Building a Gear Shaper
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- Опубліковано 26 вер 2024
- I've tried to make internal gears by a number of methods in the past, but it's never quick, easy or reliable with normal hand or machine tools. The gear shaper is the perfect machine to do this, so I thought I'd have a go at building one.
This has to be one of the best, if not the best diy machine builds I’ve seen on UA-cam yet. Your use of the donor mill casting was a great idea. It retains the quill functionality to get your reciprocating motion (shaper motion) and you get the dampening properties of cast iron that all proper commercial machine tools are built from. Most diy machine tool builds I’ve seen are of the “built up” variety, with housings fabricated from steel plate and bolted together or a combination of bolted construction and weldments. The cast iron construction being more rigid and thus more ideal for machining.
Can’t wait for part 2!!
Thanks! The only thing I'm slightly concerned about is that the rack and pinion gears on the quill are not that big and probably not designed for this type of use. That's why I used the shear pin. I'm probably being over cautious though and it will outlast all the use I'll ever need from it.
@@AndysMachines I agree. The rack and pinion gears will probably wear out first (after a LOT of gear cutting). Maybe a bell-crank arrangement at the top of the spindle driven from your new reciprocating arm could drive the spindle up and down directly?
@@chrisarmstrong8198 Good point. Not sure how the bellcrank would be fitted, but I was thinking of a piston. Could you elaborate?
Amazing man, most content creators would have stretched this into a 15 part series. I love the high-level overview that shows the most interesting parts of the process in your style of filming.
funny you said this. I could watch this all day. a 15 part series sounds fantastic :D. Andy always delivers!!! TIA, Greg
Absolutely fantastic! can't wait for part 2! I love that you are re-using/re-purposing old item to make a completely new machine- that in turn makes other parts for other machines- Brilliant!
Absolutely amazing work. I love seeing you take crappy chinesium machine tools and turn them into other machine tools with amazing precision. Can’t wait for part 2!
Simply the best. No other teacher, which he definitely is, can transmit so much information in such a precise and clear way. Learn from him and you will be a better machinist, his ideas for obtaining a very complicated process in a simple attainable way using available parts and new technology are outstanding. Congratulations 👏
Very impressive, taking the old mill and converting it like this, so clever. I'm looking forward to part 2
That moment when you wanted to make internal gears for a while now - and have a spare milling head... Looks like another project for myself down the road.
This is awesome! Thank you for sharing this!
Astonishing vision, design and execution. Well done on such a brilliant build. 👏👏👍😀
FINALLY !!!! I HAVE BEEN WAITING FOR SOMEOME TO TREPAN SOMETHING FOR YEARS!
Incredible build and some amazing techniques. This really makes for an incredibly precise piece of equipment and endless possibilities well done!
I love your videos so much. The effort, skill, and knowledge are immeasurable.
Now that is a LOT of work.
WOW... a very impressive build!!!
What a great start to the weekend! Always a delight to see a new video.
Your channel is awesome and extremely underrated.
Fabulous project, fabulous work, and fabulous explanations. Thanks for sharing this with us.
Regards Mark in the UK
BRAVO, Andy!
Wow! So keen for the next one!
Very interesting project. Thoroughly enjoyed.
You’re back! ❤
I never actually went anywhere, but time flies!
Absolutely brilliant. I love it.
Always exciting, interesting, educational and entertaining content that I eagerly look forward to watching. Thank you 👍👍😎👍👍.
totally brilliant. Inspiring!
Simply brilliant! Looking forward to the math involved to get it all to sync.
Also hoping on more elaboration on inside gears, particularly, tooth profiles.
Fantastic work Andy, you certainly have a wide range of skills
Wow , best explanations on gears ever , thank you 🙏
Excellent video!
Very impressive! You do such well thought out projects.
I am so impressed with your designs !! 👌👍👍It is a pity that I do not have such knowledge in the field of CNC. 🤥Greetings from Poland
Jestem pod wrażeniem twoich projektów !! Szkoda, że nie mam takiej wiedzy z zakresu CNC.
Good work. We shared this video on our homemade tools forum this week 😎
You sir are a mechanical genius. I loved watching that!
Impressive!
Cheers and thanks for sharing Andy,, 🍻😎👍👍
impressive work
thank you for sharing your experience
Your videos are very impressive, Thank You very much for sharing them.
Absolutely amazing!!
Spent most of a day researching how I was going to do this for the ring gear of a planetary setup last week... Then presto! Andy beat me to it. Kudos.
This channel covers so many different topics I'm interested in, and I really have a limited interest in gears. Just became a patreon supporter.
WOW! Your video production is always so well done. Your engineering and clever design ability (i.e. talent) is exemplary.
This is not applicable to your implementation, but I turned a motor shaft down a few years back, on a new 3 phase motor I was fitting on my lathe. In my case a V-belt pulley. I didn't think about it at the time, but I left a sharp corner on the reduced shaft. Within 20 hours of running, the vibrations of the motor caused a crack to develop at that corner and the shaft with the pulley went rolling down the shop floor. Big lesson learned. Never thought that small vibration and radial load would do this on a 19mm shaft, at least not in my lifetime.
That is so cool. Once you have enough tools you can make so many other tools!
Legend !! Who would have ever thought about doing that !!
I’m loving all the gear making videos, keep up the good work!
hahaha, you got me with "The two, in no way fit together"
Cool build Andy, looking forward to the rest of the series.
Cheers
Best part is when he said "gimmie dat, gimmie dat" while building his monster. KEEP SPEED! Ok ok oh god I could say so much. But the transition from CNC spot drill to HAND DRILL really got me. 😅Pure genius.
