Homemade Gear Cutting Indexer Blends Art With Engineering

Ordinarily, when we need gears, we pop open a McMaster catalog or head to the KHK website. Some of the more adventurous may even laser cut or 3D print them. But what about machining them yourself?

[Uri Tuchman] set out to do just that. Of course, cutting your own gears isn’t any fun if you didn’t also build the machine that does the cutting, right? And let’s be honest, what’s the point of making the machine in the first place if it doesn’t double as a work of art?

[Uri’s] machine, made from brass and wood, is simple in its premise. It is placed adjacent to a gear cutter, a spinning tool that cuts the correct involute profile that constitutes a gear tooth. The gear-to-be is mounted in the center, atop a hole-filled plate called the dividing plate. The dividing plate can be rotated about its center and translated along linear stages, and a pin drops into each hole on the plate as it moves to index the location of each gear tooth and lock the machine for cutting.

The most impressive part [Uri’s] machine is that it was made almost entirely with hand tools. The most advanced piece of equipment he used in the build is a lathe, and even for those operations he hand-held the cutting tool. The result is an elegant mechanism as beautiful as it is functional — one that would look at home on a workbench in the late 19th century.

[Thanks BaldPower]

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Hackaday Links: May 17, 2020

Consider it the “Scarlet Letter” of our time. An MIT lab is developing a face mask that lights up to alert others when the wearer has COVID-19. The detection technology is based on sensors that were developed for the Ebola virus scare and uses fluorescently tagged DNA fragments freeze-dried onto absorbent strips built into the mask. The chemistry is activated by the moisture in the sputum expelled when the wearer coughs or sneezes while wearing the mask; any SARS-CoV-2 virus particles in the sputum bind to the strips, when then light up under UV. The list of problems a scheme like this entails is long and varied, not least of which is what would possess someone to willingly don one of these things. Still, it’s an interesting technology.

Speaking of intrusive expansions of the surveillance state, Singapore is apparently now using a Boston Dynamics Spot robot to enforce social-distancing rules in its public parks and gardens. The familiar four-legged, bright yellow dog-bot is carrying cameras that are relaying images of park attendees to some sort of image analysis program and are totally not capturing facial or personal data, pinky swear. If people are found to be violating the two-meter rule, Spot will bark out a prerecorded reminder to spread out a bit. How the system differentiates between people who live together who are out getting some fresh air and strangers who should be staying apart, and whether the operators of this have ever seen how this story turns out are open questions.

Those who lived through 9/11 in the United States no doubt remember the deafening silence that descended over the country for three days while every plane in the civil aviation fleet was grounded. One had no idea how much planes contributed to the noise floor of life until they were silenced. So too with the lockdown implemented worldwide to deal with the COVID-19 pandemic, except with the sometimes dramatic reduction in pollution levels. We’ve all seen pictures where people suddenly realize that Los Angeles isn’t necessarily covered by an orange cloud of smog, and that certain mountain ranges are actually visible if you care to look. But getting some hard data is always useful, and these charts show just how much the pollution situation improved in a number of countries throughout the world after their respective lockdowns. For some cities, the official lockdown was a clear demarcation between the old pollution regime and the new, but for some, there was an obvious period before the lockdown was announced where people were obviously curtailing their activity. It’s always interesting pore over data like this and speculated what it all means.

While the in-person aspects of almost every conference under the sun have been canceled, many of them have switched to a virtual meeting that can at least partially make up for the full experience. And coming up next weekend is Virtually Maker Faire, in the slot where Bay Area Maker Faire would normally be offered. The call for makers ends today, so get your proposals in and sign up to attend.

And finally, there aren’t too many times in life you’ll get a chance to get to visualize a number so large that an Evil Empire was named for it. The googol, or 10100, was a term coined by the nine-year-old nephew of mathematician Edward Kasner when he asked the child for a good name for a really big number. To put the immensity of that number into perspective, The Brick Experiment Channel on YouTube put together an improbably long gear train using Lego pieces we’ve never seen before with a reduction ratio of 10103.4:1. The gear train has a ton of different power transmission elements in it, from plain spur gears to worm drives and even planetary gears. We found the 2608.5:1 harmonic gear particularly fascinating. There’s enough going on to keep even a serious gearhead entertained, but perhaps not for the 5.2×1091 years it’ll take to revolve the final gear once. Something, something, heat-death of the universe. [Ed note: prior art, which we were oddly enough thinking of fondly just a few days ago. Synchronicity!]

Simple Demo Shows The Potential Of Magnetic Gears

We’ve probably all used gears in our projects at one time or another, and even if we’re not familiar with the engineering details, the principles of transmitting torque through meshed teeth are pretty easy to understand. Magnetic gears, though, are a little less intuitive, which is why we appreciated stumbling upon this magnetic gear drivetrain demonstration project.

[William Fraser]’s demo may be simple, but it’s a great introduction to magnetic gearing. The stator is a block of wood with twelve bolts to act as pole pieces, closely spaced in a circle around a shaft. Both ends of the shaft have rotors, one with eleven pairs of neodymium magnets arranged in a circle with alternating polarity, and a pinion on the other side of the stator with a single pair of magnets. When the pinion is spun, the magnetic flux across the pole pieces forces the rotor to revolve in the opposite direction at a 12:1 ratio.

