there are much more mistakes, but this show is for non-technical people to watch, as i did 11-12 years ago as kid that got me into studying mechanical manufacturing engineering.
dtlssm The first gears were made with ink, compass, scribe and file. You would use the compass to scribe a circle in the ink. Cut most of the excess off, leaving a little so it’s easier to make marks on the perimeter of the circle scribe. Then you would set the angle of the compass to a smaller size, estimating based on the size of teeth you expect. Then you would walk the compass around the perimeter, scribing as you go. If the compass was set too big, then reduce the angle and try again (redo the ink so only the new scribe marks shine). Rinse and repeat until you’re satisfied that the markings are accurate enough. Then sand/file the rest of the excess off. Now you have a circular slab with markings around the circumference. At this point, you file each tooth to your satisfaction. This is a lot of work to do, and it is very difficult to get consistent teeth. That’s why you would use a shaper, like Sarvesh says above. A shaper is just a machine with a table and vice, and it has a reciprocating arm which you mount cutters on. Your are able to move the vice up and down so that you only cut a little at a time. This way, you can at least get consistent teeth, but only straight, no helical gears. Similarly, a mill can be used to cut the teeth using a vertical rotary table. Now because the original procedure of marking out the teeth being so tedious, and with limited precision (you can do pretty good, but in automotive and similar applications, really high precision is needed if you want quiet smooth meshing), people made indexers, which can be used to rotate a very specific amount. The critical part of these is an indexing plate, which you can either buy, or make using that original marking procedure. Usually a thread is used that makes the table turn once every 40 turns of the handle, or some similar number, so the precision of the original marking method is increased by that amount. Helical gears can be made by coupling the travel of the mill table (with, you guessed it, a bunch of gears) to the rotary table, so that it rotates an amount proportional to the travel of the table. This also means that the pitch of the cutter needs to be set appropriately. TL;DR People with a LOT of elbow grease and determination
dtlssm The way that they show here is the way that factories make gears. Machinists do things quite differently usually. This is because a factory needs to make thousands of the same exact part, while a machinist generally needs to make completely custom parts. So a factory can afford to spend 10 thousand dollars on a gear cutting machine that can only cut a certain type of gear, while a machinist will do things a slower and less efficient way, because they cannot afford a ten thousand dollar machine for every new order they take. A gear hobber on its own is a quite expensive piece of equipment, and it can only be used to cut a specific gear. So machinists pretty much never use them. If you’re a real DIY kind of person, you could make a basic disk shaped gear cutter (only cuts one groove at a time) without much difficulty, but professional machinists would usually just buy a set of this type of gear cutters, because you can use such a set to cut most of the gears you might need to.
@alanhowitzer You can made them from wood. My Grandfathers father build windmill about 120 year ago, there was 2 gears, one with 10 tooth and another 32. Both made from hardwood. It is quite big but it works. You can shape wood by saw, axe, knife etc.
You are right, thanks. I checked wikipedia and it says that steel is made by combining iron with carbon (between 0.2% and 2.1%), and that higher amounts of carbon produce an alloy called cast iron.
@Saltaren Actually they dont use cutters to cut them again after heat treatment, they grind them. you are right though cutting them with regular inserts would destory both
Secondary machining, like you said, is used a lot for when a powdered metal part has a mating surface to another part or needs holes drilled, threaded, or extreme tolerances. However, majority of pm parts, including gears, are finished once they are sintered. I've run a few secondary jobs through my shop in the past. I've had the great misfortune of being stuck in the tool and die end of this industry for 20 years, lol. It has paid some bills I guess, but I hate it with a passion.
Because the number of teeth on the gear and the angle at which they might have a "helical cut" is different every time. You'd have to have a sand casting and pattern for each one. It's quicker to just cut them using tools and a lathe.
@alanhowitzer the machines that make the gears are CNC (computer numeric control) machines in other words programmable machines, they are or were made by hand at one point which made them expensive and so werent very common then as more CNC machines were made they too could make parts for CNC machines and other mechanical applications So what started as a purely human task requiring immense amounts of time and money is now mainly a machine based job but it costs a lot!
