Repairing a Broken Gear Tooth Part 1 - Milling a Dovetail Slot on a Horizontal Milling Machine
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- Опубликовано: 3 ноя 2013
- The process I used to repair a broken gear tooth. Includes making a holding fixture, turning a custom tool holding arbor, and milling a dovetail slot on a horizontal milling machine.
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Joel Hunger
2014-11-27
I spent 35 years as a machinist I always found the greatest pride came from just finding a way to get it done right. Making your own fixtures and tools is the best part and often the only way.
I just like the fact that there are people out there who see more than scrap metal when they find an old machine that's so rough and rusty. Its definitely not easy, or just a little work to get it going again, lots of work went into this for sure.
Thank you - I just love to bring pieces like this back from the dead and give them new life!
compactc9 up lore
May I apologise for some of us viewers who think we know better. We haven’t done it or videoed it as you did and am thinking not qualified to judge your workmanship. Pls keep it coming
I love watching these videos of old manual machines. I am a cnc machinist/programmer and I am often humbled by the amount of skill and patience it takes to do a job like this. Thanks Keith, keep up the good work!
Love the way you do it. When I worked in the Oldsmobile factory, decades ago, I saw the skilled-tradesmen repair a broken tooth like that. But they did it by welding onto the broken tooth, and then machining the weld into the shape of the tooth.
Didn't even have to finish the video to realize I have to subscribe . Your an artist that I can learn to utilize every tool I have at my disposal .
Great job keith.I learned alot from you.I remember making a gear for a debarker machine for a sawmill out of T-100 plate.We used a new one as a template,free hand cut out teeth with a acetylene torch and finish with bluing and a grinder to fine fit.lol.Then bored out for a 3 inch shaft for mounting.It was an idler gear and we didnt want to mismatch a new idler with old worn gears without replacing them all as a set.It lasted for a few months before teeth started to crack and sometimes break.Then a single tooth was cut and re welded in.Just a funny story of what we can do to keep old machines running.Thanks for the vid.
Hi Keith,
Love hearing that train whistle!!!!!!!
Thank you for the video.
George
I'm new to machining, going to school and learning. Your videos are so very helpful in opening my mind to "thinking outside the box" the experience and knowledge you share are invaluable. Some of the set ups you use are extremely simple yet I would never think of something like that, and it makes me feel dim. These things weren't come up with over night, they are tried and tested methods that have been passed down. I'm just at the bottom of the mountain looking up.... So much to learn. Thanks for your videos Keith.
Thanks Brandon. The main way to learn is to get out in the shop and just start doing things. Try things out and don't be afraid of making a mistake. Experience is a great teacher! But always try to learn from those who have already been taught some of the really tough lessons. And work around as many different machinist as you can - they will all do things differently and you can learn from each and every one of them!
Outstanding job. It utilizes everything a true machinist should be able to do, from problem solving and invention to executing the actual production of the piece. A dying breed we are, a true shame, I fear for the future when know one knows how to fix or build anything. Great video.
You're a true artist and I loved seeing you at work. Thanks for the great video. I'm off to see part two!
No, I have a real job that pays the bills - the museum is where I go to have fun! I worked there 20 years ago when I was a student in college as a part time job to help pay for school and loved it so much that when I got out of school, I just continued to volunteer. I learned most of my machine shop skills when I worked as a machinist for several years before I went to college while I was saving up money to go. I love to make, build, and fix things, and the museum gives me that outlet!
I Love how you take the Time to make the Tools to do the Job. I World Not have thougth, that this much effort wents into the preperation of such a Job. Thank you for the Video.
Keith, I'm blown away by your talent. Amazing!
+Glenn Martin Thanks for the kind words Glenn!
Thankyou. Love what you can do and your patience letting us in on your journey.
Always interesting watching a master machinist work. Damage like that would be a real problem for a kid with a CNC mill to repair.
With CNC you would just make a new part....these days you can laser scan the old one. The part is symmetrical so the g code would be easy
Amazing job, it brings to mind that old saying , Where there is a will there is a way !
wow - highskilled machining right here!
Very nice video!
Thanks
Stephan
i watched it about 2 years ago and still watching it,,,love these videos
excellent...
Thank you sir!
Keith Rucker - VintageMachinery.org
your more than welcome
“Well Done Sir” As always, thanks’ for taking the time to make this video! ~M~
Thanks for sharing. I just got a Horizontal Mill and this motivates me!
Wonderful job in explaining the beautiful logic of machining! Thanks so much.
I enjoy your videos. I spend way too much time doing electrical and automation this days, and I miss machining sometimes. The problem-solving aspect of your job would make it a very enjoyable one to have. When I thought to myself "Why is he using a 3-jaw chuck? Why isn't he boring the hole for the tool bit?" you turned between centers with a dog and my questions were answered. Very nice.
