Straight bevel gear cutting.

Straight bevel gear cutting.


I'm guessing the lubricating oil is filtered and recirculated? Never been involved in operating one of these...


Definitely is recycled, usually well beyond the time when it should be replaced. Smells awful


Then you tell the new guy he has to clean the tank And get rid of that atomic Sludge that came out of the hulk's ass after a taco Tuesday.


My work picked up a horizontal band saw with this type of coolant. Between that and the way too much metal in it I had to completely empty and clean everything over a few hours. The new stuff looks much better and actually works. It should probably go on my list to clean tomorrow while it's still easy. I'm not even the new guy, that's just my job unfortunately.




Here's a sneak peek of /r/BrandNewSentence using the [top posts](https://np.reddit.com/r/BrandNewSentence/top/?sort=top&t=year) of the year! \#1: [Road rage about to be like a COD lobby](https://i.redd.it/5d1o4htymd261.jpg) | [733 comments](https://np.reddit.com/r/BrandNewSentence/comments/k3vh5b/road_rage_about_to_be_like_a_cod_lobby/) \#2: [**[NSFW]** The… what?](https://i.redd.it/rjmtd6bg2pn71.jpg) | [827 comments](https://np.reddit.com/r/BrandNewSentence/comments/potn2w/the_what/) \#3: [Illegal underground grandma karaoke bars](https://i.redd.it/wtpgvsrn5p261.jpg) | [878 comments](https://np.reddit.com/r/BrandNewSentence/comments/k51ok6/illegal_underground_grandma_karaoke_bars/) ---- ^^I'm ^^a ^^bot, ^^beep ^^boop ^^| ^^Downvote ^^to ^^remove ^^| [^^Contact ^^me](https://www.reddit.com/message/compose/?to=sneakpeekbot) ^^| [^^Info](https://np.reddit.com/r/sneakpeekbot/) ^^| [^^Opt-out](https://np.reddit.com/r/sneakpeekbot/comments/o8wk1r/blacklist_ix/)


"Filtered" generally with a mesh screen.


seems like an extremely high flow rate for that


It’s sifted rather than filtered.


Filtered by Brita


It always amazes me that there are people out there who have programmed and made these machines (that do the cutting)


This is one of the simpler ones, just indexing and linear movements.


Agree. The spring making machine last week.. that was something.


Got a link?


I think its this one https://www.reddit.com/r/EngineeringPorn/comments/ptx06v/spring_making_machine/


Awww, deleted!


I got you. https://m.imgur.com/tIai0do


Damn.... 👏 and thanks man!


Don’t you think that is just way to much mechanics to make that spring?


To make a single spring, sure. To make tens of thousands? Not so much.


NICE! There was one making fatter springs I can't find. Meh could be one of my other 200 subs.


I’ll take a few of some more spring machines like that this week!


What's the cut during this process?


Programming is easy. Just give it coordinates or a parametric equation of motion. Coming up with a manual way to do these things is the hard thing.


The old machines that were "programmed" with cogs and oddly shaped cams. That is something special.


simple G-Code tbf.


Bro this is easy mode. You know that programming has been around for over 65 years now.


That is what I call well oiled machine.


After watching high speed manufacturing machines I'm always surprised that machines that take this long are economically viable.


The machine is paid for. It runs by itself once set-up. The big cost of a job shop aside from overhead is labor. Someone gets this running and does something else. It doesn't matter how long the run takes until you have make more parts a month than this machine can make running 24-6 as long as the time spent to swap parts is short.


Out of curiosity, can machines like detect faults? Like if the part or the cutting edge cracked or something?


If it were important for it to do so, it could be done. But it comes down to a more fundamental issue. If the parts break often, the system should be designed differently. Something is being done wrong in that case. If they don't break often, then why bother adding complexity for a problem that happens very infrequently?


Well, it depends on what's the severity of fault. If it could destroy the machine or send flying shrapnels everywhere then you may want to add that extra complexity.