They make them on a different machine, duh. But I'm not sure what makes the gears in *that* machine. ;-) I did once see a fascinating documentary, one small part of which was a little old mad-scientist-type man who was making gears with very specific numbers of teeth from sheet brass, using only tin snips, a pair of dividers, a file and a magnifier. He was incredibly skillful and wonderful to watch. I think he said it took about 15mins to make a gear that could go in a clock.
-DTP2A- our question 1- what is the function of oil is placed on the center of the hole gear? 2- why of the project should be placed into the oven fire is burning? do not that if do like that? 3- what is the temperature used when the gears is in the oven? 4- how long of a gear to be completed? 5- what is the speed of the tool used for turning gearyang desired pattern?
The oil is used to lubricate the cutter, extending tool life and surface finish. The oven is used to heat treat the steel, making it harder and more abrasion resistant. Overall tougher after heat treatment.
Dalila Dst And the rest of your questions, it always depends on the material used, or size of that gear, and in your last question, also what tool you have. So no exact answers :D
Machining is not a waste. All the metal is recycled. Sure you got to remelt the shavings but usually places with big kilns keep them going 24/7 for energy costs. If only we could recycle like this with plastics instead of sinking barges in the ocean.
I think when the world's oil supply dwindles (whether demand falls because of fusion, or environmentalists cordon it off) people will be mining landfills for plastics to recycle.
Noah Dobson Actually it's possible to ban most of the plastic in food industry. Pass the law that will force all beverage producers to use standardize glass bottles, that u can reuse. Same with bags, you can make bags out of marijuana which grows super fast, weed ropes are one of the strongest ropes.
avednamada That would be true, except that our politicians are being elected by companies who save money using plastic. Also, I doubt that hemp will be used industrially without further contributing to youth vagrancy.
Sure, but a lot of the time sintered gears still require some post-production machining work, especially if the gears require extremely precise tolerances or crazy shiny surface finishes.
It was made in the exact same manner! - Except that It was made out of a different type of tool steel then heat treated afterwards to increase its hardness. If the cutters are carbide then they were ground with a stone wheel to final dimensions. :)
the video is correct, the internal was shaped could also have been broached, and the external is hobbed, but if a bigger hob was used they could have done it in one pass
To the guy attempting to begin the cycle of gears making gears. As with all machinery. The first parts/machines are made by hand. By qualified 'fitters' these parts are put together to form machines which in turn can produce other parts. Mind = blown. I am a mechanical engineer. That's how I know this.
I used to inspect gears north of seattle. Italians bought the company and chased all the gear machinists away. too bad. you cant push these people around. they will just go across the street and work if they have to. But they like making gears. I like inspecting them. they were mostly manually manufactured. no cnc. they do now though
Absolutely! Things of no small complexity have been made in the past and the technology lost for generations. Oftentimes the methods were deliberately hidden to prevent other nations gaining an advantage. I remember one example of the Philistines who had developed iron weaponry which was superior to softer bronze. They forbade the use of that technology in the lands they conquered in order to maintain that advantage.
The very first gears, like machine tools were made by hand. By craftsmen. CNC is just modern day methods not how things were first done. Go to Blacksmithing and you will see a real trade that is still practiced, these people are the ones that made the first machines and did the old school heat treatment. Cheers from John.
Most of these machines are not cnc. A hobbing machine is based on manual hobbing, it is basically the same thing but without a motor. The only 2 cnc machines are the lathe and the inspection machine.
The best example is the Antikythera mechanism from about 65 BC which was an especially fine piece of work. That technology didn't turn up again for another 1000 years. Bottom line is that they cut the gears by hand. I didn't believe this until I actually watched someone make a very accurate gear that way.
Looked like some of the procedures did NOT use coolant for the tooling. Drilling the four holes for lightening, or the initial facing of the blank. I used to operate a CNC lathe. We used coolant for EVERY step. Even carbide tools appreciate coolant.
@Cdabek It would be a waste of money to heat treat all gears if some of them won't met the specifications anyway. It is also because untreated metal doesn't cause as much wear on the manufacturing tools as heat treated / hardened metal.
