Adam Savage's One Day Builds: Machining a Gear!
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- Опубліковано 28 вер 2024
- Adam embarks on a build he's long wanted to make: a supersized flywheel powered toy car that can move with tremendous energy. The first step: machining a scaled-up version of one of the gears in the toy's gear train. Machining a working gear with a specific number of teeth and gear pitch is something Adam has never done before, so it's going to be a fun machining exercise!
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#adamsavage #onedaybuilds #machining
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Adam should try doing cuts on the lathe no more than 25 thousandths at a time to prevent chatter, and potentially damaging his equipment, particularly the cutting edge of the bit.
Those nice long curly offcuts is what you want to see when you start seeing little chips check your feeds and speeds.
When the zombie apocalypse comes, I’m heading for Adam’s
As a machinist the noise when cutting gears is exactly that 😂😂
I've been building my own design little 2 cylinder engine and had to make gears a few months back , went through this whole process. It took a bit but i now have a set of gears lol. I tried with a slittingbsaw first but ended up getting a set of involute cutters. Wasnt that bad
Beautiful work mate, muuuuuch prettier than my first pinion! Look forward to watching this build :)
If it was me making that lil pretty gear and getting that comment on it afterwards I'ld get all gitty inside, I have a feeling same goes for Mr. Savage. Thank you both for your outstanding work and passion sharing across platforms
I just got secondhand glee from seeing this comment! I absolutely know Adam is going to have it tenfold. Your work is beyond exceptional!
honestly hearing adam mention he watches click spring made me smile and relize just how down to earth adam is ! id love to see clickspring visit adam and see them swapping tips and tricks with eachother
Much better than my first attempt as well Chris!
This is high praise coming from Clickspring!
The one day builds where Adam does something for the first time are the best one day builds imho
Hey Adam, I'm a phd student whose primary research area is on gear geometry and applications. I just wanted to say it was cool watching you learn a bit about the subject and make a couple of spur gears in this video!
'I dog-eared the page. I've been here before.' Is an almost cinematicly beautiful point of discovery. There were people here before.... and it was us. They've left us a message. This'll make me smile for hours.
Adam, thank you for showing people the skill needed to be an engineering machinist; in today's modern world of CinC tools, seeing someone having to work the way my grandfather, father and brother learnt to do their profession is satisfyingly interesting.
Much of the equipment used in small production/job shops is still manually operated. In my shop we have only 2 CNC gearcutters: a gasher and a hobber. Everything else uses an annoying number of gears (because of that, the CNCs are most useful for prime numbers of teeth over 100 teeth).
😅
Back when I was working as an engineer, part of my job was programming an Agie wire EDM and gears were often some of the parts we made on it. Wire EDM's are extraordinary machines and ideal for making gears. It could even make bevel gears. It was my favorite machine.
This Old Tony has some excellent videos explaining gear cutting and gears in general as well.
Gears! But were afraid to ask.
I went through this exercise digitally, had a 3d printer project that had gears, and I'm the type of person who likes to understand the why and how, so i googled the machinists handbook, walked through the process of manually drawing the gears by hand, using all the complex geometry with all the overlapping and intercecting circles and tangents in CAD. It took me a couple days to truly understand what i was doing and be able to re create the process from memory instead of reading step by step.
Now i just use the gear creator tool and it does it for me, but i understand what is going on!
My working life was spent as an engineer. Working on large industrial gearboxes and gears manufactured for high end engine manufacturers in the UK, Europe and North and South America. I traveled all around solving problems with customers. Power train engineers do have their own "speak", which to most is a foreign language. I loved my job.
The time lapse when cutting the teeth was way more satisfying when watching the drill bits spinning from vibration in the background
Nice looking job! Looking forward to seeing the complete result. Small Tip! Instead of cutting oil (or nothing at all), you can use petroleum. It gives Bronze, Brass and Aluminium a smoother surface and saves the cutting edge of your tools.
It's also a huge potential fire hazard ;)
@mike dierickx Nope. Been using that for many years when I was still working in the machineshops. We have never witnessed any fires using that and didn't take special precautions.
Good luck with the project!
@24:53 The "chatter" you are hearing is caused by a combination of factors, including the lack of lubrication, the high cutting speed (measured in in SFM, surface feet per minute), and the lack of rigidity caused by the excessive tool "stick out".
You positioned the cutter right at the far end of the arbour, thereby maximising is distance from the spindle. As each tooth cuts, the rection force tries to flex the arbour and that sets up an oscillation which you can hear. You can then also see the wavy "chatter" marks on the finished gear.
Hope that helps, and you can get smooth chatter-free cutting in future.
A tip for you. when putting the tailstock center into the part, make it a point to have your handwheel handle over the back of the center. That way gravity will keep it snug, and it won't loosen up.
It would be amazing if you and Clickspring did a project together.
Always a pleasure to watch Adam work 🥹
The section when you start cutting the teeth and it's sped up.. reminds me of the Bicentennial Man intro, love it.
Hey Adam, great job making your first gears! I don't have a metal lathe or milling machine but I make wooden gears with my table saw. I use AGMA formulas and get a true involute tooth profile that runs very smooth. I have also made helical and elliptical gears too. Cheers!
