Inscribed "Joh. Melchior Wetschgi, Augsburg, 1726", this device is for cutting gears with different numbers of teeth. The work was mounted on the vertical mandrel in the center; to cut a gear tooth, the cutter wheel mounted on the horizontal shaft, rotated by a belt attached to the brass pulley, was advanced into the blank using the big windup key, and then the disk was advanced to the next index hole to cut the next tooth. At about 5:00 you can see stamped into the disk the number of teeth in each ring of holes. Appears to be the same animal shown at digital.deutsches-museum.de/en/digital-catalogue/collecti...; the description there reads "Gear cutting machine by Johann Melchior Wetschgi: The hand-operated gear cutting machine, built without a tripod, allowed the watchmaker to quickly make gears of various diameters."

I made a test fixture for the skew bevel gears that I made with the Climax locomotive project so now I can demonstrate the two gear types side-by-side. It is interesting to see how much more compact the skew fixture is.

After a preliminary pass with a saw, the bevel gear tooth is machined by a cut on each tooth side, left, and right, using a two-sided form cutter.

In this setup, the rotary table is aligned with the X axis of the mill and the angle of the cut is created by the coordinates in the CNC program.

Here we have 6 sets of smooth running stainless steel bevel gears, enough for a three truck shay locomotive model. The pinions have 19 teeth and the gears have 39 so that each tooth will mesh to keep wear and lubrication evenly distributed.

The photo shows a shop-made 8 tooth gear cutter where the involute tooth shape is approximated by a circular arc calculated from the 20 degree contact point. The cutter is mounted in a shop-made holder for the Tormach TTS tool holding system.

This is a replacement for the one-tooth, reversible, off-center cutter design of Kozo. My one-tooth cutter was not holding up, and I think it was getting deflected from the cut edge because of its thinness. This cutter is thicker - it fills the tooth gap at the narrow end of the bevel gear. The fact that there are 8 edges means I can feed 8x faster and it should hold up 8 times longer. The cutter holder is easier to make because of its circular symmetry. There is less milling to make the cutter, but the added complexity of needing an 8 position indexer. Each tooth has a 5 degree relief which was easily done by milling about 0.040" beyond the radial center lines. The cutter diameter is 15/16" by .156" thick. Each tooth is about 0.090" high which is sufficient to cut the gear teeth to a height of about 0.054".

I've started to machine stainless steel pinions using the brass gear as a test model for fit.

I modified my CNC cutting program to allow for the fixture having run-out characterized by a radius and an angle. With this modification, I can correct for the imperfection of the pinion holder. I can also use it as an adjustment to cut the teeth a little deeper at any given angle.

Cutting the stainless steel is more of a cold forming operation than a cutting operation. I am needing several passes of the form tooth cutter to get a working fit.

A 5C collect indexer was used to position the gear cutter for milling the 8 edges.

40 tooth Gear cut in Delrin

Macro

Cutting a Gear on a Mini-Mill

Copy from old sales catalgue by kind permission of precision Components

The gear cutting equipment is mounted on the table of a hybrid Hardinge/Bridgeport milling machine. This solid set up provides stability and repeatability in a compact space.

Downtown Pittsburgh Pa

#makeinindia #manufacturing #gearcutting #wormgears #wormgear #progearsive #process #industry #engineering #hobber #gears #gearhobbing #mechanical #worldofengineering #machine #technology #gearboxes

Galbiati Group has recently manufactured a large gear wheel with relative carburized pinion, intended to be positioned inside a twin drive gearbox, for R1-F1 rolling mill control.

Some steps of the gear wheel machining are shown below.

Initially, on the gear wheel, welding operations (WPS) were carried out on high-strength steels, respecting the temperature parameters of the aforesaid materials.

The welds were finally certified thanks to the execution of magnetic testing, ultrasonic testing and die penetrant inspection.

Since the gear wheel is made of electro-welded material, made of high-strength steel, at the end of the welding, thermal stress relieving treatments have been carried out to avoid possible materials deformation.

The wheel gears are made with a protuberance hob, then ground and hardened on the surface with a correct profile. Gear quality equal to 6 DIN-3962.

The gear wheel was at last clamped on a slow shaft (diameter 800 mm, length 3.500 mm), always made at the Galbiati Group workshops.

Galbiati Group has recently manufactured a large gear wheel with relative carburized pinion, intended to be positioned inside a twin drive gearbox, for R1-F1 rolling mill control.

Some steps of the gear wheel machining are shown below.

Initially, on the gear wheel, welding operations (WPS) were carried out on high-strength steels, respecting the temperature parameters of the aforesaid materials.

The welds were finally certified thanks to the execution of magnetic testing, ultrasonic testing and die penetrant inspection.

Since the gear wheel is made of electro-welded material, made of high-strength steel, at the end of the welding, thermal stress relieving treatments have been carried out to avoid possible materials deformation.

