Adam Savage's One Day Builds: Machining a Gear!
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- Опубликовано: 21 сен 2024
- Adam embarks on a build he's long wanted to make: a supersized flywheel powered toy car that can move with tremendous energy. The first step: machining a scaled-up version of one of the gears in the toy's gear train. Machining a working gear with a specific number of teeth and gear pitch is something Adam has never done before, so it's going to be a fun machining exercise!
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Shot by Adam Savage and edited by Josh Self
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#adamsavage #onedaybuilds #machining
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Adam should try doing cuts on the lathe no more than 25 thousandths at a time to prevent chatter, and potentially damaging his equipment, particularly the cutting edge of the bit.
Those nice long curly offcuts is what you want to see when you start seeing little chips check your feeds and speeds.
When the zombie apocalypse comes, I’m heading for Adam’s
As a machinist the noise when cutting gears is exactly that 😂😂
I've been building my own design little 2 cylinder engine and had to make gears a few months back , went through this whole process. It took a bit but i now have a set of gears lol. I tried with a slittingbsaw first but ended up getting a set of involute cutters. Wasnt that bad
Beautiful work mate, muuuuuch prettier than my first pinion! Look forward to watching this build :)
If it was me making that lil pretty gear and getting that comment on it afterwards I'ld get all gitty inside, I have a feeling same goes for Mr. Savage. Thank you both for your outstanding work and passion sharing across platforms
I just got secondhand glee from seeing this comment! I absolutely know Adam is going to have it tenfold. Your work is beyond exceptional!
honestly hearing adam mention he watches click spring made me smile and relize just how down to earth adam is ! id love to see clickspring visit adam and see them swapping tips and tricks with eachother
Much better than my first attempt as well Chris!
This is high praise coming from Clickspring!
Some tips to make your next experience better:
1) it's called a tail stock on the lathe, it's called a footstock on the mill. This isn't about gatekeeping, knowing the proper terms makes finding spare parts easier
2) let the stock cool between your last roughing cut and the finish cut. Measure and adjust the DRO accordingly. Makes hitting the number easier.
3) use a four jaw independent chuck on your dividing head to dial in the part to tenths on the mill.
4) you don't have to go full depth in one pass on the gear cutter. Take two or three passes to reduce chatter, improve finish, and prolong cutter life.
5) look up the surface speed for the material you are cutting and the chip load per tooth for the cutter. Use those to calculate RPM and then feed rate. This also improves dimensional accurate, surface finish, and cutter life. And no hammering of death noises when cutting.
yeah the one pass cutting was a bit much for me
Yep, the chattering really hurt to watch and listen to.
I would add milling conventionally instead of climbing the cut. Deflection in the arbor contributed to the unpleasentness, and could have been mitigated by milling conventionally. Also it can lead to a bad crash. 'specially with slitting saws.
I'm not a machinist or engineer but even I cringed when he was cutting the gear, you could see the tool wobble and hear the chatter.
@@4d4m22 Just at the point the music came in...
A long-term design point: using brass or bronze against iron/steel is a good choice because it prevents surface galling. The cost is that most of the wear happens on the gear made of the softer material. Typical practice is to spread that wear out across as many teeth as possible, so we usually make pinions of steel and use brass/bronze/plastic for the larger wheels.
For the project you're doing now, it hardly matters. You might see the effects of wear on the brass gears if you use the toy every day for the next ten years. The idea becomes more important if you make gear trains that run continuously, or carry a lot of force, and is one of those bits of knowledge you pick up as you spend time working with gears.
I could watch Adam build anything and be entertained
Just like we can watch anything Ryan Reynolds makes, lol
so true. He is a great entertainer and has the passion for bringing the joy of making to the masses
@@DB-rg2dk "we"? Speak for yourself.
'I dog-eared the page. I've been here before.' Is an almost cinematicly beautiful point of discovery. There were people here before.... and it was us. They've left us a message. This'll make me smile for hours.
Don’t leave us waiting too long! We want to see the whole build!
The one day builds where Adam does something for the first time are the best one day builds imho
Expert gear engineer here, love your explanation of pressure angle etc. It is as complex as you explain actually.
You should look into gear hobbing, which actually mills different teeth shapes (tooth counts) on gears, using the same tool. Nice video 👌
A little Fellows #7 shaper would probably be more reasonable for a shop his size. Hobbers have a big footprint.
