>>If you create a Gcode generator and a simple setup you can make formed cutters that will allow >>just about anything. Don't get stuck on only using endmills.
We wont be, I plan on using tilted 4th axis at first, as it will cut most any bevel angle..
I then plan to put out code for cutters for normal spurs and helicals.
. The tilted 4th axis is just the first step to prove the concept and get bevels cutting..
>>You can do most strait cut gears on a 2.5D/3D if you create a cosine stretched formed endmill. This would allow most users to make a cutter with one easy setup and the gear with another easy setup.
Im not sure what a cos stretched endmill is usefull for.. can you explain that one. If I stretch an endmill by cos, the involute would be lost woudlnt it? At least on spurs it would..
>>A non stretched involute form will do most of your gears with the 4th axis set at the pitch angle. This can be a fly cutter for strait teeth or a formed endmill.
YOu mean bevels? I think the invcoltes woudl be lost.. (I think..
>>I do have a question for you Art, is the involute curve the same at the small pitch end of a tooth as it is at the large end? By this I am asking if one profile form can make the correct shape for the entire tooth with varying pitch?
No. Thats the problem, since the diamter of the pitch changes, ( and the base circle), a proper involute changes over the length of the face. Unless I use a parrallel machined bevel.. which is possible but weakens the teeth..
>>If a form cutter can be made to cut the small pitch end and the angle of the gear set to cut the widening tooth any pitch strait tooth could be made with a formed fly cutter or a formed endmill. The spiral teeth would require a formed endmill.
A formed cutter doesnt help much with a proper bevel.. as far as I can see.. The involutes would be deformed across the length of the face..
Zeroing and such I sont think will be a problem.. its more of a question of intuitive
ness to ensure peopel can zero simply and easily.. I guess thats one that can be worked on when we're cutting to make sure people are happy.. pretty easily changed anyway I think..