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Tools, Glorious Tools! #10 (Part 4) - Shop Made Gear Cutters - Making 'Cycloidal' Cutters (Patreon)

Published:
2020-08-23 20:27:07
Imported:
2026-06
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Downloads

  • Clickspring Universal Gear Cutter Geometry Calculator v3.7.3.xlsx
  • Clickspring Cutter Blank - Inch.PDF
  • Clickspring Cutter Blank - Metric.PDF

Missing 1 full-res photo, 3 files, as this post has not yet been imported.

Content

Hi Folks,

Part 4 of the shop made gear cutter series is a deep dive on making 'cycloidal' profile gear cutters - do please enjoy!

Also, if you happen to be free for an hour or so this evening/morning at 6pm EDT (2200 UTC) be sure to drop in for the weekly Discord chat. Ask a question, share some pics of what you've been up to in the shop, or just come and say G'day. Details below on how to connect, if you've not yet checked it out.

Cheers,

Chris.

Connect to the Clickspring Discord: support.patreon.com/hc/en-us/articles/212052266-How-do-I-receive-my-Discord-role-

Direct links to the video -

Vimeo: https://vimeo.com/450881477/3ba675eff1

Youtube:  https://youtu.be/8-eAhLGmsNQ

-------------- Video Notes: ---------------

Some top resources on Gear Theory:

John Stevenson Blog Post - http://metalwebnews.com/howto/gear/gear1.html

WO Davis – “Gears For Small Mechanisms”: https://amzn.to/2Yj2Ben

JM Wild - "Wheel & Pinion Cutting in Horology": http://amzn.to/2HI6ca9

"Gears and Gear Cutting", Ivan Law: http://amzn.to/2FKmaUI

Tony's gear videos: -  https://www.youtube.com/watch?v=Q-XOM4E4RZQ

https://www.youtube.com/watch?v=ds6qZ7Ss2fA

Stefan on sharpening with pro gear, and a discussion on profile error: https://www.youtube.com/watch?v=7sxq5khqeWI

Mr Pete's Gear Videos -

https://www.youtube.com/watch?v=JMhYuXx35Ik

https://www.youtube.com/watch?v=12sdMFr5CNU

https://www.youtube.com/watch?v=2lPNqn8LU4Q

https://www.youtube.com/watch?v=dQVUI1YhN0E

https://www.youtube.com/watch?v=mXU-URNdUFU

https://www.youtube.com/watch?v=Dipd0ohrYzg

Andy Pugh's Gear hobbing video's:

https://youtu.be/ZhICrb0Tbn4

https://youtu.be/xdE46yvckbM

"The Watchmakers' Lathe " Ward Goodrich - https://amzn.to/2Wijchr

Hugh Sparks - https://www.csparks.com/watchmaking/CycloidalGears/index.jxl

"The Clock & Watch Makers Guide to Gear Making" Porter - https://amzn.to/2xuFP7I

Online Gear Generator: https://geargenerator.com/

Alan Pinkus’s Gear Generator - http://www.micro-machine-shop.com/gears.htm#Gearotic_Motion

Matthias Wandels gear generator: https://woodgears.ca/gear_cutting/template.html

(Amazon Affiliate links)

Cameras:

Panasonic GH5 - https://amzn.to/2rEzhh2

Panasonic X920 - https://amzn.to/2wzxxdT

Books:

"Wheel & Pinion Cutting in Horology": http://amzn.to/2HI6ca9

"Solidworks 2013 Bible": http://amzn.to/2FObS1D

WO Davis – “Gears For Small Mechanisms”: https://amzn.to/2Yj2Ben

"Workshop practice Series": https://amzn.to/2WgeGh0

Tools & Shop Products:

Sherline Lathe: http://amzn.to/2pnXM19

Sherline WW collets: http://amzn.to/2FYZ7F8

Starrett S828 Wiggler Center Finder With 3 Attachments - https://amzn.to/3hoAsK1

Optivisor Headband Magnifier: http://amzn.to/2HFg1FU

Norton 1-by-2-by-8-Inch Fine/Coarse India Combination Oilstone, Red: http://amzn.to/2tTEPb0

Hegner Scroll Saw: https://amzn.to/2IhteVW

Digital Caliper 6 inch/150 mm Electronic Vernier Calipers: https://amzn.to/2EArNRU

Generic Dial Indicator 0.001": http://amzn.to/2FOFTyF

Interapid Dial Test Indicator: http://amzn.to/2FPInwH

Saint Gobain (Norton) - 4 Arkansas Stones + case: http://amzn.to/2HCOAMX

Dormer A190202 Jobber Drill Set, 1.0 mm - 6.0 mm x 0.1 mm Size: https://amzn.to/2DR5fdb

Dormer A190203 Jobber Drill Set, 6.0 mm - 10.0 mm x 0.1 mm Size: https://amzn.to/2ITfeTa

