'helical gear' - 5 axis or 4!

[Sumac Andy]

Hi all 4/5 axis gurus.

 

I have a part as attached here of a helical gear that I need to manufacture.

We have 4 axis and 5 axis capability and posts but I'm unsure about how to go about making the rotational movements required to make it.

Can anyone help me please?

TIA.

 

Andy.

modified gear.mcx-8

[Sumac Andy]

I'm thinking now of a swarf movement but that's leaving me a ridge in the bottom centre of the lower tooth form - any ideas to get rid of that bit?

 

Again, TIA.

Andy.

[Müřlıń®]

I'm thinking now of a swarf movement but that's leaving me a ridge in the bottom centre of the lower tooth form - any ideas to get rid of that bit?

 

Again, TIA.

Andy.

Do another controlled tilt path in center perpendicular to a surface using the 2 bottom chains.

[Newbeeee™]

Andy - this may help or not.

Different form - we had to design this gear as a special for a customer so it's effectively 60deg form and 2mm radially deep.

We're using a carbide centre drill (tip removed) after centreline clearing the 'meat' out using a 1.5mm cutter.

Prog 1x tooth and xform the rest.

For yours - can you do a form tool for the V with a flat bottom?

Rough down in the Z and use a 5ax curve path on the centreline?

 

OKAY - I'm getting an error message for uploading as it's too big?

Your file is larger than this but the message says I can only upload 48k???

PM me your email address and i'll send it over.

 

We're 30 miles away along the coast from eachother so it shouldn't be a problem!

Curse the big pond in the middle causing the problem!

[Sumac Andy]

Do another controlled tilt path in center perpendicular to a surface using the 2 bottom chains.

Hi.

 

Thanks for the suggestion.

I've tried something like this but didn't like the result - it looks close so I may come back to this, but for now I'll keep on trying other routes.

 

Cheers.

Andy.

[Müřlıń®]

Hi.

 

Thanks for the suggestion.

I've tried something like this but didn't like the result - it looks close so I may come back to this, but for now I'll keep on trying other routes.

 

Cheers.

Andy.

Ya what you need to do is to use a bull instead of a sharp to swarf the walls.

That way a bull down the center will blend better in the corners without having to be perfect.

[taperlength]

Is that the customer's model?   Most gears have an involute profile to the teeth, which would be a nurbs surface on a model.

[Reko]

Well, if you have a large number of them and you want to get all fancy... design and purchase custom ground form tools... put them in a 90 degree head set at the helix angle... part mounts on a 4th axis... program a straight line move with the proper 4X rotation... bamm... you can bang those parts out in about 15 minutes apiece.  

[Sumac Andy]

Is that the customer's model?   Most gears have an involute profile to the teeth, which would be a nurbs surface on a model.

 

Part of it is - the tooth form - I've removed all other proprietary information from the model for this forum. 

We know what it should be and we will discuss this with our customer later.

They are using this gear as a very expensive 'consumable' part at the moment. This may be deliberate but we don't think so, the mating gear is involute form so we're not sure why at the mo.

Thanks.

Andy.

[Sumac Andy]

Well, if you have a large number of them and you want to get all fancy... design and purchase custom ground form tools... put them in a 90 degree head set at the helix angle... part mounts on a 4th axis... program a straight line move with the proper 4X rotation... bamm... you can bang those parts out in about 15 minutes apiece.

 

Was thinking along those lines to start with - if it were an involute form we would need to work the correct rotational movement into the machine -  I did gear cutting as an apprentice using the correct DP tools, universal milling machine, working out the angle for the table to be set at, the gear train of the dividing head (driver/driven) etc.... that was around 29 years ago  - if we use the 5 axis machines we need to work out all that information given a 2.5MOD tool on an extended holder with A axis at an angle - maybe 45°? then working out the small angular movement in C axis to form the tooth? IDK how to work all that out - yet!

 

Thanks.

Andy.

[AHarrison1]

Shameless plugging on a 4 year old thread...tsk,tsk, tsk

[crazy^millman]

4 hours ago, AHarrison1 said:

Shameless plugging on a 4 year old thread...tsk,tsk, tsk

Exactly. Spammer needs to go.