welp, as the title suggests, anyone here have experience with cutting helical gears?

I was thinking about trying to experiment with some old d-series parts.

the mainshaft has an integrated 1st gear. I was thinking about TIG welding some high strength metal to it, then using a lathe to smooth it out and make it like a blank, then send it somewhere to get the helical teeth cut.

I realize that gear designing isn't an easy task, but I've been reading up on it and think that this would be a fun project.

The goal here is to get a 2.75 1st gear for d-series. I realize that there may be alternate routes (different transmission) But it is something that I think I would enjoy doing/learning

 

more then likley the gears in a honda tranny are hardend tool steel or something close to that nature. This makes it almost impossible to machine. So i don't think its possible.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by silentdaredevil2 &raquo;</TD></TR><TR><TD CLASS="quote">more then likley the gears in a honda tranny are hardend tool steel or something close to that nature. This makes it almost impossible to machine. So i don't think its possible. </TD></TR></TABLE>

Tool steel can be machined it just has to be cut sloooowly and the endmill will wear out quickly.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by silentdaredevil2 &raquo;</TD></TR><TR><TD CLASS="quote">more then likley the gears in a honda tranny are hardend tool steel or something close to that nature. This makes it almost impossible to machine. So i don't think its possible. </TD></TR></TABLE>

how did they machine it then?

 

Welding on material would be a bad idea for many reasons.

You would have better luck going straight to a gear cutting company and letting them decide what type of material to make the gear out of. There are alot of variable in gear cutting that pretty much makes it financially undo able for an individual to do.

Good luck none the less.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by rkeith &raquo;</TD></TR><TR><TD CLASS="quote">

Tool steel can be machined it just has to be cut sloooowly and the endmill will wear out quickly. </TD></TR></TABLE>

yeah it can be machined before the hardening with a carbide cutter (not sure how you gonna cut a a gear with an endmill) <TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by Bense &raquo;</TD></TR><TR><TD CLASS="quote">

how did they machine it then?</TD></TR></TABLE>

they do it before they harden it.

 

gear cutting is somewhat of an art..

many small production gears are rough cut on a lathe, and then reground on a gear grinder.

the most common (and typically, acurate) form of gear cutting uses a gear hob, where the rotation of the workpiece is mated to the rotation of a toothed cutter, transfering the profile of the cutter onto the workpiece.

obviously, as stated earlier, the hardness of a gear is only a factor after its been shaped, and hardened.

at any rate, a gear is a hardened piece. I'm not much of a metalurgist (nor have I ever cut a gear in my life,) but I can see difficulty with hardness (or rather, equal hardness) after welding on the gear itself.

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http://www.amazon.com/Machiner...books

http://www.amazon.com/gp/produ...=UTF8




Modified by rlockwood at 9:59 PM 9/30/2006

 

if you look on the far left in this pic, you can see the first gear. the straight cut gear is the reverse gear, 1st gear is the one all the way to the left.

The problem here is that I already have a close ratio gearbox from 2/3/4/5 but first is too short and the gap from 1st to 2nd is huge

I have emailed ATS, MFactory, Gear-speed, Jamie at housemann, and still waiting to hear back from liberty gears. I can't find anyone that can make me a custom mainshaft.

I've been reading up on calculating spur and helical gears, but my math skills are holding me back from comprehension Guess I better learn how to do this myself

 

if you have a good cad system, specifically one with gear/screw creation, it can be a large help when visualizing the formulas.

at any rate, both of the books I linked to are GREAT resources, whether you continue on this specific path or not. They're pricy on amazon, and could likely be had on ebay for much cheaper (I dont think much has changed in machinerys handbook in ages, either.. a 1st edition would probably be perfect assuming the pages are all intact.)

I wouldnt think any of those places would have trouble with making the gear, they more likely see your emails as a guy with a pipe-dream. Look in your local yellow-pages, often, the local guy is the easiest to work with. As I said, we dont do any gear work in our shop and likely never will. We've contracted to our local gear shop (http://www.geartechindustrial.com/) one time that I can think of, and would reccomend them. I dont believe you're remotely local, so its probably not useful. Good guys though, and could likely offer you some insight. These guys know gears.

It sounds like you're after a close ratio 6 speed, without first?

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by rlockwood &raquo;</TD></TR><TR><TD CLASS="quote">It sounds like you're after a close ratio 6 speed, without first?</TD></TR></TABLE>

That is basically exactly what I am going for. ideal is jdm k20a transmission with like a 5.0xx final drive. but in doing this, 1st gear becomes basically worthless.


ideal would be
1st = 2.75
2nd = 1.944 (jdm dohc zc)
3rd = 1.565 (mfactory)
4th = 1.259 (crx si 3rd as 4th)
5th = 1.000 (mfactory)
final = 2.95, 3.25, 3.7222, 3.888, 4.058, 4.25, 4.437 (all these finals being oem readily available d-series finals) also a few more aftermarket ones.

I'll be sure to check out those books, thanks for your insight

 

kinda digging this one up, but its atleast moderately pertinent.

<U>http://video.google.com/videoplay?docid=-952907967082928959&q=tsugami</U>

 

http://www.inscocorp.com/

These guys do a lot of GM's gears and Bakers bike tranny gears.

 

great links. thanks guys

 

rob moore 619 296 9180 he can help

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by Fabman &raquo;</TD></TR><TR><TD CLASS="quote">rob moore 619 296 9180 he can help</TD></TR></TABLE>

but is this something that's going to run like $5000 ? if that's the case then it's just not worth it.

Bone says that jamie @ houseman can do it, but he states that if I have to ask how much, I can't afford it. *sigh

 

I think emachineshop can cut gears.

 

if you successfully get this made, i am extremely interested in buying this.