of 3D trigonometry including extensive book research and a custom spreadsheet
- You made a delrin mockup to practice the job
- You tolerated (I'm guessing) 35 thousandths of runout on the horizontal mill, tearing up your antique cutter, messing up your speeds and feeds, and probably compromising on the part's tolerances and finishes, because meh
Again, I like you, I get your notifications, and I'm gonna keep watching this project. And I also develop blind spots when my perfectionism kicks into high gear and I fixate on my favored part of a big system. But it's easy to see how a reasonable person might suggest that you skip some extreme-precision scraping on your planer and repair your mill!
Raman Shah, there’s only so many hours in a day.
You made that look easy, I would have screwed it up at the point when you took the backlash out of the head. Great video. Definitely learned a lot
There's a lot more to bevel gears than I'd ever thought. Thanks, Keith!
Keith, I think that was your best video ever! Learned a lot, as did you apparently. Thanks.
Very well done Keith, thanks for posting
That was great, your quite the teacher, I’m learning more and more through your channel
An intense segment, well done !!
Thanks for letting us to look over sholder,you explained the process very well and made the operation understandable....but way above my pay grade.🤗🤗
Beautiful video work too. Seeing the profile of the gears appearing was pretty hawesome.
Wow, every time I thought, ok, not too bad, then you'd add the next part to the plan. Good to be very methodical! I liked how you explained, or didn't explain! The spreadsheet! Well Done.
My Machinery's Handbook is a 1959, 16th Edition. I've always had it in my kit for all of 40 plus years and now I'm "retired", it sits beside me at my worktable at home.
I need to cut 6 pinions for my new Shay project and this video should be of great help. Thanks Keith!
" Old machines" make you think. They also make you work a little harder at what you are trying to do. Your set up has to be a little more thought out and refined. Old stuff is what I learned on. Young people can't seem to deal with it. They want everything new. I once ran an old long tabled mill that had so much wear if you tried anything longer than 12 inches from center you had to shim your fixture. Table had that much drop in it. But you learned these things and made your set ups to compensate for it. You still made good parts you just had to work a little harder to get them. I think Keith did a fine job. Like it when you sped it up. Makes it look like an NC machine......
Appears the spacers (left of cutter) ID could be a scoche oversize creating a ‘wobble effect’. Just speculative! But for all I know it could be bent like a banana! Enjoy your videos and thanks sharing them!
You owe me a new chair Keith. Every time you RAPID THE WORK TO THE SPINNING CUTTER I flinched. LOL! Every arbor runs out. Even new ones. This means that only 1/2 of the teeth are cutting. Keep this in mind when doing your feed formula. Anyway I think you went one notch faster than I would've. I gotta tell ya, I can't wait to see the first chips from this planer. Congratulations on the bevel gear! I'm a tad jelly.
The arbor isn't supposed to run out. Would you accept 1/5th of full productivity and even smaller fraction of the possible tool life in a production run which they were made for?
If a new arbor would run out, it's 99% chance of user error and 1% of faulty product that slipped through inspection or something like that, lol
Arbor run out is just a fact we live with when using these horizontal mills. In this instance, Kieth is more like a job shop than a production shop. If I had a choice, I would not use these types of mills for production. Set up is too labor intensive.
@@Scooter-k1h for some jobs the horizontal mill is ideal, for example you can gang mill a lathe bed casting to be ready for grinding the ways in one pass. Lots of other similar applications as well but mostly if not all for production. The setup times matter the most in one-offs.
Keith,
I’ve only ever cut spur gears, both involute and a different tooth form for clocks, and haven’t touched any machine tool since 1990 when I moved to a new workplace and lost access to workshops.
Interesting to compare the cutting of this bevel gear to the helical gear which you did more recently. The helical gear was quite simple; it took a lot of time and different videos, but most of that work was in finding or making missing, broken or incorrect parts. There was also the need to use the universal head due to the large helix angle of that gear. Now you have everything set up cutting another helical gear would be a fairly simple matter.
The bevel gear is more complicated to set up. I then thought about whether it would be possible to combine the two techniques to cut a spiral bevel gear on a horizontal mill without needing a specialised machine. Looked on UA-cam and there’s a video of somebody doing it; looks like they’re using a fly cutter. Amazing what you can get a horizontal milling machine to do.
Have noticed that both of your dividing heads have two handles, the one with the plunger pin to fit the holes in the index plate and a plain handle. Obviously you couldn’t turn the plain handle while the pin was engaged in the plate, and it would be difficult to hold the pin out with one hand while turning the plain handle with the other. Is it possible to lock the pin back while turning the plain handle? This would seem like a good idea but I’ve never seen it on any devising head that I have used.
Can either of your dividing heads do differential indexing? Might be useful on the k type with it’s 5:1 ratio where you might need to turn the handle by a small amount to index a large number of divisions.
I had never heard of K&T until I watched your videos. Do you have a copy of one of their catalogues showing all of the various attachments they made? If you do it would be interesting to see a scan of it.
Best wishes.
Keith, sir, you have my admiration. Thank you 👍👍👍👍👍👍👍
Oh man! I need to build 1 if not 2 in the distant future for a wringer washer. Good video to start out on
This is why I watch. Great machining, and interesting parts to be machined. Keep up the good work.
very interesting video. great camera shots. thanks keith
Amazing making
Great video discussion/demonstration/build
That was very interesting - I had no idea how to mill a bevel gear. Thanks for the great video.