Chickens don't eat enough calcium to justify the shell of the egg they lay. Chickens can transmute other elements into calcium for the shell. So, either iron or magnesium, etc. can be convertd to calcium inside the chicken. Particle accelerators can't do this, they claim. Do you ever see a chicken eat calcium?
Yes, it would be quicker, but it would be close to impossible to get it to the right shape. Air bubbles, thermal expansion, and surface tension naturally work together to make sure that filling a mold results in a sloppy, inaccurate lump of metal (in comparison to milling as seen here) instead of a precise mechanical component, unfortunately.
Why do you hate it? I've done machining work as well and I actually find a great amount of enjoyment in it. I can see how tool-and-die work could get fairly monotonous, though.
Fairfield engineered drive solutions is a great company who specializes in custom gears and gearboxes for off highway equipment like excavators. They are the largest gear maker in America and have been in buisness for 95 years
This is a custom gear shop folks. Forging would be a stupid choice given the tight tolerances for gears and bearings and seals. Most of which have super tight tolerances smaller than .001 of an inch. This isn't making train wheels.
FYI the tolerance on gears are mostly 0 to -0.02 mm because .001 would be an overkill considering that these gears will wear with time, and mining machines does not require that thight tolerance, thats what NASA uses :D
Corn doesn't have high levels of calcium. Eagles, seagulls, etc. don't eat corn, but they lay calcium shelled eggs. The birds that peck at the roadside are getting stones for the gizzard but may also be getting magnesium, etc. to 'transmute' into calcium. Bone eating vultures get lots of calcium. Anyway, not all birds depend on man for food. Tricalcium phosphate is the best dietary form of calcium. I guess it doesn't matter.
shdw1858 Hey man. I am a sophomore who is pursuing his mechanical engineering. I am working on a project which includes manufacturing micro gear on a micro milling machine. Do you think if gears could be manufactured using milling?
Who would dislike this? It's "how gears are made", and the video shows exactly how gears are made... Some people just wanna see the world burn... :(
i hate gears
To correct the video at around 2:30, its titanium nitride coated, not pure titanium or regular titanium alloy.
Facing the fact, that the guy explains in the first place what gears actually are won't make it better here... That's like a video for thirdgraders
there are much more mistakes, but this show is for non-technical people to watch, as i did 11-12 years ago as kid that got me into studying mechanical manufacturing engineering.
That got me all geared up to do something.
The thing people don't realize about the gear wars, is that it was never really about the gears at all
Gold
Revolio Clockburg Junior?
and who made the gears of the machine that makes the gears????
Gainster I'm watching all these videos trying to figure out how to do that myself lol
Shaper or a milling machine
The egg.
dtlssm The first gears were made with ink, compass, scribe and file. You would use the compass to scribe a circle in the ink. Cut most of the excess off, leaving a little so it’s easier to make marks on the perimeter of the circle scribe. Then you would set the angle of the compass to a smaller size, estimating based on the size of teeth you expect. Then you would walk the compass around the perimeter, scribing as you go. If the compass was set too big, then reduce the angle and try again (redo the ink so only the new scribe marks shine). Rinse and repeat until you’re satisfied that the markings are accurate enough. Then sand/file the rest of the excess off. Now you have a circular slab with markings around the circumference. At this point, you file each tooth to your satisfaction.
This is a lot of work to do, and it is very difficult to get consistent teeth. That’s why you would use a shaper, like Sarvesh says above. A shaper is just a machine with a table and vice, and it has a reciprocating arm which you mount cutters on. Your are able to move the vice up and down so that you only cut a little at a time. This way, you can at least get consistent teeth, but only straight, no helical gears.
Similarly, a mill can be used to cut the teeth using a vertical rotary table. Now because the original procedure of marking out the teeth being so tedious, and with limited precision (you can do pretty good, but in automotive and similar applications, really high precision is needed if you want quiet smooth meshing), people made indexers, which can be used to rotate a very specific amount. The critical part of these is an indexing plate, which you can either buy, or make using that original marking procedure. Usually a thread is used that makes the table turn once every 40 turns of the handle, or some similar number, so the precision of the original marking method is increased by that amount.
Helical gears can be made by coupling the travel of the mill table (with, you guessed it, a bunch of gears) to the rotary table, so that it rotates an amount proportional to the travel of the table. This also means that the pitch of the cutter needs to be set appropriately.