The wheel gears are made with a protuberance hob, then ground and hardened on the surface with a correct profile. Gear quality equal to 6 DIN-3962.

The gear wheel was at last clamped on a slow shaft (diameter 800 mm, length 3.500 mm), always made at the Galbiati Group workshops.

Galbiati Group has recently manufactured a large gear wheel with relative carburized pinion, intended to be positioned inside a twin drive gearbox, for R1-F1 rolling mill control.

Some steps of the gear wheel machining are shown below.

Initially, on the gear wheel, welding operations (WPS) were carried out on high-strength steels, respecting the temperature parameters of the aforesaid materials.

The welds were finally certified thanks to the execution of magnetic testing, ultrasonic testing and die penetrant inspection.

Since the gear wheel is made of electro-welded material, made of high-strength steel, at the end of the welding, thermal stress relieving treatments have been carried out to avoid possible materials deformation.

The wheel gears are made with a protuberance hob, then ground and hardened on the surface with a correct profile. Gear quality equal to 6 DIN-3962.

The gear wheel was at last clamped on a slow shaft (diameter 800 mm, length 3.500 mm), always made at the Galbiati Group workshops.

Galbiati Group has recently manufactured a large gear wheel with relative carburized pinion, intended to be positioned inside a twin drive gearbox, for R1-F1 rolling mill control.

Some steps of the gear wheel machining are shown below.

Initially, on the gear wheel, welding operations (WPS) were carried out on high-strength steels, respecting the temperature parameters of the aforesaid materials.

The welds were finally certified thanks to the execution of magnetic testing, ultrasonic testing and die penetrant inspection.

Since the gear wheel is made of electro-welded material, made of high-strength steel, at the end of the welding, thermal stress relieving treatments have been carried out to avoid possible materials deformation.

The wheel gears are made with a protuberance hob, then ground and hardened on the surface with a correct profile. Gear quality equal to 6 DIN-3962.

The gear wheel was at last clamped on a slow shaft (diameter 800 mm, length 3.500 mm), always made at the Galbiati Group workshops.

Galbiati Group has recently manufactured a large gear wheel with relative carburized pinion, intended to be positioned inside a twin drive gearbox, for R1-F1 rolling mill control.

Some steps of the gear wheel machining are shown below.

Initially, on the gear wheel, welding operations (WPS) were carried out on high-strength steels, respecting the temperature parameters of the aforesaid materials.

The welds were finally certified thanks to the execution of magnetic testing, ultrasonic testing and die penetrant inspection.

Since the gear wheel is made of electro-welded material, made of high-strength steel, at the end of the welding, thermal stress relieving treatments have been carried out to avoid possible materials deformation.

The wheel gears are made with a protuberance hob, then ground and hardened on the surface with a correct profile. Gear quality equal to 6 DIN-3962.

The gear wheel was at last clamped on a slow shaft (diameter 800 mm, length 3.500 mm), always made at the Galbiati Group workshops.

Galbiati Group has recently manufactured a large gear wheel with relative carburized pinion, intended to be positioned inside a twin drive gearbox, for R1-F1 rolling mill control.

Some steps of the gear wheel machining are shown below.

Initially, on the gear wheel, welding operations (WPS) were carried out on high-strength steels, respecting the temperature parameters of the aforesaid materials.

The welds were finally certified thanks to the execution of magnetic testing, ultrasonic testing and die penetrant inspection.

Since the gear wheel is made of electro-welded material, made of high-strength steel, at the end of the welding, thermal stress relieving treatments have been carried out to avoid possible materials deformation.

The wheel gears are made with a protuberance hob, then ground and hardened on the surface with a correct profile. Gear quality equal to 6 DIN-3962.

The gear wheel was at last clamped on a slow shaft (diameter 800 mm, length 3.500 mm), always made at the Galbiati Group workshops.

Galbiati Group has recently manufactured a large gear wheel with relative carburized pinion, intended to be positioned inside a twin drive gearbox, for R1-F1 rolling mill control.

Some steps of the gear wheel machining are shown below.

Initially, on the gear wheel, welding operations (WPS) were carried out on high-strength steels, respecting the temperature parameters of the aforesaid materials.

The welds were finally certified thanks to the execution of magnetic testing, ultrasonic testing and die penetrant inspection.

Since the gear wheel is made of electro-welded material, made of high-strength steel, at the end of the welding, thermal stress relieving treatments have been carried out to avoid possible materials deformation.

The wheel gears are made with a protuberance hob, then ground and hardened on the surface with a correct profile. Gear quality equal to 6 DIN-3962.

The gear wheel was at last clamped on a slow shaft (diameter 800 mm, length 3.500 mm), always made at the Galbiati Group workshops.

This is 6.8mm in diameter and was made on my lathe when setup for gear cutting - shown awaiting the next steps in securing to the fusee. The old wheel had a couple of missing teeth.