55 years ago we used to calculate all the tooth / root radii manually using logs - brain still hurts !
Wait till he sees the math for a helix or a bevel
Got a 0.5 hob years ago but don't have the machine to use it. Been on my maker list for two decades. Time to revisit this as I reach retirement.
@@ToofKilla Been there, got the T shirt, done the maths 😁
Y'know this description of gears at the start.. like you're right I don't need to know it, I'm immediately forgetting it, but the depth of human understanding and capability about any given subject always blows my mind. How far and how perfectly a person can understand something to keep making it better. Beautiful.
Hey Adam, I'm a phd student whose primary research area is on gear geometry and applications. I just wanted to say it was cool watching you learn a bit about the subject and make a couple of spur gears in this video!
Welcome to my world! 40 years experience as a clockmaker. While clocks typically use a different type of gearing, the concept is essentially the same. I've cut hundreds of gears on a Bridgeport milling machine. Glad to see you enjoy a new experience.
I always thought it would be neat to have "human-powered drag races" where people would make vehicles with flywheels or springs or super-capacitors/generators. Maybe 30 seconds to add energy from zero, and classes based on mechanical or electrical.
I feel like I’ve seen something similar
What's neat is nitro methane drag races. A word to the wise if you're watching in person bring ear plugs. It is loud!
Nice! I imagine one team using a couple of cyclists pedalling a hard as possible, meanwhile another team has a strongman lifting as many weight blocks on top of a platform, etc.
Would make a good Little Rascals movie
@@JanTuts that sounds awesome
Adam, this is fantastic and always wonderful to watch someone machine something complex like this. If you're curious about a full size "flywheel" car you might be interested in what Porsche (and to some extent Williams F1) did with a mounted flywheel. It was mag-lev and used magnetic induction to spin so as to reduce friction loss. Very cool tech on what it a very old idea.
Thanks for that little research mission!
Adam, thank you for showing people the skill needed to be an engineering machinist; in today's modern world of CinC tools, seeing someone having to work the way my grandfather, father and brother learnt to do their profession is satisfyingly interesting.
Much of the equipment used in small production/job shops is still manually operated. In my shop we have only 2 CNC gearcutters: a gasher and a hobber. Everything else uses an annoying number of gears (because of that, the CNCs are most useful for prime numbers of teeth over 100 teeth).
😅
I love the little bit of text at 25:38 saying “not blood”
I had to rewind and rewatch several times as I thought I was seeing things
I think
This Old Tony has some excellent videos explaining gear cutting and gears in general as well.
Gears! But were afraid to ask.
Everything about this video was top notch. Perfect amount of intro story time, flair of goofy transitions, time lapse commentary. Everything!
There is something so beautiful about learning the language of a discipline. There are things that I have no idea how to even begin doing, but I can name them, so I can learn the things I need to know to learn the other things I need to know
Gear cutting is a beautiful engineer. David Brown Gears and Citroën greatest gear manufacturers in the world at one point. Thank you your work and way you simplify engineering to get people interested.
For small straight cut gears, making the cutyers from silver steel stock and dividing head . Well done
Back when I was working as an engineer, part of my job was programming an Agie wire EDM and gears were often some of the parts we made on it. Wire EDM's are extraordinary machines and ideal for making gears. It could even make bevel gears. It was my favorite machine.
Nothing new yet from This Old Tony or Inheritance Machining... Adam puts out a machining video.
👌😙 chef's kiss
Old Volvos are amazing. My 940 had 440 000km in it when I changed it and some had even double to mine before it stopped working. One of the best cards I've ever had.
I love the introduction of education here. I know nothing of this type of machining or even mathematics, but I love to learn. Keep those things coming Adam, even if your only have marginalized knowledge of them, because any experience helps people with none.
I love the color of bronze and I love the strings it makes while cutting!
It just so happens, I’m going to be cutting 10 tooth gears for the 1864 Arithmometer I’m going to build. This video is a Godsend! Thank you, Adam!!!
Had this up on my big TV watching and my grandfather started watching with me as he worked at a machine shop for a long time, and he wanted me to mention something to you even though i know youll probably never see this.. XD
He said "Please tell him that gloves or not, touching your part while spinning to check for smoothness is very dangerous. I know is common, hell i was even taught to do so in training! But its still not safe, you can still be pulled in. And that in case you are pulled in dont pull away from the part, push into it."
He worked in the shop for 50 some odd years!