Interesting. Very nice work
Great video! The only thing that I would change is to make the worm taper , but your system works good as well…keep up the good work!
Just pure awesomeness
Excellent work and video, thanks!
Brilliant idea 👍👍
Part two? really. I hate suspense. Anyway, this just looks like another awesome build. Top notch build for a difficult challenge. Great jOB.
Your videos are amazing; thanks for making them! Cheers from across the pond.
Thanks, Andy! A new machine to obsess over! I happen to have an old XLO mill head….hmmm.
Help me a lot. Thanx brother
Nice work. Thanks for sharing
Awesome!!! It’s like my maker Channels know I’ve been tooling up to make gears!
o yes!Dont forget the relief on up strokes!Somebody with your calibre can easily program that in.Cant wait to see Andy...
Good job c'est une idée géniale
This is excellent, cheers.
Can't wait!
Thanks for sharing.
So much garbage on youtube that gets millions of views. Content like this is why I watch youtube, I'm rooting for you that your channel will blow up big, you deserve it.
Nicely done! Thinking outside to box here. 🤔
Amazing transformation and very good machining 👍
Just a little upgrade tip add another stepper motor to bed horizontal movement you will get rack shaping machine too 🤑🤑
Love the fact you are sinking your teeth back into the whole gear topic. I believe its somewhat of a black art for most machinists s its great to learn about it.
Spectacular! That has money maker written all over it! ;)
Very cool upcycling
Технари друг друга всегда поймут. Шикарная работа!
Very Impressive! This 14 minute video must have taken 40 hours of real time to make.
Thanks a lot!! 👏👏👏👏👏👏👏👏👏👏👏
Awesome build. When I do projects they keep getting interrupted by 100 other tasks and months later my project may get completed😊
Phenomenal.
Brilliant.
I have made a planetary gear set 8mm. Tick using a a laser cnc cutter and it's working perfecly
Great video, as usual. Are you still working on the T-800? I would really like to see that finished.
Thanks! Yes I am. In fact I need this machine to make some of the T-800's gears.
Brilliant stuff :)
Awesome.
Very nice. See you in Part2D2. :)
6:30 'They call me Dr Worm... I'm not a real doctor, but I am a real worm'
I'd be interested in power skiving, I'm doing quite some gear hobbing myself.
I love this
cool amazing skill
The information I wasn't aware of is the blank also rotates with cutter
Amazing!
But have to wait for part 2… 😬😉
Another fascinating build! No need for adjustment on the stroke length? Or does that add a level of complexity not warranted in this design?
I chose a stroke length to suit the type of gears I want to make, I probably won't need to change it, if I do the only way is to shorten or lengthen one of the lever arms.
I liked the oscillating link. Could make the crank arm length with a slot, to allow for different offset, and different length of stroke.?
Yes, I did think about doing something like that and other people have mentioned this too. But for now at least it's unlikely I'll need to change the stroke for the gears I want to make.
impressive it is my first time to see that 😍
You might want to redesign the upper crank for the linear motion with a slot so you can adjust the stroke...
😐🇬🇧
inspiring to say the least 👍
Thank you! You are such a great resource for all things "gears" ! Home shop engineering is so enjoyable. Thanks for all of your great videos! PS: Consider creating an email address and adding it to the "About" section of your UA-cam channel for direct communication. Regards.
You are mad but genious !
gear skiving is more interesting , keep going on that bro
It is! The problem is it needs a specific cutter for each number of teeth, and the geometry is much more complicated. A shaping cutter (which looks very similar) will cut any number of teeth, like a hob.
Bold project Andy. Did you meticulously plan and design everything before you started or figure it out as you progressed?
I usually make a broad plan to start, but it often evolves as I build it. Usually it's steered by the parts and materials I have available. You'll see in part 2 how the control system evolved.
great job andy!!! I'd love to know how much force it takes to cut a chip with that setup. I did a small experiment on a 9x30 lathe and it didn't seem rigid enough. Also, why not just drive the cut with your Z motor? Would it stall or were you just worried about ware?
Thanks! It's actually capable of applying a downward force on the cutter of around 6000N (~600Kg) in the middle of the stroke. This would possibly be enough to strip the quill gears but hopefully the shear pin would go first. I don't know how much force it actually takes to make a cut, but considerably less, even when cutting steel the motor doesn't appear to be under much load at all. Using the Z motor (Nema 34 stepper) would be much slower, have less force, and also there would be more backlash as when using the quill I lock the head to the column.
Amazing work! Do you need to add extra lubrication for the quill and rack and pinion now they are constantly in motion? Looking forward to the next video. You'll be making a lot of gear trains when this is done!
Yes, I did make sure it was all well lubricated when I reassembled it. The quill is easy to lubricate in use, but the rack and pinion gears are not so easy to get to without pulling out the gear shaft.
@@AndysMachines ah yeah. Maybe a little oil dripper above the pinion?
Well, that sure looks a very handy tool was you a machinist by trade ? I've made clock gears in the past and found them very challenging with manual dividing heads would love a stepper motor dividing head like yours 👍
Nice work 👏 💞💞🌺😘
Merci infiniment!!!
Super
A constant oil supply will be a must
I laughed out loud at "no spinny roundy tool but a stabby in-and-outy tool", thanks.
Btw, how so that you didn't cut the worm while it was mounted to the axle? That'd be way more accurate, or am I mistaken?
Maybe I'm not sure what you mean, but the worm and shaft were all machined as one piece, though I didn't show much of this in the video.
@@AndysMachines then that should solve the case. I was thinking of having the smallest compound error of the worm/gear system as it pertains to concentricity.
The greatest thing in today's world is knowing the ledge if you don't know then it will cost you a lot of money that you don't have
Great content! New subber too.