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  1. #1426
    Join Date
    Jul 2008
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    near Warragul, Victoria
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    Quote Originally Posted by Michael G View Post
    A neighbour showed up on the doorstep last night with an old metal housing belt sander, suggesting it has broken a gear tooth and asking whether I could fix it. (He tells me that the whole street knows that I'm the guy with the shed ) We've known him for nearly 20 years so couldn't really refuse as it sounded a simple job. Opening the machine up it was a little more than that - the whole gear was stripped (and the mating gear is a little suss). I suspect that it was started under load once too often and that just chewed up the gear (to be fair to my neighbour, he got it from his FIL's collection when things were tidied up so it was not positively known as a going concern). Making up a replacement took a couple of hours - might have been quicker except that having a limited metal working background he was fascinated by the machines and what they did so we had to stop for explanations just about every time, along with explanations of what DP means and why the thread is UNF and not UNC and s Not shown in the photo is the hex socket in the far end, made using the old standby of drilling a hole and then just hammering in a length of greased hex key. Michael
    Great work . What type of steel did you use ?

  2. #1427
    Join Date
    Oct 2011
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    Norwood-ish, Adelaide
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    59
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    Quote Originally Posted by morrisman View Post
    What type of steel did you use ?
    Wasn't rusty enough to be 4140 so I think it must have been some silver steel or W1.
    (In the shed I have mild, 1040, stainless, 4140 and silversteel, and all but the first are randomly collected offcuts)

    Michael

  3. #1428
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    Mar 2012
    Location
    Western NSW
    Posts
    543

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    Attachment 342789


    Wow Michael that is a great job. Cutting a helical gear is a whole new ball game to cutting an ordinary spur gear. I have been trying to collect the various kit for doing this. Have just got a universal dividing head with all the attachments for spiral milling. As I have never cut one do you want to start a new thread and describe the process of cutting a helical gear. The pre machining calculations required and setup you used. I recently brought a copy of Milling machine treatise by Brown and Sharp which has a good chapter on this.
    Would love to hear your thoughts.

    Mark

  4. #1429
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    Jun 2007
    Location
    sydney ( st marys )
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    64
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    Not bad but with the correct mill and dividing head and gearing a basic operation .nothing to get overly excited about unless not much excites you.

  5. #1430
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    May 2011
    Location
    Murray Bridge S Aust.
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    71
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    Quote Originally Posted by pipeclay View Post
    Not bad but with the correct mill and dividing head and gearing a basic operation .nothing to get overly excited about unless not much excites you.
    Maybe not to you, but for us mere beginner machinists, I think it is unreal!!!!!
    Kryn

  6. #1431
    Join Date
    Oct 2008
    Location
    N.W.Tasmania
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    1,407

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    Quote Originally Posted by pipeclay View Post
    Not bad but with the correct mill and dividing head and gearing a basic operation .nothing to get overly excited about unless not much excites you.
    I'm not sure of Michael's background, or exactly what machinery he has available to him, but I gather from this comment that he made in an earlier post that he may not have done fitting and turning as a trade.
    Well, for that matter, I never cease to amaze me with what I am capable of. Jobs like this do toss up interesting challenges. I still make unforced errors at times but learn enough from them to know how to do better next time. I used to think that my machining skills were on par with those of a new apprentice. Perhaps I've finally made it to second year...
    If that is the case, then perhaps his effort is somewhat akin to you Peter, doing successful surgery on some poor accident victim that you came across in the outback, without the appropriate medical background, just a basic first aid book for reference.
    Well done Michael, both the job and dealing with your neighbour with dignity and good will.
    Rob

  7. #1432
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    Sep 2011
    Location
    Ballarat
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    65
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    3,103

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    Quote Originally Posted by pipeclay View Post
    Not bad but with the correct mill and dividing head and gearing a basic operation .nothing to get overly excited about unless not much excites you.
    Great job Michael, and I am a qualified fitter and machinist that didn't leave the trade.
    Just so you know, if there was a dislike button I would hold my finger on it for about an hour for Peters post.
    One off helical gears measured from a damaged part have never been a basic operation.
    Just sayin'

    Phil

  8. #1433
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    Oct 2011
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    Norwood-ish, Adelaide
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    59
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    Thanks for all the positive comments guys. I'll try and do a "make a helical gear" show and tell one day but it's a bit like a shaper, in that still photos don't do it justice.

    Quote Originally Posted by pipeclay View Post
    Not bad but with the correct mill and dividing head and gearing a basic operation .nothing to get overly excited about unless not much excites you.
    You may do things like this all the time in your day job, but as Rob has picked up, I haven't got trade training and so for me one of the challenges is working out how to do things. I don't post everything I do but just things that I think might catch the imagination of others and (hopefully) inspire them to try things that might otherwise look daunting to them. It looks like I have met that goal from some of the comments made.
    When I first joined this forum it seemed there were always people posting pics of what they had done, either fixing machines or items they have made. Others invariably offered encouragement and sometimes alternatives to methods that were also interesting. I really liked that because again it showed what was possible as well as revealing techniques. The posting doesn't seem to happen as much these days but I live in hope.

