Re: [CAD_CAM_EDM_DRO] Buying or CNCing some odd angle bevel gears. I'm stuck !!

Some excerpts taken directly from Machinery's Handbook:

"A correctly formed bevel gear tooth has the same sectional shape throughout
its length, but on a uniformly diminishing scale from the large end to the
small end. The only way to obtain this correct form is by using a
generating type of bevel gear cutting machine."

"Bevel gears to large to be cut by generating equipment may be produced by a
form-copying type of gear planer. With this method, a template or form is
used to mechanically guide a single cutting tool in its proper path to cut
the profile of the teeth. Since the tooth profile produced by this method
is dependent on the contour of the template used, it is possible to produce
tooth profiles to suit a variety of requirements."

"....there are still some cases where straight bevel gears are produced by
milling. Milled gears cannot be produced with the accuracy of generated
gears and are generally not suitable for use in high-speed applications
where angular motion must be transmitted with a high degree of accuracy."

So...bearing in mind your application....do you need accurately generated
gears or would milled gears suffice? If you can use milled gears, you
could make your own...but it's NOT an easy task..especially since you'd be
working with both compound angle setups and would require numerous radial
moves. All the info you need relative to angles and gear construction are
in the handbook should you desire to undertake the task.

IMO it would be a lot cheaper in the long run to have a set of custom gears
made for your application...if you can't find 'off the shelf' gears.
Besides...maybe you could sell them to other model builders in the future.

Smoke