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Thread: How to shave a gear
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27th Oct 2021, 04:04 PM #1
How to shave a gear
Whenever I mill a gear it has a horrific burr on it. The best method so far has been to run it with emery paper and after that run a wire wheel on it.
Any better ideas ?
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27th Oct 2021, 04:06 PM #2Most Valued Member
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I find climb milling the teeth rather than conventional milling can really help. Tough do do on a worn machine but if you drag the table locks a bit it works.
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27th Oct 2021, 04:12 PM #3
Well, my Schaublin is really old, it was manufactured back in 1955 and it has developed a healthy backslash of 0.4 mm on the X-axis. Unfortunately this machine has no adjustment for the nut inside there. I quess I could replace the screw and the nut. Also, if the table lock is engaged even so little, this disables the power feed.
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27th Oct 2021, 04:42 PM #4Most Valued Member
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Maybe you could cut the blanks a little wide then after cutting then skim both sides in the lathe. You'll still have a burr but it will be a lot weaker and easier to deal with.
Shaving and skiving machines or maag/reishauer grinders which would solve this are very dedicated single purpose machines and I can't really think of a home brew quivalent.
If you need gears to run really quiet then there's nothing like proper form grinding of the teeth.
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27th Oct 2021, 06:20 PM #5Gear expert in training
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We have a gear shaver at work, very specialised and very expensive. It also won't do anything to the burr.
You could make a sacrificial backer out of aluminium and sit that behind the gear, that will prevent burrs being generated on the back face; if you're making multiple parts, lock the backer to the arbor with a grub screw so you can use the same one for the whole job. We do this often at work for fibre composite and plastic gears.Gear cutting specialists and general engineers www.hardmanbros.com.au
Fine pitch gear cutting from 0.1 Module www.rigear.com.au
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27th Oct 2021, 06:57 PM #6Philomath in training
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I'll typically use a linisher or a file to knock the main burr off then wire brush (on a bench grinder) to take the last bit off, although that usually requires wire brushing from 2 or 3 directions.
Michael
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27th Oct 2021, 09:23 PM #7Most Valued Member
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Were you cutting towards the tail stock or away from the tail stock?
Did you have a chamfer on the gears?
The type of material will play apart in the amount of bur, also the size of cutter.
Is the bur only occurring on one side of the gear?
Have you considered using a flap disc on a grinder to remove the burs and then using a wire wheel to finish?
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27th Oct 2021, 09:58 PM #8
Wow no idea what rpm or cutting depth/coolant your using.
I'm a novice in cutting gears as I usually buy them cheaper for projects, but have lately needed a gear on a custom shaft.
Here is my first attempt using a AliExpress HSS gear cutter mod 2 number 1 12/13 teeth.
Only a needle file was needed to clean up for the tiny burrs.
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