Gear Cutting on 4th Axis

[Anonymous]

I am trying to cut a gear using a 4th axis and a slitting saw or involute gear cutter.  CAM keeps wanting to cut slots through the top of the spline, but I need the slitting saw to cut on the side of the spline.  Anyone know how to do this while using toolpath wrapping?

[LibertyMachine]

Could you export and share a sample part? File > Export > Save to local folder. Return to thread and attach the .f3d file

Are you talking about running the saw on the side in a 2 axis config, or are all 4 axis moving (X,Z,A and possibly Y)

[Anonymous]

Thanks, Seth.  It is a normal spur gear, not helical, so I think xy axis cuts only should work ok.   However, options are nice to have so if you know how to do it using continuous c and z axes, there would probably be some benefit in that.  Attached is the gear.  I am wanting to use a convex .02" saw.  Big problem I see is that fusion doesn't recognize a saw.  The user must modify another type of cutter to create a saw. 

[Stuart-H]

Removed by me not sure if it was any use

[LibertyMachine]

If you want your simulation to be correct, you are going to need to draw up your saw as a form mill.

For the machining of the part, you are going to want to program one tooth and dump it into a Pattern > Rotate > Number of Instances (Teeth).

I've made a rather lengthy screencast that is uploading currently. When it is ready, I will update this post

[LibertyMachine]

@Stuart-H that was a valid answer, you should leave it. Don't see how it would break forum rules.

[Anonymous]

Seth, thanks for the awesome video.  that is very enlightening.  Since I don't have a way of making a form mill for this, I want to use a standard slitting saw.  is there any way to do this such that it makes multiple passes to pocket out the shape of each tooth?

[Stuart-H]

I posted this befor but thought better of it , due to Seth comment here it is again

google “gearotic” it’s a gear related cad/cam package yes it’s cluncky awkward but it will do what you are after

ie cut gears on the 4th either with a normal straight end mill or shaved with a slitting saw 

with it you can design any gear train in DP or Mod it will give you all the info blank size etc. 

What it wont do is cut bevel gears of any sort let alone a Gleason type

it can design imposble wobbly gear trains that rotate for fun 

from my sig you will note I am a hobbyist so have a look and make your own mind up 

They author is Art the guy that coded mach3 and got the parallel port to talk like Microsoft never imangened 

[LibertyMachine · Accepted solution]

One comment, if I may: Cutting gear teeth with a straight slitting saw is going to be an absurdly long cycle. If your tooth profile is an industry standard, I can guarantee you that a saw exists commercially that will cut the profile you are looking for. Search "Involute Gear Cutter"

[Anonymous]

Thanks, Seth. Well noted.  

[a.grauert]

Hi Seth @LibertyMachine ,

it is a long time ago, that you have made this in my eyes excellent description to handle this issue.

By the way, the one and only I have found in the net.

I do have , a may be stupid, question. If I measure the tool for this operation with my probe, is the length reference than the the tip of the cutter, here lower center of the disc, similar to a flat  end mill tip or is it the reference point, you have mentioned in you screencast, and this than in the center for rotation?

Kind Regards

Achim

[a.grauert]

Hi Everybody.

In the meantime I have got it managed to the do the whole process by my self now.

Seeing than the picture in the tool library first time, it seems to be clear now for me.

There is black dot under the tool which should indicate the tip of this tool, so length can be measured  there by the probe.

Kind Regards

Achim 

[bdlamini3QTME]

Thank you for this video , this is really helpful!

[abaknon]

Thanks for the excellent write up. Just setting up a gear now to cut.

Cutting on a Haas using the Haas A non NGC post.

Is there a check box for keeping the tool down and not going to Z0 between every tooth?

Thanks