TL;DR
People with a LOT of elbow grease and determination
dtlssm The way that they show here is the way that factories make gears. Machinists do things quite differently usually. This is because a factory needs to make thousands of the same exact part, while a machinist generally needs to make completely custom parts. So a factory can afford to spend 10 thousand dollars on a gear cutting machine that can only cut a certain type of gear, while a machinist will do things a slower and less efficient way, because they cannot afford a ten thousand dollar machine for every new order they take. A gear hobber on its own is a quite expensive piece of equipment, and it can only be used to cut a specific gear. So machinists pretty much never use them. If you’re a real DIY kind of person, you could make a basic disk shaped gear cutter (only cuts one groove at a time) without much difficulty, but professional machinists would usually just buy a set of this type of gear cutters, because you can use such a set to cut most of the gears you might need to.
This show was awesome. Love narration
“what really grinds my gears”😂
I like your video. You have shown how gear is made in very neat and clean manner.
@alanhowitzer You can made them from wood. My Grandfathers father build windmill about 120 year ago, there was 2 gears, one with 10 tooth and another 32. Both made from hardwood. It is quite big but it works. You can shape wood by saw, axe, knife etc.
Great video. loving it. thanks for sharing mate.
You are right, thanks.
I checked wikipedia and it says that steel is made by combining iron with carbon (between 0.2% and 2.1%), and that higher amounts of carbon produce an alloy called cast iron.
@Saltaren Actually they dont use cutters to cut them again after heat treatment, they grind them. you are right though cutting them with regular inserts would destory both
Secondary machining, like you said, is used a lot for when a powdered metal part has a mating surface to another part or needs holes drilled, threaded, or extreme tolerances. However, majority of pm parts, including gears, are finished once they are sintered. I've run a few secondary jobs through my shop in the past. I've had the great misfortune of being stuck in the tool and die end of this industry for 20 years, lol. It has paid some bills I guess, but I hate it with a passion.
that is a nice planetary gear at the end
and how did they get the gears for the FIRST gear manufacturing machine which produced the FIRST gears?
Keeping machinery going at every turn! What an awesome comment!
The majority of gears nowadays are formed in a press with punches and a die. They use powdered metal for the gear material.
can you send me a video link please
2:26 - Giggity-giggity-giggity!
Glad to see I wasn't the only one that found that part funny.
Quagmire approves
How were the machines that make gears made? Now that must have been difficult!
I need my transmission gears fix or replaced, I can’t find aftermarket gears besides a bog box. Need help
How are the gears that transmit power to the gear making machine made?
@alanhowitzer Older machines were driven by leather belts and pulley systems. some really old ones were even made of wood.
Cassette players also work with gears but great information
4:43 no, the gear teeths are angled because then there is more area to transmit energy
Best gear video on the internet
Just found your channel and Subscribed. Very interesting. Very nice work
Man that's satisfying...
If you think that's satisfying, check our relaxing machinery: ruclips.net/video/PhdTWit0fYI/видео.html
Yep.
Because the number of teeth on the gear and the angle at which they might have a "helical cut" is different every time. You'd have to have a sand casting and pattern for each one. It's quicker to just cut them using tools and a lathe.
@alanhowitzer the machines that make the gears are CNC (computer numeric control) machines in other words programmable machines, they are or were made by hand at one point which made them expensive and so werent very common then as more CNC machines were made they too could make parts for CNC machines and other mechanical applications
So what started as a purely human task requiring immense amounts of time and money is now mainly a machine based job but it costs a lot!
Great video
They make them on a different machine, duh. But I'm not sure what makes the gears in *that* machine. ;-)
I did once see a fascinating documentary, one small part of which was a little old mad-scientist-type man who was making gears with very specific numbers of teeth from sheet brass, using only tin snips, a pair of dividers, a file and a magnifier. He was incredibly skillful and wonderful to watch. I think he said it took about 15mins to make a gear that could go in a clock.
How did they make the gears on the machine if the machines are the one who are making the gears?
On a serious note, this is pretty cool. I thought gears were just moulded or something.
-DTP2A-
our question
1- what is the function of oil is placed on the center of the hole gear?