The Machinery handbook brings back memories when I was at Ford tractors. We used get the SAE book set of specs. every couple of years. I was in inspection, I think gears were measured with rollers. Now retired. Nice shop setup.
My working life was spent as an engineer. Working on large industrial gearboxes and gears manufactured for high end engine manufacturers in the UK, Europe and North and South America. I traveled all around solving problems with customers. Power train engineers do have their own "speak", which to most is a foreign language. I loved my job.
Made my first and only gear 30 yrs ago. I got to relive that experience today. Thank you!
I love Clickspring videos too and he makes it all look so easy!
At 7:28 Adam mentions cutting gears and watching the ClickSpring RUclips channel. Great and beautiful stuff there. Another very good machinist's channel is Keith Rucker's Vintage Machinery channel. He is a very good teacher.
Those are great recommendations. I'd like to add Blondihacks to the list, makes machining look much less of a black art and more approachable by mortals.
the editors need a raise!
25:37 "not blood"
25:41 "i think"
you guys crack me up!
I saw that too. LOL!
The time lapse when cutting the teeth was way more satisfying when watching the drill bits spinning from vibration in the background
Machinery's handbook might just be my favorite book.
Really looking forward to seeing the rest of this build!
Any chance you could do an interview or podcast with Clickspring? I'd love to hear the two of you talk about machining and precision.
I feel like Adam would love This Old Tony's video on gear teeth as much as I did... goes into the whole involute and everything. ohh imagine a collab between Adam & This Old Tony!? that would be amazing... mainly because they are both amazing on their own surely thats a recipe for even more awesome sauce... right?
Thanks Adam. I miss building stuff now that I've been stuck in a care center for the last four years plus. You Rock!
I went through this exercise digitally, had a 3d printer project that had gears, and I'm the type of person who likes to understand the why and how, so i googled the machinists handbook, walked through the process of manually drawing the gears by hand, using all the complex geometry with all the overlapping and intercecting circles and tangents in CAD. It took me a couple days to truly understand what i was doing and be able to re create the process from memory instead of reading step by step.
Now i just use the gear creator tool and it does it for me, but i understand what is going on!
11:48 that was a pretty fantastic non-copyright-infringing flying mammalian superhero TV show transition!
Back when my "guys night out" was a machine-shop "class" at a local high-school, I just *LOVED* machining brass and bronze. Always pretty results, and as you observe, the swarf is just so very attractive as well. In fact, my very-first project on the lathe there was a pair of replacement bronze bushings for the power-head of our vacuum cleaner.
LOVE how you take the time to break things down and explain them-including your thinking aloud-which we all know is often so helpful. And the car-repair analogy was brilliant and spot on!
Gears are fascinating to me. The "Machinery's Handbook" is the bible for any machinist. For me gears were the next step after learning threads. My step-grandfather (Wilbur Harbold) created "Harbold Gearworks" in Belmont (in the Bay Area). As a kid, going to the shop was a special treat to get to see the machines. As a late teenager I remember going to the shop needing to replace the nylon gears that had stripped in my R/C car (Tamiya Rough Rider). I asked if he had time to make a set of replacement for me and he said "yes", I was so excited. While I was at the shop looking around (being amazed at the "Gleason" helical gear cutter machine and the process of making worm drive gears - some of which were used on old Pierce Arrow vehicles) I was presented with not just replacement gears for my R/C car but stress-proof stainless gear set with press fitted sealed ball bearings (the stock drivetrain in the R/C car used bronze bushings). They worked perfectly. Thanks so much for triggering the gear related memories...lol. Great video Adam :)...I guess the next step would be to learn how to machine a cam shaft...hehe
Cheers,
Jeff (Garage Maker Guy)
Always a pleasure to watch Adam work 🥹
Its super satisfying watching Adam play with his adult Legos.
I like this man. He is good people.
I'm proud of you Adam. Great work.
The section when you start cutting the teeth and it's sped up.. reminds me of the Bicentennial Man intro, love it.
Love your work Adam, putting the fun back into machining. I have a machine shop full of CNC machines but you seem to be able to put the fun back into discovering new machining processes. 10/10
I was watching this and I realized just how far the internet and monitors have come. I am watching it on my big screen through my Nintendo Switch. He goes to shave a tiny amount off that brass, and I could see the bar being thinner. That would not be possible 10 years ago. I just thought it was amazing, considering what the internet was like when I was in highschool in the late 90's.