YG1 NC Spotting Drill 8% Cobalt HSS 1/8 to 1/2" 120 Degree 5 Pc Set CNC Machine: https://amzn.to/2G7ylv6

Blazer GB2001 Self-Igniting Butane Micro-Torch: https://amzn.to/3f5Gzlh

Magnetic Base Adjustable Metal Test Indicator Holder Digital Level 14" - Tool Stand: https://amzn.to/2PkyoTV

Anytime Tools Angle Block Set 1°, 2°, 3°, 4°, 5°, 10°, 15°, 20°, 25°, 30° Precision +/- 20 Seconds, Machinist Tool, 10 Piece Set: https://amzn.to/2QFqM2Y

Jewellers Bench Block - https://amzn.to/3clHQD2

Consumables:

Super Pike Saw Blades Size 3/0 pkg of 144: https://amzn.to/2uI0QdT

Blue Matador Abrasive Paper: https://amzn.to/2IAFiBT

Bergeon Professional Cleaning Rodico: https://amzn.to/2NwcM6y

Dykem 80300 Steel Blue Layout Fluid, Brush-in-Cap (4oz): http://amzn.to/2HGPaJJ

Files

Previews only

TGT10 Pt4 Making Cycloidal Cutters YT

Comments

Rod Cole

I can't find the "T" Tooth Cycloidal Wheel that you have in the green heading. With some help from a Lodge Brother I got the excel spread sheet to open in my MacBook Air but now I can't find the cycloidal department. I'm looking to make the gears for the Skeleton clock~. Never mind, I found it - I was beginning to feel stupid, and did some more looking - low and behold, there it was!!!

Rod Cole

Chris, when making the four faces on the cutter with the end-mill I see the one dimension to be on line with the center of the cutter, but I can't find a reference to depth of cut with the end-mill, it looks to be about in line with the indexing hole center but I'm not sure of this. Maybe it's not critical.

Adam Gill Creations

For the cycloidal wheel & pinion cutting, I think I will make a button cutter and use one side only, and offset by 2 deg as explained ... Gives me an excuse to make all the jigs & fixtures ... Excellent gear calculator sheet!

Justin J.

Excellent! More TGT!

Justin J.

Hey Chris, if you don't mind me asking, what sort of cutting oil are you using when you machine the cutters? Or if it's already been mentioned maybe direct me to the right place? Thanks!

clickspring
>>42714353

I use a generic compressor oil - nothing fancy, just the sort you can pick up at any auto shop - Cheers :)

Justin J.

Ah, great, thank you. It looks so, well beautiful and clean, in the video. Makes sense, compressor oil is nice and light, See you.  👍🏼

Robert D

TGT is ever so satisfying Chris.... Well Done.

Michael Lloyd

Very nice! Did you do a video showing the indexer at the back of the lathe and the "spinny bits" on the carriage?

Kevin Reardon

Good to hear that voice again. Also, showing me how to properly cut gears at home. Next, SteamPunk gear!

Iain Deas

Im sure I’m not the only dummy in the group but what time is the discord chat in Aussie time?

Justus Dehegovit

So for Involute wheels, you would have to make a cutter (shank and pair of cutter buttons) for every wheel that has its own individual tooth count and size. Also pinion cutting is difficult (can you even make involute pinions?). Whereas in cycloidal tooth gears, as long as you only make wheels and no pinions, you can use one cutter for every tooth count, as long as it is the same tooth size/module. Pinions are a little bit more difficult, but also possible. This is interesting for clock gear trains, where gears often have to share coaxial shafts so many gear pairs come not only with their individual tooth counts, but also individual modules to manage the shared shafts!

clickspring
>>42741301

Hello mate - Yes on the Cycloidal wheels only requiring the one cutter across the entire count range of 17 up to a rack, and yes pinions are a little more difficult but still fairly straight forward. For the Involutes you can certainly do a unique cutter for each count if you want to, but its not essential. It would be quite reasonable to take the same approach as we do for commercial involute cutters where a set of cutters span the full range, and each individual cutter accounts for a specific section of the range - for example a #6 cuts gears with counts 35 to 54 teeth, a #7 cuts 55 to 134 etc - Cheers :)

Justus Dehegovit
>>42741301

Hi Chris, thanks for the reply. The reason I wrote my initial comment was because I applied the theory you thought us in these videos onto my Astronomical clock project. The clock features 19 wheels, the lowest tooth count being 17, with almost every gear having a unique tooth count and size. Even when you apply the commercial involute cutter ranges, for these 19 wheels I would still need to make 15 involute cutters. On the contrary, if I made these gears cycloidal, which follows the original plans, I would only need 7 different cutters. Thats quite the difference. By the way, was the website for plans we talked about already announced or did it still need tweaking?

clickspring
>>42741301

Ah terrific, that is a huge reduction in work, well done. I am still working on the new platform - its taking a lot longer to build than I had hoped, but it is progressing. I will certainly let you know when it is ready for you to use - Cheers :)

Benjamin Marn
>>42737985

Which, for my fellow Americans, translates to 6pm EST, 5pm Central, etc etc. (Sorry, I couldn't help myself :)

Thomas

I’m curious, are you making these tools for a future project, or just adding to your arsenal of cutting tools and showing how you make them?