Watching the video below, it would be easy to assume such an arrangement would only work for low torque applications, but [William] demonstrated that the system could take a significant load before clutching out. That could even be a feature for some applications. We’ve got an “Ask Hackaday” article on magnetic gears if you want to dive a little deeper and see what these interesting mechanisms are good for.

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Can Lego Break Steel?

Betteridge’s Law of Headlines holds that any headline ending in a question mark can be answered with a resounding “No”. But as the video below shows, a Lego machine that twists steel asunder is not only possible, it’s an object lesson in metal fatigue. Touché, [Betteridge].

In pitting plastic against metal, the [Brick Experiment Channel] relied on earlier work with a machine that was able to twist a stock plastic axle from the Technics line of parts like a limp noodle. The steel axle in the current work, an aftermarket part that’s apparently no longer available, would not prove such an easy target.

Even after beefing up the test stand with extra Technics struts placed to be loaded in tension, and with gears doubled up and reinforced with extra pins, the single motor was unable to overcome the strength of the axle. It took a second motor and a complicated gear train to begin to deform the axle, but the steel eventually proved too much for the plastic to withstand. Round Two was a bit of a cheat: the same rig with a fresh axle, but this time the motor rotation was constantly switched. The accumulated metal fatigue started as a small crack which grew until the axle was twisted in two.

The [Brick Experiment Channel] is a fun one to check out, and we’ve featured them before. Along with destructive projects like this one, they’ve also got fun builds like this Lego playing card launcher, a Technic drone, and a Lego submarine.

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Gear Up Your Gear Knowledge With Gears

Gears are fairly straightforward way to couple rotational motion, and the physics topics required to understand them are encountered in an entry level physics classroom, not a university degree. But to really dig down to the root of how gears transfer motion may be somewhat more complex than it seems. [Bartosz Ciechanowski] put together an astonishingly good interactive teaching tool on gears, covering the fundamentals of motion up through multi-stage gear trains.

Illustrating the distance traveled at different points on the disc

The post starts at the beginning – not “how to calculate a gear ratio” – but how does rotational motion work at all. The illustrations help give the reader an intuitive sense for how the rate of rotation is measured and what that measurement actually represents in the real world. From there [Bartosz] builds up to describing how two discs touching edge to edge transfer motion and the relationship of their size on that process. After explaining torque he has the fundamentals in place to describe why gears have teeth, and why they work at all.

Well written explanatory copy aside, the real joy in this post is the interactivity. Each concept is illustrated, and each illustration is interactive. Images are accompanied by a slider which lets you adjust what’s shown, either changing the speed of a rotating gear or advancing the motion of two teeth interlocking. We found that being able to move through time this way really helped form an intuitive understanding of the concepts being discussed. This feels like the dream of interactive multimedia textbooks come to life.

Casting Gears At Home

Automatic doors and gates are great, except when they fail, which seems to be about every three days in our experience. [MAD WHEEL] had just such a failure, with a plastic gear being the culprit. Rather than buy a new drive unit, they set about casting a replacement in metal.

The video is light on instructions and heavy on progressive rock, and may be a little difficult to follow for beginners. The process begins by gluing the original plastic part back together, and filling in the gaps with epoxy putty. A mould is then created by setting the gear in a gelatine/glycerine mixture. This mould is then filled with wax to create a wax copy of the original part. The wax gear is fitted with cylindrical stems to act as runners for molten metal, and then a plaster mould is made around the wax positive. Two plaster moulds are made, which are placed in an oven to melt out the wax.

The aim was to cast a replacement part in aluminium. The first attempt failed, with the aluminium cooling too rapidly. This meant fine details like the gear teeth simply didn’t cast properly, creating a useless metal blob. On the second attempt, the plaster mould was heated first, and this kept things hot enough to allow the aluminium to fill in the finer details. With that done, it was a simple matter of some post-processing to remove the runners, clean up the gear teeth and refine the shape of the gear on the lathe.

The resulting part does its job well, meshing properly with the other gears in the drivetrain and moving the gate effectively. Many in the comments have stated that the original gear being plastic was likely as a safety measure, to strip out in the event the gate is jammed. While this may be true, it’s a far more robust design practice to instead use a breakable plastic key rather than breaking an entire gear in the event of a problem.

Casting is quite accessible to the dedicated home maker. It’s a great way to make custom metal parts once you’ve learned the fundamentals! Video after the break.

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A (Mostly) 3D Printed Servo/Gear Reduction

This servo/gear reduction was assembled with almost all 3D-printed parts. Apart from a brushed 36 V DC-motor, a stainless steel shaft, and screws for holding the servo together, the only other non-printed part is the BTS7960B motor driver.

Some interesting stats about the plastic servo – its stall torque is about 55 kg/cm, reaching a peak current draw of 18 A when using a 6s LiPo battery outputting 22-24 V. The shaft rotates using two 20 mm holes and lubrication. (Ball bearings were originally in the design, but they didn’t arrive on time for the assembly.)

The holes of the gears are 6.2 mm in diameter in order to fit around the shaft, although some care is taken to sand or fill the opening depending on the quality of the 3D print.

This isn’t [Brian Brocken]’s only attempt at 3D-printing gears. He’s also built several crawling robots, a turntable, and a wind up car made entirely from acrylic. The .stl files for the project are all available online for anyone looking to make their own 3D-printed servo gears.

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