CNC Router Help

[Doug19]

I've been searching around the Pittsburgh, PA are for someone who would be willing to cut a few pieces out of 1/4" plywood for me. I can't seem to get anyone to return my calls or emails for a quote. I'm looking to have the below gears cut out of 1/4" plywood so I can use them as a template. Anyone have any suggestions. I draw it up in SketchUp and have been sending the .DWG and .DXF over to the companies I have contacted. Is there such a demand for this that these people don't feel the need to return calls or answer emails or am I asking for something to complicated. Seems pretty simple to me.

 

[AndeiH]

its probably not worth it for a company, not enough profit in a couple of pieces.

maybe contact your local makerspace and see if they can help.

your local one is http://www.hackpittsburgh.org/

 

[Jim Johnstone]

Two issues I see, first off a small order like that may not be very desirable to a busy shop with bigger jobs on the go. Secondly, gears aren't cut on a 3 axis vertical cnc. They are usually hobbed on a gear hobbing machine or cut in one by one on a conventional mill using a rotary index. Is there a reason this must be plywood? If it's just for a template perhaps a plastic like nylon or acetal would do, or aluminum. You may have better luck contacting a dedicated gear cutter and having them quote it. In my experience, very few machine shops cut their own gears anymore.

 

[ilovevocs]

A 3D print may be a better avenue of your looking to outsource.


Sent from my iPhone using Tapatalk

 

[Doug19]

I don't really need the accuracy as they won't be used as actual gears. I wanna use the template with a flush trim bit to make the below.

https://aldeahome.com/home-accessories/mirrors/cog-mirror-iii.html

 

[Jim Johnstone]

I see. Have you tried going into any machine shops in person and explaining what you want? Like I said a lot of machine shops shy away from anything resembling a gear. Some also refuse to cut wood.

 

[ilovevocs]

I don't really need the accuracy as they won't be used as actual gears. I wanna use the template with a flush trim bit to make the below.

https://aldeahome.com/home-accessories/mirrors/cog-mirror-iii.html

Way the wood grain appears to me the gear teeth were constructed then adhered to round center section. Seems like it would be the simplest approach.

 

[G1K]

I know that the link points to a decorative mirror and it's "art"- but the cogs won't move in that orientation. As an engineer I find that humorous.

 

[Doug19]

Problem is I could use a bandsaw but I don't have a big enough on and it would take forever. I would prefer rough cutting on the bandsaw and tablesaw and then usemail the template to cleanup with a flush trim router bit.

 

[jczv]

Post on the mechmate forum it's basically a build yourself CNC primarily for wood. There may be sombody local or somebody who'd do it and send. There's both hobbiests and businesses.

 

[Zeke]

There is no reason you can't make the finish parts with a drill press with a hole saw and a jig, band or scroll saw. And you can sand the perimeter inside and around the teeth with a mounted drum sander.

You might be over thinking this. I know making a template and using a router with a guide bearing sounds like the way to go but for one-offs, I'd just get going on this w/o some fancy CNC template.

I can also think of a way to use a single tooth template and the router on a trammel.

 

[paranoid56]

am i looking at the pic right? largest part is 1ft? i can do that for you on my CNC if you want. figure 25 bucks shipped via usps priority mail. as long as it fits on a flat rate box.

 

[Doug19]

am i looking at the pic right? largest part is 1ft? i can do that for you on my CNC if you want. figure 25 bucks shipped via usps priority mail. as long as it fits on a flat rate box.

The largest one has a diameter of 1'10". I can email you the .dwg file and if you are willing to take a look at it I'd would really appreciate it.

 

[paranoid56]

yea shoot me the file at [email protected] and i can check tonight.

 

[Doug19]

Paranoid I sent the files over let me know if you don't see them.

 

[bullnerd]

Looks like a fun project, good luck Doug.

 

[paranoid56]

Paranoid I sent the files over let me know if you don't see them.

hmm didnt get it. try again with no attachment and i can reply.

 

[wkearney99]

Way the wood grain appears to me the gear teeth were constructed then adhered to round center section. Seems like it would be the simplest approach.

That would seem like a faster/easier way to make it. Bevel a long strip with the profile of the teeth and then cut it up. Use a dowel/domino in each into the 'wheel'.

How many of these are you planning on making? Seems like a jig would be overkill unless you plan on making a bunch of them.

That and what about only making a sectional jig? Use a board with registration pins of some sort. Only cut a few teeth, reposition, cut more, repeat until done. Seems like a smaller jig like that would be a lot easier to make with a jig/bandsaw. Tiled pages printed from a 8.5x11 printer would work to make the pattern. What Zeke said:

I can also think of a way to use a single tooth template and the router on a trammel.

 

[paranoid56]

going to take me a bit as there is a whole bunch of extra **** in this file lol.

 

[paranoid56]

lol, ok, so this file has like 100000 extra lines in it and is crashing my weak laptop lol. (only a I5 w/ 16gig ram)

do you think you can try saving this as a dxf? or maybe try downloading the free program emachineshop.com and redrawing it.
and use this http://www.emachineshop.com/machine-shop/Free-Gear-Design-Software/page506.html
should make it stupid easy

 

[bullnerd]

Have him draw one tooth of each gear(if they are different), and you sweep/copy/rotate it with your software?

 

[gazza]

Hi guys, i cant help with cutting this file for you, only because I'm on the other side of the world but I may be able to help with converting the file.
On my sign program I can export in 3 formats of dxf files and lots of other formats, the laser cutters I use can only open one format of dxf which from memory is "lines and poly arcs".
I you get stuck let me know and I'm happy to try and reformat the file to open it easily.
cheers

 

[manwithtools]

Are you thinking you will use a router and a flush trim bit to follow the template? A router and pattern/ flush bit can't make those teeth profiles, the inside corners are square.

Did you notice the unit you reference is 4" deep - do you need that depth on the finished product? If more than a inch of depth is desired, the only way I can envision making it is by gluing the teeth to the cylinder of wood.

If you look at the picture you posted the teeth are glued on individually for the reason I state above. Making a gear that large of glued up solid stock is not trivial.

If you "have" to have a template, I'd find someone with a laser engraver / cutter and have them cut it out of polycarbonate or hardboard. 1/4" plywood is a poor choice for this application.

 

[speed bump]

I would probably find someone to cut it with a laser in 1/4" plywood.

Otherwise you could a build jig to cut it easily: a circle routing jig and a circle with pinning holes. The gears won't look real but I don't think that matters for your application.

 

[Ralphxj]

I can cut them out of metal for you.

 

[Gamble]

I can cnc plasma them for you too
I can try to cut them on my cnc router but I'm still a novice with it

 

[RPH]

Look at this guys site. He make wood gears. Sell the program dirt cheap. Band saw is what he recommends. Guy here used it here to make rack and pinion gears for his trailer. I got it but have not had the chance to use it.
https://woodgears.ca/gear/