2- why of the project should be placed into the oven fire is burning? do not that if do like that?
3- what is the temperature used when the gears is in the oven?
4- how long of a gear to be completed?
5- what is the speed of the tool used for turning gearyang desired pattern?
The oil is used to lubricate the cutter, extending tool life and surface finish.
The oven is used to heat treat the steel, making it harder and more abrasion resistant. Overall tougher after heat treatment.
oohhh, thank you :)
Your welcome.
Dalila Dst And the rest of your questions, it always depends on the material used, or size of that gear, and in your last question, also what tool you have. So no exact answers :D
thanks .. :)
Well, that was pretty cool to watch...
Ok here is my question the machine that made the gears , had gears in it , so which came first the gear or the gear making machine ?
When the video started I first thought "what plugin crashed this time?"
Machining is not a waste. All the metal is recycled. Sure you got to remelt the shavings but usually places with big kilns keep them going 24/7 for energy costs. If only we could recycle like this with plastics instead of sinking barges in the ocean.
You could gasify the plastic with coal and turn it into truck fuel...
Noah Dobson 00
I think when the world's oil supply dwindles (whether demand falls because of fusion, or environmentalists cordon it off) people will be mining landfills for plastics to recycle.
Noah Dobson
Actually it's possible to ban most of the plastic in food industry.
Pass the law that will force all beverage producers to use standardize glass bottles, that u can reuse.
Same with bags, you can make bags out of marijuana which grows super fast, weed ropes are one of the strongest ropes.
avednamada That would be true, except that our politicians are being elected by companies who save money using plastic. Also, I doubt that hemp will be used industrially without further contributing to youth vagrancy.
The ultimate question though, what the heck made the gears that make the gears? =)
great video
would they recycle the metal that comes off during the milling?
almost certainly. It'll make them some money apart from anything else.
Sure, but a lot of the time sintered gears still require some post-production machining work, especially if the gears require extremely precise tolerances or crazy shiny surface finishes.
how did the machines that make gears get their gears?
It was made in the exact same manner! - Except that It was made out of a different type of tool steel then heat treated afterwards to increase its hardness. If the cutters are carbide then they were ground with a stone wheel to final dimensions. :)
the video is correct, the internal was shaped could also have been broached, and the external is hobbed, but if a bigger hob was used they could have done it in one pass
It gets heat treated, which hardens the material from 60 to 80 rockwell.
My x- wife heart was 80 Rockwell, can relate!
The probe is called a CMM coordinate measuring machine.
totally nice
@Cdabek how would you cut it, if it was heat treated?
beautiful video
niice give you 5 stars mutch good information come on whith more techinfo of gears and boxes
To the guy attempting to begin the cycle of gears making gears. As with all machinery. The first parts/machines are made by hand. By qualified 'fitters' these parts are put together to form machines which in turn can produce other parts. Mind = blown. I am a mechanical engineer. That's how I know this.
Thx .this was really informative
What was the name of the golden gear that make gears, I couldn't undestand, and I try to listen many times
Gear Hobber
If you were wondering the company is Accurate Gear and Machine. I'm sponsored by them
I used to inspect gears north of seattle. Italians bought the company and chased all the gear machinists away. too bad. you cant push these people around. they will just go across the street and work if they have to. But they like making gears. I like inspecting them. they were mostly manually manufactured. no cnc. they do now though
Absolutely! Things of no small complexity have been made in the past and the technology lost for generations. Oftentimes the methods were deliberately hidden to prevent other nations gaining an advantage. I remember one example of the Philistines who had developed iron weaponry which was superior to softer bronze. They forbade the use of that technology in the lands they conquered in order to maintain that advantage.
Interesting video.
How long does it take to make 1 of these? Oh my. This looks too slow to me.
This is super awesome
Good
Aliens man, aliens.
The very first gears, like machine tools were made by hand. By craftsmen. CNC is just modern day methods not how things were first done. Go to Blacksmithing and you will see a real trade that is still practiced, these people are the ones that made the first machines and did the old school heat treatment. Cheers from John.
Most of these machines are not cnc. A hobbing machine is based on manual hobbing, it is basically the same thing but without a motor. The only 2 cnc machines are the lathe and the inspection machine.