This Old Tony has a great video explaining how to make gears from scratch
I would LOVE to see the rest of this project!
i love when he pulls out some of the odd pieces of mythbuster stuff.
Adam goes full on "6 years old" at 8:48 "...I wan't it to go for like a BLOCK!" just cracked me up 🤣
...man what a world this would be if everyone would hold on to that level of energy in their life.
The amount of knowledge and experience to learn from in this video is invaluable! Thank you so much for the many years of videos Adam and the rest of the Tested crew, you all make dreams come alive.
Really appreciate the comment … we’ll pass it along to Adam!
25:37
"not blood"
"I think..."
love it!
Adam running that stone over the mill triggered all my ASMR…. Lit up like a Christmas tree…
"its almost like you could name it." i love this man.
A tip for you. when putting the tailstock center into the part, make it a point to have your handwheel handle over the back of the center. That way gravity will keep it snug, and it won't loosen up.
Now I want to build one I really can't wait to see it finished
Paused the video and pulled out my own copy of Machinery's Handbook that I have never had reason to use before to figure out the measurements before Adam gave the answer. Took a while, but I got the correct diameter and learned a lot about gears along the way. D=(N+2)/P where N = number of teeth and P = Diametrical pitch. D=(10+2)/12=1
To find the outside diameter of any standard non modified pitch diameter spur gear all you do is add 2 to the number of teeth in the gear and divide by the diametral pitch. This works for metric and circular pitch gears as well when you convert those pitches to diametral pitch. The result with be in inches.
Nice looking job! Looking forward to seeing the complete result. Small Tip! Instead of cutting oil (or nothing at all), you can use petroleum. It gives Bronze, Brass and Aluminium a smoother surface and saves the cutting edge of your tools.
It's also a huge potential fire hazard ;)
@mike dierickx Nope. Been using that for many years when I was still working in the machineshops. We have never witnessed any fires using that and didn't take special precautions.
Hey Adam, great job making your first gears! I don't have a metal lathe or milling machine but I make wooden gears with my table saw. I use AGMA formulas and get a true involute tooth profile that runs very smooth. I have also made helical and elliptical gears too. Cheers!
No less than 13 years ago even, great work! love those wooden blinds with wooden gears.
@@zarster Thank you!
All I want for Christmas is to see every single last detail, mistake, correction, paint, and test drive of this project!
Your homily about the learning process on your Volvo resonated with me. My auto mechanic 'tutor' was an ancient Bedford van that had a three speed, column change gearbox and sliding doors. I swapped out engine block, cylinder head, crankshaft, clutch, gearbox and brake system complete, mostly from parts salvaged from the scrap yard. Happy days well before all the black box technology of modern vehicles.
Thanks for an interesting video.
Props to the editor for the "To the lathe, Boy Wonder" transition!
An absolute JOY to watch! I don't know anything about machining and very little about gears. Thanks you so very much for showing every step along the way.
Truly a man of many talents! I grew up with Mythbusters and now nearly 20 years on, you still amaze me Adam.
Adam, I try not to ask much of the channels I watch, but please don't let this be the last we see of this project. I wanna see the build and see this car go 200+ yards.
Adam being a lathe with chatter for 5 seconds: 26:30
Never change, Adam xD
Good luck with the project!
@24:53 The "chatter" you are hearing is caused by a combination of factors, including the lack of lubrication, the high cutting speed (measured in in SFM, surface feet per minute), and the lack of rigidity caused by the excessive tool "stick out".
You positioned the cutter right at the far end of the arbour, thereby maximising is distance from the spindle. As each tooth cuts, the rection force tries to flex the arbour and that sets up an oscillation which you can hear. You can then also see the wavy "chatter" marks on the finished gear.
Hope that helps, and you can get smooth chatter-free cutting in future.
Hey Adam and the Tested crew...
I don't know what is going on with youtube lately but none of your new vids have been recommended to me for months now. I am an avid watcher and see Adam and his "doings" as something of a mythical being that I inspire to be one day haha....
But it is upsetting knowing that youtube is not showing your videos to someone who would literally listen to your "theories on washing the dishes" (if that ever comes out haha.)
Anyway, at least I have a 3 or 4 month backlog to binge on.... I just thought you should all know that your hard work and content is not being spread to the people who love you all and you should maybe as RUclips why this travesty is happening.
Thanks again for all of your great work. You are a huge inspiration.