One thing, though. That tap you were using is a spiral-point tap. You don't need to break the chip. It pushes the chips ahead of it. Since you were threading a through hole you could have put it in the machine and run it right in under power without a tapping head (as long as you can stop it before it hits the far side of the hole, that is...). Turning the tap backwards to break the chip just invites chipping the leading edges of the tap. Buy hey! I understand. Old habits die hard. :) Actually, another thing. You were using dark thread cutting oil as a lubricant on the late (believe me... I could smell the sulphur in my mind) but you used clear thread cutting oil for actual thread cutting. You prefer Tap Magic to sulphurized for hand tapping?
Mike
Awesome, love how you make everything to fit that job too.
Thank you for a very well made and educational video. Your explanations during each step was above and beyond most. The explanation of why and how leads to a better understanding and judgement of application..
Great video! This isn't my trade, but I always enjoy seeing a good craftsman at work!
I've never seen an overarm support used to support a cutter like that, bloody ingenious
Excellent. Great machining.
I can smell the foundry just looking at that beautiful gear.
This video appeared on my play list. I watched it out of curiosity. I subscribed immediately.All I can say Keith, you sir are an artisan! Keep up the great work and videos!
+James Weber Thanks James - glad that you found the channel and I hope that you enjoy the projects I have going on in the shop!
Nice work i miss those old machines.
I like your custom arbor too.
Hi Keith,, thanks for the great videos, I enjoy watching them and I learn some new techniques. Please keep them coming,
Pretty amazing work. Nice job!
Excellent setup Keith
Tried to watch this video with my ear buds in cause everyone was asleep, not a good idea, the hammering was about to pop an eardrum. Looks like an awesome project though. Thanks for posting
There is always time for learning something new, Thank you Keith.
If it were me I would have replaced the bushings first, and then made my fixture to fit the right sized bushing. That way if you ever needed to do work on it again you could, and if you needed to use it on a slightly worn gear you could shim it a bit.
Seems to be a lot of secondary work before completing the primary work. Who would have thunk it. Good work !!
Always great to see a metal working machinist do a good job, these skills are being lost.
excellent video!
thanks for sharing your knowledge with us!!!
Thanks, I spend my time with pleasure during watching your video. Perfect video to open mind and think like engineer :)
***** Thank you!
Great job from a fellow owwm'er. Looking forward to part 2.
Nice work! Old school. Thank you.
Impressive! Congratulations and good luck for future projects! Dan.
That was remarkably well done! You area superb machinist. It has been very well thought out as it should have.. Greetings from Arizona.
I had a great time here today, and I'll be back for more.
+James Monahan Please do stop back by!
Yes, I was running the same RPM with the dovetail cutter - 250 RPM. I ended up keeping the feed the same throughout the project as well - 1/2" per min. I probably could have pushed the feed up a notch or two, but it was cutting good and I was not in a hurry,
Nice video & great shape.
How far you have come in 8 years! AND you lost weight!
Awsome job ! Enjoyed the video !
Nicely done job.
Two thumbs up Keith. Maybe try the Tom Lipton silicone bronze brazing sticks.
That's a cool mill vice!!
Nice machining there.
You can also pin it then build it up using oxygen & acetylene with brazing rods. Takes a lot of heat but very strong repair. Infact the finished weld is stronger than the C.I no issues with the parent metal even near the welds.
Fine Work - well done!
I will either braze or silver solder the tooth in place, I have not decided yet. As to building up with weld and re-cutting it, I did consider that but chose not to go that route for two reasons. First, because of the flange at the back of the gear, it would be hard to cut the tooth because you can not cut all the way through, and second, because it is cast iron and welding to cast is not as strong as steel.
Is it just me but rusty steel becoming clean fresh steel again is just great
Great video! If I could recommend a tip for a zero runout tooling arbor for the mill. Leave the cutter hole ID undersized at the lathe. Mount the arbor into the mill spindle and bore it out with a boring bar mounted to the mill's table. That's not nescecary for the big cast gear you had here, but you never know when you might need a more precise setup.
Excellent reminder of how to keep tolerances intent.
Very interesting. I'm anxious to see how you make the tooth.
great method, wish I'd used it when repairing a broken gear tooth (not cast) I got a weld build up and had a profile of three teeth made and filed with hand file to tooth profile, hard monotonous work.
great work!!!
Amazing repair work, passion and patience ! Congrats !
You certainly appear to know what you're doing. Nice work.
very nice work
The lathe we have out at the museum is a Lodge & Shipley 16" Model X lathe. I have not been able to find a serial number on it to date it but suspect that it was probably built in the late 1940's or early 1950's. The museum acquired it in the early 1980's off of government surplus and it came from the Savannah River Nuclear Plant in SC. It has seen very little use over the years...
Keith Rucker - VintageMachinery.org ... Does that lathe glow in the dark?
I am surprised that Keith didn't press out the badly worn bushings out and make the hold down tool fit the hole in the cast iron.
Wow,, thumbs up,, perfect video,, i Enjoy every minute,,,
Skilful stuff, Keith, compulsive viewing.
You make awesome videos--thanks!!!
Thank you Alex!
