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Milling helical gear teeth on a turn mill
Hello,
We would like to try milling helical gear teeth on our Samsung turn mill. It is a pinion lathe with X, Y, and Z axis and live tooling. We do not want to mill it as a surface mill feature, but mill along the Z axis while the C axis is rotating. Has anybody dealt with programming this type of feature? I just need a starting point to begin trying different methods.
Thank you,
-John
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What are you using to cut the teeth?
Inventor Professional
Autocad LT
FeatureCam Ultimate
Fusion 360
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We are planning on using a 4 or 5 flute carbide end mill with the end facing X-. Our plan is to mill along the Z axis as the C axis rotates. We have several different gear pitch sizes, so the actual diameter would vary from one to the next. I just don't know where to begin as far as building the feature. Would I need to unwrap the helix first, then wrap it around Z axis, or does another feature recognize the twist in the helix? First attempt to select the feature as a side told me it could not built a feature.
-John
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It is very difficult to see. Can you give me a FC file I can simulate, from what little I can see it is something different. I attached a screenshot of how the part looks in the machine.
-John
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Hi John,
This is what i can show you in this case. see the attached file.
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J,
Sorry if I did not use the proper verbage, but we are looking at more of a pinion gear with a helix. Were you able to open the pdf of the screenshot? This gives a good look at the part with the helix gear teeth. You might need to rotate the view after opening, as the gears are side by side, not one on top of the other.
-John
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Hi,
Great now I see what you mean, I forgot to see in the pdf-file. Can you share the part?
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Hi @Anonymous,
Thanks for supplying the part.
I am able to create a toolpath using isoline method. As your primary requirement was C rotation, I have kept the tool axis To-line so it should create a 4-axis toolpath. I am attaching the fm file for your reference.
Thank You.

Abhishek
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Hi @Anonymous,
I have got this result, but struggle to get the tool flipped in the right angle, maybe @abhishek.juvekar can assist here.
https://www.screencast.com/t/wuL4H9H2z
I attached the project here.
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Hello @Anonymous and Jacob,
I could be wrong but I am not sure if we can do this with wrapped feature because nature of the side walls of gear tooth are not straight or fixed tapered. Due to the nature of surface of the wall, I can only think of surface milling feature with to-line axis to generate true 4-axis toolpath.
Thank You.

Abhishek
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Yes, I got the same fix from FC tech and we are missing the fact that the sides of the gear teeth are on a radii. I can do a standard surf mill, but my boss is determined to use the sides of the end mill and cut along the Z axis!