Love the "not blood" Easter egg! It could very well be fake blood, though, from the knife episode.
It's funny. I was just talking to a coworker yesterday about my love of gears and bearings, and how beautiful, crisp, and precise they are when they are new. Marveling at how they do it, then Adam put out this video today. I love it!
Gotta say, I love watching as little of the videos cut out as possible because its so much fun just to see you acting like yourself while you do the projects that interest you!! I'll always watch as long as you're making the videos!!
Hi Adam, I used to build a gearbox for a jigsaw myself as well. With a dividing head on the milling machine. I did the calculation for that too. In Germany we have a table book with all the formulas for calculation. A little tip. Harden the surface of the teeth, then they live longer.
Random comment, but I really want to compliment the sound editing/design on these. Particularly when you're going in and out of fast motion, making sure you've got smooth audio that makes sense throughout suddenly strikes me as a problem that's not as easy to solve as you make it look.
It would be amazing if you and Clickspring did a project together.
Thank You !!
Manufacturing gears is something I've always wanted to be good at, and am still learning/experimenting. Using an actual gear cutter/hob is still on my bucket list, so it's nice to see my favorite engineer actually post a video about it. Awesome!!
9:35 Gandalf: I have no memory of this place.
A friend of mine is a CNC specialist and has other things under his belt, I’ve seen him make all types of things from scratch and also drawn up on a CAD program, he’s made personalized items for his vehicle’s and home and now works with a company who makes giant gears for paper mills, like 50ft in diameter or bigger and it’s just crazy on how they make that shit and it’s also balanced perfectly after it’s been machined.
Little double stick tape and you can put that up on the fridge. Looks great for first shot! In 40 years in the toy biz I never used any thing but 20 deg pressure angle and I am glad I never found out why. Good luck with the rest of the build, although I don't think you will need it. Can't wait.
I just want to thank Josh Self for the Batman lathe transition. It was 🤌
I am watching it on a Wednesday. Thats a good looking gear.
Amazing video, Adam! Thanks!
Adam, I hope you see this. I wanted to say that I grew up on a steady diet of Mythbusters and I always anticipated new episodes and enjoyed reruns of it as you, Jamie, Tori, Kari, Grant (R.I.P), et al were doing such a great job of entertaining, educating, and fact checking. It warms my heart to see you're still creating content that enriches those who take the time to consume it and I look forward to seeing many more projects. (That Samaritan is SICK!) I hope you, the Missus, as well as Thing One and Thing Two have a wonderful holiday season and I wish you all the best. Thank you so much for so many years of smiles and insight and I look forward to many more! May you and yours be blessed in all you do!
Gears are a bunch of radial levers doing their work on each other. What a great way to break down something wildly complex to its basic parts. Sometimes I feel like Adam is the teacher I wished I had in school.
You can also think of them as simply 2 cylinders rolling against each other. The contact point is the pitch circle, while the teeth merely prevent slipping on the theoretical cylinder.
This video was like a trip to the memory lane, when i first made a gear in my university workshop as a 2nd year mechE grad.
Just finished re-watching This Old Tonys' video on gears!
I find videos about gear cutting to be very engaging, but that's just my 'pinion.
There's something supremely satisfying about precision machined parts like that - they're like little works of art :)
"RPR Discount Volvo Parts, across from Hotsy Totsy on San Pablo" I didn't know I needed this sentence in my life until it was said. Even stripped from any context, it's just a wonderful sentence to be verbalized.
Weird, I was just watching a video the other day of someone 3D printing gears for a project like they were candy. No explanation, just Ta-da !!! I just focused on the gears and thought "yeah but HOW do you make the gears?". And here you are my knight in dented, weathered, battle damaged armor !
Oh my got found you again loved watching you years ago you are amazing and I’m not clever as you far from it but I love the way you give me a chance to understand and so enjoyable love yr cave I wish you so much success and love you Adam love little Fran 🇬🇧 xxx happy 2023 xx
I love watching Adam, I really do, his makers enthusiasm is highly infectious. I watch nearly every episode, but, I live to get those brief glimpses we occasionally get of the Samaritan. There is something about that object that is both mesmerising and magical and I find it difficult to explain and understand why.
I found it amusing when he started talking about pitch and pressure angles and had that split second facial expression where he realized he just went down a rabbit hole he now has to explain in more detail.
I would like to see James May in the workshop. The two of them could talk tools and gadgets until the cows come home. Would be a blast.