Very nice work, but geometrical, both nearby teeth will be much much weaker now. Expeecially from a force on the side of the teeth which faces the replacement tooth. It will pull the tooth out in some time. A better solution would be to smooth all the teeth into a round shaft, and installing a new gear as a bushing using high temparture on the gear and use a press. I bleave the right gear can be found and modified, but it seems this guy have also the skills to creat one.
Keith, you are doing great work, this mecgine will be a great adition to the colection, my question is about how will the story of the planer matcher be told, live or staticly and will you adress the restoration too
great work love your channel
+Aaron Dixon Thanks for watching!
Kool beans learned some stuff today Thank you
Nice video these are skills a lot of today's generation will never know, it's a shame.
don't worry, we are learning...
dont be so cocky man, manual machines are still used today
Machining and tool/fixture making is my daily life. There is no limit to a man and his imagination when it comes to machining. a 5 or 6 axis is only as good as the programer. A man and a file is limitless
I work in motorsports engineering, yes there is a lot of tech nowadays but all the old traditional machines and methods are still used on a regular basis. Particularly in the Fab shop. Our company has several 5 axis machining centres, but it also has 3 old manual mills and 2 manual lathes. In the fab shop there are hand folders, rollers, swaging wheels etc etc. Don't worry none of these skills are being lost.
Thank you for the video ...what sort of load does a tooth experience and is it shared
While I agree that my lathe can take bigger cuts than what I am cutting, my limitation is in some of my tooling, which is quite honestly a bit on the small size for this lathe. Right now, I am taking cuts that I am comfortable with based on my past experience and experiments. I am planning on investing in some larger tooling soon, which should allow me to hog off more material in a single pass.
Brilliant !!!!
Thank You, I really learned a lot.
Frank Patti Sr.
+Frank Patti sr Thanks for watching!
Interesting job you got there - I don't think there is too much meat left in to the bushing but the soldering maybe will add the strength back again ... or ?
Wow, so much work that went into this!
+Alan Fox Thanks!
Keith Rucker - VintageMachinery.org The hammering at the beginning was a little annoying but the stream whistles add a wonderful ambience. How close do they get to coming though the shop? :-)
Alan Fox
gorillaau bof g
WAOO !
IS Incredible !
+Victor Noghea Thank you!
Nice seeing how much work goes into something like this.
How would this have been fixed back in the days when these machines were in commercial use? Would the same process of dovetailing a new tooth be used or the entire gear wheel replaced with a new casting ?
Hi, Really interesting the way you've set about this problem. What are they going to do when they finally run out of skilled Machinists? Regards.
before I retired, I used to put Dykem on the dull end to remind me.
I liked this.
Just wondering how you aligned the rotation of the gear wheel/broken tooth to the arbor/mill axis. Was it just eyeballed? It is skipped in the video.
Using the upper and lower feed wheel feed,the momentum wheels 5 groups,5 groups simultaneously under strong feed and can be variable transmission.
I see the best of everything good about the usa in this video.
Keith, really cool and thoughtful video. Is there any reason you didn't mill broken tooth out, build up weld in its place, and then mill tooth back to shape?
This is absolutely amazing work. I'm just curious if you considered sand casting another complete gear. I did sand casting in my early years. University foundries are a good place to have specialty items made.
Knott Reel Perhaps time was a factor. In order to cast another gear, you would need to make a pattern to create the sand mold. Metal shrinks when it cools.
The tooth, to the right of the broken one, as viewed from the top, is bent to the right. By a large amount. I wonder how it’s going to mesh? It was likely bent when the other tooth broke off. You can see where metal was scraped off when the problem occurred.
Very clever use of the horizontal mill with your improvised extended tool holder Keith. I love the old K&T mills! Next time if you want a cutter arbor to run true, drill undersize, indicate the arbor concentric, then single-point bore the hole. I guess it didn't really matter that you had runout in your extended holder since you got the job done handily. What brand is that stout old vise on your vertical mill? I like the simple reversible v-block jaws.
Великолепный мастер!!!
excelent work waoooo
Man...a lot of extra work with the arbor, etc.....but sometimes it's better to take the long way 'round if you know you get good reliable results every time.
Very impressed with your technique and your expert machining, Your comments are helpful for those who may be unfamiliar with machining. I'm subscribed- keep up the good work! I'd like to know the name and location of that RR museum. Thanks,.
Thanks for the sub - the museum is the Georgia Museum of Agriculture in Tifton, GA
I also learned that in your very next installation! It has a nice website.
nice video specifically the horn wheres whistles !!
Very interresting to see, now I know it is called ducktale. :-)
+Mads Thorup Dovetail* not being a smartass just checking you now know
is that the 0-4-0 in one of the other videos in the background? Now that is one sexy little machine!
I sat down and watched the vulcan operation video and am now going to finish this one...
Given that the bronze bushings were worn and therefore no longer concentric, wouldn't it have been better to have pressed the bushings out, and made the fixture to fit the hole bored in the gear itself?
Another advantage of this, is that the fixture would be of a larger diameter, and hence more rigid.
That was weird! I could hear the whistle from the steam train on the Severn Valley Railway in the UK in one ear and the whistle at your museum in the other! Stereo! :-)
Beats working near a regular line!