No less than 13 years ago even, great work! love those wooden blinds with wooden gears.
@@zarster Thank you!
Little double stick tape and you can put that up on the fridge. Looks great for first shot! In 40 years in the toy biz I never used any thing but 20 deg pressure angle and I am glad I never found out why. Good luck with the rest of the build, although I don't think you will need it. Can't wait.
I'm proud of you Adam. Great work.
Manufacturing gears is something I've always wanted to be good at, and am still learning/experimenting. Using an actual gear cutter/hob is still on my bucket list, so it's nice to see my favorite engineer actually post a video about it. Awesome!!
All I want for Christmas is to see every single last detail, mistake, correction, paint, and test drive of this project!
Oh my got found you again loved watching you years ago you are amazing and I’m not clever as you far from it but I love the way you give me a chance to understand and so enjoyable love yr cave I wish you so much success and love you Adam love little Fran 🇬🇧 xxx happy 2023 xx
ThisOldTony did an amazing video on gears.... one of those things you think is so simple then realize just how much incredibly clever innovation has gone into them. When you get into the geometry of how they mesh so perfectly always giving the optimum amount of contact and always pushing in the optimum direction while avoiding issues that you'd never even think of.... well It's the type of stuff you're not even sure how someone conceived of it, never mind figured it out.
Adam running that stone over the mill triggered all my ASMR…. Lit up like a Christmas tree…
The sound at 23:49 is one of the best things ever.
(the air powered chuck)
26:31 Interesting collection of sounds.
Adam, I try not to ask much of the channels I watch, but please don't let this be the last we see of this project. I wanna see the build and see this car go 200+ yards.
Growing up I had a toy car that you revved up by rolling it across the ground and it made this groaning rumbling sound and I loved it but never understood how it worked. I just watched Adam roll that car across the table and heard that sound again and nearly 20 years later just received a profound understanding of how it actually worked.
congratulations 🎉
"To the lathe, Boy Wonder" with the gear transition made me big laugh.
22:07 One of my favorite things about making is when you can make the tools you need as well as whatever project. 3D printing parts for your 3d printer, forging new tools for your forge etc.
The real world of gear tooth geometry is unbelievably complicated.
However complicated you might imagine it could possibly be, it's more complicated than that.
Amazing video, Adam! Thanks!
Tramming in different equipment on your mill was cool, a nice introduction for those of us who know nothing. A intro to what the basics are with your since 2020 advanced knowledge of machining would make a great “tool tip” or similar video I believe
Mills and lathes are magical. I'd love to have a shop big enough to have both
Got a good laugh out of him moving the jig from the mill over to a table
What i love Adam is that we can see your brain working in real time 😀
Your enthusiasm always makes me happy. Putting your hand near the spinning, not so much. Stop that mister!
Aw! It's so cute!
Swarf.
28:50 that part immediately reminded me of tony stark he sounds like him; I could till because I've been rewatching those movies
Adapm, don"t know if others already mentioned it, but setting up your vise offset to one side or the other allows for other jobs to be setup on the other side without having to remove the vise. Also negates the tendency most mills have to wear out in the middle area of the table.
The symbol for Renault, is a stylised representation of syncromeshed gears.
Renault were one of the first European companies to get them and use them.
Making gears is pretty complicated work. Im impressed. But you don't need any lube when turning bronze. It cuts like butter. That oil is just making smoke.
I wish I could like this more than once ❤
It's Friday, nailed it.
Quick Quacks Camera-MAN! Quickly to the ADAM LATHE!
I look forward to the flywheel car build XD
Used to work in a shop that machined large bronze bearing parts. Bronze swarf looks pretty, but I was warned that if you get a splinter of it in you, it will go septic really fast. Never heard this anywhere else so interested if this was just a myth (see what I did there?!) or if others have heard of this. Did search for this, but found nothing on google.
Ah yes Swarf. Full name Swarfolomew! Half man, half swog. Seasoned traveler of the stars and loyal of Prince Lone Starr. Truly a god amongst machining chips anywhere in the universe!
Got to the end, saw the gear, how it works, what it looks like and had no idea how I’d gotten there and completely forgot why he was making it. ;-)
That reminded me my master thesis about the cog railways... Anyway, I think that gears and screw threads are much easier in metric part of the world 😜
I got nothing against technology and progress, but doing something the older/slower way is sometimes so enjoyable, chill and entertaining :D ... Yes I could just pull out phone from my pocket and find what I am looking for in 20sec, or I could grab my giant super thicc math/chem/physics book of all kinds of tables, and just leaf through the pages :D
PS: Editor you are funny fella today :P
Gear cutting is awesome, it's kinda like the mill's equivalent to thread cutting in a lathe.
Usually, when using mixed metals for gears, the pinion is harder and the larger wheel softer, but I can't deny I'd do exactly the same thing If I had a nice chunk of bronze calling to me from the drops pile! Can't wait to see where this leads, those gears would take the power of a MUCH bigger flywheel! And living in a notoriously hilly city, with potential energy literally everywhere, this may be a viable form of personal transport!