    In this particular case when I first got them some years ago the lathe and dividing head both required significant repair before they would even function (the mill required repair but was functional). In this the age of CNC, I'm not even sure that the equipment used would be familiar to some of the newer qualified tradespeople.
    The part itself went from the lathe to mill to lathe without losing setup. It incorporates turning, helical milling and single point threading. One end has to match a small plain bearing that had worn slightly from new condition. The other is a register diameter to match a motor driven pulley so the part requires concentricity, accuracy and reasonable surface finish. The hex socket was simple but at the same time I'd never done one.

    Agreed it is not overly exciting but for someone that is self-learning it represents a step forward. Perhaps you can post pictures of the things you do at work or some of your projects at home to show us what excitement looks like

    Michael

  9. #1434
    Join Date
    Aug 2011
    Location
    Melbourne
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    4,779

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    Its typical. Its typical of another great job done by you Michael.

    And, its typical for PC's sad sack attitude to life!

    It's far superior than anything ive seen out of your shed PC.

    Simon
    Girl, I don't wanna know about your mild-mannered alter ego or anything like that." I mean, you tell me you're, uh, super-mega-ultra-lightning babe? That's all right with me. I'm good. I'm good.

  10. #1435
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    Mar 2008
    Location
    nowra
    Posts
    1,598

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    Nice gear fantasic machining as usual Michale and as a third year fitter machinist apprentice I can can say that we don't cut any gears in fact we do the gear module of the course on the internet thanks government for cutting 12 weeks a year from the course.
    BETTER TO HAVE TOOLS YOU DON'T NEED THAN TO NEED TOOLS YOU DON'T HAVE

    Andre

  11. #1436
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    Jun 2011
    Location
    Australia east coast
    Age
    71
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    2,713

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    Quote Originally Posted by Michael G View Post
    Agreed it is not overly exciting but for someone that is self-learning it represents a step forward. Perhaps you can post pictures of the things you do at work or some of your projects at home to show us what excitement looks like

    Michael
    I agree, helical gear cutting is an interesting challenge. Perhaps pipeclay, using his extensive experience and massive tooling collection, might deign to show us something really challenging, say a matched pair of helical gears in herringbone configuration, using prime numbers for the gears - I suggest 73 teeth for one and 127 teeth for the other.

    I'd be delighted to see someone do this using all mechanical equipment, because it sure stopped *me* many years ago. I cheated.

    PDW

  12. #1437
    Join Date
    Jul 2006
    Location
    Athelstone, SA 5076
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    4,255

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    Quote Originally Posted by Michael G View Post
    A neighbour showed up on the doorstep last night with an old metal housing belt sander, suggesting it has broken a gear tooth and asking whether I could fix it. (He tells me that the whole street knows that I'm the guy with the shed )
    We've known him for nearly 20 years so couldn't really refuse as it sounded a simple job. Opening the machine up it was a little more than that - the whole gear was stripped (and the mating gear is a little suss). I suspect that it was started under load once too often and that just chewed up the gear (to be fair to my neighbour, he got it from his FIL's collection when things were tidied up so it was not positively known as a going concern).
    Making up a replacement took a couple of hours - might have been quicker except that having a limited metal working background he was fascinated by the machines and what they did so we had to stop for explanations just about every time, along with explanations of what DP means and why the thread is UNF and not UNC and so on.
    Attachment 342789
    Not shown in the photo is the hex socket in the far end, made using the old standby of drilling a hole and then just hammering in a length of greased hex key.

    Michael
    ...and am I happy that you live around the corner

  13. #1438
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    Nov 2006
    Location
    Bendigo Victoria
    Age
    80
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    7,471

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    Quote Originally Posted by pipeclay View Post
    Not bad but with the correct mill and dividing head and gearing a basic operation .nothing to get overly excited about unless not much excites you.
    Yes pipeclay, you can always be relied on to provide a positive and uplifting addition to any thread.

  14. #1439
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    Mar 2014
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    South of Adelaide
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    1,225

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    That gear looks pretty good. I reckon the 3rd year apprentice at work would struggle making that.

  15. #1440
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    Aug 2011
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    Melbourne
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    Quote Originally Posted by simonl View Post
    Its typical. Its typical of another great job done by you Michael.

    And, its typical for PC's sad sack attitude to life!

    It's far superior than anything ive seen out of your shed PC.

    Simon
    Hi PC,

    I have had a think about my post and I owe you an apology. What I said was out of line and quite harsh. If I had have walked away and thought a little more I could possibly have responded in a more constructive way. I know you have churned out many a fine piece of work and I know you are very much accomplished at what you do.

    I won't deny that I found your post rather disappointing and quite deflating though. Any, enough of this. Lets look at more projects!

    Simon
    Girl, I don't wanna know about your mild-mannered alter ego or anything like that." I mean, you tell me you're, uh, super-mega-ultra-lightning babe? That's all right with me. I'm good. I'm good.

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