Terence Dixon

I note that you make reference to John Stevenson's excellent web pages above. I don't know if you know but John died last year I 'knew' John through various forums and exchanged messages. He could appear rather cantankerous but was helpful and generally courteous if treated with respect but didn't suffer fools gladly.

Tor Halsan

Great to see another excellent video from you, especially on such an interesting topic. Have you considered diving even deeper into gear cutters and do a series on the Eureka form relief tool?

rfproject

Another superb video. My favourite YouTube channel without question.

Benjamin Marn

Great video! You mentioned that these shop made cutters should last about as long as a commercially made one if cared for properly. On average, how long exactly is that? In short, how often would one need to go through the trouble of making these?

clickspring
>>42805100

Yes I was aware that he had passed away - I never knew him directly, but like so many of the engineering writers of his calibre, I felt like I knew him from his work. His writing on technical matters is outstanding. Accurate, informative, economically written and easily applied. I very much wish I had had the chance to meet him in person.

clickspring
>>42787020

Its a bit of both - this short series has been on the to-do list forever, but the next few years of projects pretty much requires that I get it done now - Cheers :)

clickspring
>>42810367

Very pleased you enjoyed it mate! I may look at the Eureka tool in the future, but its not a priority at the moment. This method will sort out the cutter costs of most typical home shop projects, and it has the benefit of being very straight forward for even someone quite new to machining to implement - Cheers :)

clickspring
>>42830233

Its a really hard question to answer Benjamin, because it depends on so many factors that will be different for each user - However personally, I use both my commercial and shop made cutters regularly for typical home shop work: one off projects, repairs, doing work for friends etc. Assuming that I look after them properly I do not expect to have to either re-purchase, or re-make a given cutter ever - Cheers :)

David Few

Hey Chris asan aside, when making clock wheels, once they are polished what coating do you give them so they keep their lustre?

clickspring
>>42873318

Hi David, it depends a bit on the broader style of the mechanism - if its a highly finished device (but electoplating is not intended), then my preference is to get the parts to a highly polished state using Bill Smith's Rub-n-brite polish, and then simply leave them. Providing the surface is kept meticulously clean (free of fingerprints etc) then it will slowly form a nice dark patina. If the device is a little more 'everyday' with a brushed finish, then something like Renaissance wax is good. Again it slows and regulates the patination into something quite nice and uniform. The other option is electroplating with an inert metal like gold or rhodium - Cheers :)

Chris Schmedding

Hi Chris , where do you source your EN8 from if I may ask ?

Joris van 't Land

Another excellent, informative video Chris! Every time looking forward to a new film. Thank you so much!

John S Dilsaver

This is really interesting and encouraging. My machining skills are pretty basic, but I would like to be able to produce some gears at some point. You make it seem possible! Thanks!

Karl Mansson

Very Nice! I've been looking for an approachable way to make multi tooth cutters for a while! I think you would get a better finish on the working profiles of your teeth if you honed the profiles of the cutter teeth as well. After all, it is that profile that will be imparted on the work.

Reed Bowman

You should totally try using your brass gear cutter to cut aluminum. I mean, if copper chisels work on stone...

Seán Ó Fearghail

Hi Chris, Thank you so much for doing theses. It is fantastic! is that what you would call a cone runner, coming from the tail stock to steady the pinion at around 16mins in?

Eric Maillet

Hi Chris, Sharpening tool done, cutting arbor done, cutter blank done. So far so good. I am starting work on my buttons for the form tool. I need to cut Module 0,148 , 70 tooth mainspring barrel for a watch. Calculations in your excel sheet work fine except I cannot get a round bottom radius value because the sheet does not give me one. Does that mean I cannot cut a round bottom? It doesn't really matter in the end since the meshing will work fine, but I just wanted to make sure I had the numbers right.

clickspring
>>88183531

Hi Eric, the 'Fillet radius r' (for round bottom cutters) is the value you are looking for, its the field just below the 'Number of Teeth T'. This radius is also illustrated on the section view sketch so you can visualise it - Cheers :)

Eric Maillet

Hey Chris, thanks for your reply. It doesn’t show as a number. It gives me a VALUE! alert. I’ll check the file. Might be a version issue. Thanks again!!

Eric Maillet

Hello Chris, I am still having an issue with the excel file, and now I can't get my infeed values. Is there another way for me to calculate them? My lathe is all zeroed in, if you know what I mean. I took a screenshot if you want to see. I think the columns are not wide enough for all the numbers. Thanks!

clickspring
>>88993201

Hello mate, yes send a pic to chris@clickspringprojects.com and I'll see what's up - Cheers :)