Also, the pinion is wider than the driven gear, because each tooth will contact another tooth (more tooth to tooth contact events) than the teeth on the driven gear. If the 48T driven is 1" wide, cut the pinion 1.25" wide.
Adding learning to use a lathe back to my list of skills , I have used one, twice
brilliant video Adam your a star mate .
Nice.
So it's not magic?
That was impressive. As you went thru the process, it made me think how much is involve with making a simple gear. Therefore how much is involved in every day devices that we take for granted.
*Looks at Adams horde of bronzen curls*: "I see your Swarf is as big as mine!"
That bronze will lap right into the other gears. There may be a little extra lash as the gears seat and flatten out the peaks from cutting though. Maybe slick them up with a little sanding block or just send it, as is ;)
Now I'm thinking of a human sized petal powered flywheel toy car.
I just got, well getting for Christmas a semi universal dividing head.
Seeing those bronce curls, I think, they shoiuld be put into a box, sent to NICK ZAMETTI, so he can put them into resin and make car cubes of them or something else to be put into the car, to recycle the cuttings.
"Not blood... I think" cudos to the editor 😁
Clickspring shoutouts never get old ❤️
Mr Spacely would approve. Cogswell remains to be seen.
Great ham-bone man!
I'm glad I'm not the only one who does Belly Drums.
The difference is Chris is cutting gears the size of a pea. LOL.
The bronze swarf coil strings can go straight on the christmas tree!
I don't think Adam celebrates Christmas. You don't see any decorations in his shop, do you? So yeah he's one of those people.
@@1pcfred Totally fine! Was not talking about Adam specifically. Anyone can do what they want. :)
@@ToTheGAMES everyone can't do what they want in this world anymore though. There's too many people for that to work. What some people want is pretty unreasonable regardless.
I would go with a brake rotor for the rotating mass, they're everywhere and you can rig up a remote controlled caliper to stop it if you need to
That cast iron flywheel is almost exactly like the helm wheel of a ticonderoga class guided missile cruiser...
You should do a video on how they make herringbone gears.
Good job! Should not ‘climb mill’ though, more chance of tool breakage
My first car was a Volvo 164TE, sounds like the 245 still had the same issues.
When you were talking ab gear tooth engagement, I was thinking "a herringbone gear would be the best for that" but then I guess it would be nontrivial to machine...
Still such an amazing man✨
The Hotsy Totsy Club! You are a man of the people! (Also technically it's in Albany, CA)
"So Adam, ca you explain to the viewers what you do exactly in the shop ?"
Adam : 26:30
Just a friendly suggestion, make some keys for your vise to save tramming time between setups.
Nice one
Gonna need to balance that flywheel!
Where you cut on the gear it has those lines on it you mention at the end. Why are there lines in that orientation? Is it from the cutter moving too quickly through the part and there are slightly flatter areas or something? Just didn't expect the cutting of the gear teeth to have a pattern like that.
Machinist here, don't stone any surfaces on you machines unless you 100 percent have to. I you do that every time your table will not be flat for long
Is there a word for the fear of lathes? I think I have that. Terrifying machines.
All I can think is about all that delicious bronze swarf left over. Save it and make some knots for later or send it to me
If you ever run out of ideas for videos, I'm sure Adam could go eenie-meenie on a shelf with materials and tell a story of where a given piece is from.
Curious about how you find anything that workshop.... It looks really full.
"Not blood" "I think..." lol
I have got to say I would love to watch a Collaboration between Adam and Abome or Keith Fenner, would be very cool to watch Adam learning from some one who daily drives Machining equipment. Edited as I carnt spell Keith (face palm )
Or uncle Keith
Nice video but I do not understand why the Rotery table have to mount on the 1-2-3 block, it is so easy mount the rotery table direckt on the mill table and the tailstock the same center high
Thx for sharing @Adam Savage’s Tested I enjoy your process. Please though don’t touch a spinning part on the lathe. And wear gloves cleaning up chips.
How come you are not using oil when cutting and machining? I worked at a machine shop and they would use oil to keep the tools cool and get a cleaner cut.
Adam, I love the shirt you are wearing in this video but I can't find it on your store. Where can I get one?
"Not blood...I think" haha
Not blood. I think. Lol. Got me good there. I thought the secret message was gonna be deep and send me down a rabbit hole into other videos looking for other secret messages.
Nope.
Why does the mill sound like that when he moves the bed? I'm new to machining started working in an engineering place in February so I'm just wondering as it's usually smooth for me unless I leave the power feed on and try to move it manually as well
What happened to that project with that enormous terrifying flywheel?
Now make 4,861 more gears and build be a triple expansion steam engine for literally no reason. :)
that gear looks almost exactly like an ibselete geat for a craftsman snowblower i bought...i thought of doing this myself but i really have no idea how to make my own gears but it would be super useful to alot of people with sucha model becasue it isnt made anymore and this probably goes for alot of gears for machines..i went to a gear makign place and they wanted to charge me like 200-300 bucks for one gear..its such a shame that id have to throw out a whole machine over one stupid gear..