Bevel Gearology

Tiger,

The tooth profile is like a pizza, as shown in this giant gear they are making.

http://www.youtube.com/watch?v=Adi0GgUc2Z4

But then I thought about it, if a rotary end mill was 1/2 the diameter as the width of the gear tooth valley (which you would want since slot milling is never good anyway), you should end up with a pizza slice as the indexing turns the gear slightly with each pass of the cutter to approach the proper width of cut per tooth. At least that is the theory.

But then this would end up with the valley being straight and the ridge being a pizza? And it does not seem like they would mesh...

http://www.youtube.com/watch?v=a6wRQ2rYuWg

This stuff already makes no sense 

At this point I am looking at using the 24 pitch 30 tooth bevel gear for the prototype transmission:

http://www.mcmaster.com/#7297K16

This is very close to a metric MOD 1 pitch which is used in the upgraded main gear for the Trex 600/700 helis.

MOD 1 would be a 25.4 pitch gear which makes the 24 pitch have a slightly thicker (stronger) tooth profile at it's base.

That would be the strongest gear you can get before going to a 5/16" bore/shaft (too heavy)

What are we making out of these gears?

Ha, didn't know anyone was listening, it's still a long way off but working on another multirotor design.

You said gears and transmission so my attention has been gained ;D. I love gears and how things work. I just got done making my own tranny for a scaler from various gears and widgets

I watched that second video and I sure don't see how what he made could mesh right.  I think for $3 the McMaster solution is really good for now. 

It was really interesting how the cutters moved on the machine in that first video.

...Tiger
 

I think the 120 degree offset transmission case with a conversion from metric to SAE and then back to metric again that has never been produced before might be propietary enough for the time being  ;D

And it looks like I will be machining my own HTD belt drive pulley due to the need to integrate it with a Trex 600 one way bearing. But this should be easy because I can download a .DXF for a 2 1/2D pulley design.....