Endmills! But what made the endmills??
It's like a case of the chicken or the egg.... What made the gears which are in the gear cutter machine!??? LOL
The best example is the Antikythera mechanism from about 65 BC which was an especially fine piece of work. That technology didn't turn up again for another 1000 years. Bottom line is that they cut the gears by hand. I didn't believe this until I actually watched someone make a very accurate gear that way.
Are all gears made this way
What made the gears that made these gears?
Looked like some of the procedures did NOT use coolant for the tooling. Drilling the four holes for lightening, or the initial facing of the blank. I used to operate a CNC lathe. We used coolant for EVERY step. Even carbide tools appreciate coolant.
wow!
knowledge full
At 2:26 it really gets good. Look at that thrusting.
Metal Gear!
and now all of these operations can be done on one machine.
nice vedio
@Cdabek It would be a waste of money to heat treat all gears if some of them won't met the specifications anyway. It is also because untreated metal doesn't cause as much wear on the manufacturing tools as heat treated / hardened metal.
By using a belt powered milling machine and a rotary table.
Chickens don't eat enough calcium to justify the shell of the egg they lay. Chickens can transmute other elements into calcium for the shell. So, either iron or magnesium, etc. can be convertd to calcium inside the chicken. Particle accelerators can't do this, they claim. Do you ever see a chicken eat calcium?
Yes, it would be quicker, but it would be close to impossible to get it to the right shape. Air bubbles, thermal expansion, and surface tension naturally work together to make sure that filling a mold results in a sloppy, inaccurate lump of metal (in comparison to milling as seen here) instead of a precise mechanical component, unfortunately.
Does this mean that in developed countries like America they are manufactured in this lengthy way
@kuma982 thats just components of the cutting machine keeping cutter's up & down movement timed
Thank you science for robots and computers!
Why do you hate it? I've done machining work as well and I actually find a great amount of enjoyment in it. I can see how tool-and-die work could get fairly monotonous, though.
2:26 is like some robot porn lmaoo
thank you..that is really informative
COOL :D
i like how the intro of this video just assumes people open up mechanical watches and car transmissions as if it's an every day thing
Hi there, does anyone know a qualified gearbox manufacture for excavator?
Fairfield engineered drive solutions is a great company who specializes in custom gears and gearboxes for off highway equipment like excavators. They are the largest gear maker in America and have been in buisness for 95 years
This is a custom gear shop folks. Forging would be a stupid choice given the tight tolerances for gears and bearings and seals. Most of which have super tight tolerances smaller than .001 of an inch. This isn't making train wheels.
FYI the tolerance on gears are mostly 0 to -0.02 mm because .001 would be an overkill considering that these gears will wear with time, and mining machines does not require that thight tolerance, thats what NASA uses :D
train wheels at? I work next to a guy on a wheel lathe. hes gotta be withing 5 microns. so there not a good thing to say that is rough
3:47 is where all the bad gears go
SNAAAAKE!!!
Corn doesn't have high levels of calcium. Eagles, seagulls, etc. don't eat corn, but they lay calcium shelled eggs. The birds that peck at the roadside are getting stones for the gizzard but may also be getting magnesium, etc. to 'transmute' into calcium. Bone eating vultures get lots of calcium. Anyway, not all birds depend on man for food. Tricalcium phosphate is the best dietary form of calcium. I guess it doesn't matter.
the amount of math involved in this... i cant even...
"Keeping machinery going at every turn" haha.. i see what you did there.
VERY INTRESTING VIDEO BUT THERE IS MISS A PROCESS THAT IS GEAR TEETH GRINDING
@alanhowitzer that sir, is what's known as a chicken and egg senario.
gears don't alter forces,they just alter torque
Nice video, i actually work on gears like this, i grind the outside diameters
shdw1858 Hey man. I am a sophomore who is pursuing his mechanical engineering. I am working on a project which includes manufacturing micro gear on a micro milling machine. Do you think if gears could be manufactured using milling?
holy shit... and there i was, believing i would be able to make my own gears.....
Why dont they just forge it?
Who made the gears so the machines at the gear factory could make gears?