On Thu, Jul 4, 2013 at 7:06 AM, Gregg Eshelman <[email protected]> wrote:
> I've seen videos of turbine wheels being cut with a ball nose straight end 
> mill on a 5 axis machine. Why not cut involute spur gears on a 4 axis with 
> end mills?

Already been done
http://www.youtube.com/watch?v=SJQtx80euGM

It is a slow process though

I have a gcode implementation with a slitting saw


>
> Can LinuxCNC do that? Would be hellaciously less expensive than buying all 
> those sets of 8 cutters to cover different diametral pitches and pressure 
> angles. Hobs come in a bit less since you only need one hob per DP and PA to 
> cut any number of teeth but also need a spindle encoder to synchronize the 
> 4th axis.
>
> End mills + software = way cheaper. Probably slower than using individual 
> cutters, certainly slower than hobbing, but should be as accurate as hobbing 
> where the 8 cutters are only accurate at the lowest number of teeth for each 
> one.

Here the rotary adds error due to the worm and worm gear error and any
backlash, the gcode has to be unidirectional to remove the backlash
error, the worm and worm gear error is partly removed by the hobbing
process but to a lesser extent with a single cutter.


Dave Caroline

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