Sometimes machines will have force feedback that can be used to detect when the tool breaks. But the better method for volume production is to determine the tool life empirically when cutting that part, and have regular (preferrably automated) tool changes before breakage becomes a problem. Generally you want to change the tool long before it breaks, because wear & tear on the tool lead to changes in the dimensions and surface finish on the part.


The main method is by inspection. There is usually some kind of gauge at the machine that measures a crucial tolerance. Adjustments are made between each part to compensate for the bits wearing down. Then after so many parts we swap the cutters. After so many more the cutting fluid filter needs changed. On and on.


Generally, the machine doing the cutting would not also do part quality checks but would instead pass through a secondary inspection system to check quality


No, preventative maintenance finds issues. The cutting tool will be changed out so tool breaks arent common. That would scrap the part and tools are cheap consumables (cheap as a relative term). Good manufacturing principles means you’re not taking this machine close to that edge, because downtime costs companies thousands per day.


It's mostly for be just that I expect everything to be needed in bulk and there is a big gulf between the need for these and for soda cans. But it still comes across as odd to see machines operating in a blur and one at a sedate pace. I understand obviously that a soda can is much easier to machine and can therefore be done faster but the feeling stands.


There is a Ball can line in Golden, Colorado that makes 6 million cans a day. I don't work wherever this gear is made but an educated guess is they make less than 100 of these gears per year. Not even the same sport.


You'd be surprised how much people will be willing to pay for gears like that. Also, "high speed" production has very different needs than "high mix" production. In high mix, you're making lots of 1-off custom parts, and most of the production time is design, quoting, purchasing, tool path generation, measurement... In that case, the machine running fast isn't as important, as it's a small percentage of the total price of the item.


Not like you're going to cast gears like that. No other way to make them. Maybe additive, but we'll see, and would still need machining to tolerance.


Does this still qualify as a shaper?


Ah yes, teenage years. My father decided that around 15-16 I was old enough to start working with those gear hobbing machines. We had one for smaller cogs with a small tool that went up and down to shape the gear similar to this. But there was also a larger one for bigger gears that scared me. First I had to "program" the thing by screwing some 4-5 cogs in place, there was a small book with instructions to find out the proper way to "program" the thing with exact cogs to use, also a cabinet full of those cogs, those controlled the speed of rotation of the gear to be cut, the speed of the tool, the speed of advancement. The whole thing was clockwork. It couldn't miss a beat at all, or thousand dollars of tools & material would be good to dump if anything went out of sync. I quickly found out that bolts had to be really, really tight to ensure this. Also sometimes you had to dip your arm up to the elbow in brown cutting oil to declog the oil pump from years of iron and wood shavings. I sometimes wish I could be just a stupid teenager.


I don't understand what's happening here


The moving blades are slowly skimming material off of the gear surface.


I don't even see them touching it must be some kind of optical fuckery


I really hope they recycle all that yummy maple syrup.


Just remember to use a spoon to skim the metal shavings off. Don't want those on your pancakes


But it’s good to get extra iron in your diet!


"Your mission, should you choose to accept it, is to film the subject without showing any of the useful parts of the operation. Like, let people think they're watching something cool but you carefully pick angles and distances that mask the actual cool parts of the bevel gear cutting." Person filming this: "Oh yeah I got you fam."


I can smell the dark cutting oil from here. Lard base with sulfur additive. I was threading pipe and was done with the work. So as a joke, I reached into the oiler bucket and dabbed some cutting oil on my neck, like cologne and went to hug my wife. 😆


Cool to watch.


If this is designed using a solid modeling software, can't it generate the tool paths?


If it were a CNC machine then yes, tool pahs would be generated. This appears to be an entirely mechanical operation


Got it. I haven't been in that part of the software world for a long time.


This implies the existence of a gay bevel gear cutting.


I came to ask if anyone knows the lubricant is recycled, and a few other comments here have been wondering the same thing, haha. So… anyone know?


Yes. It's collected and filtered to remove metal swarf then pumped back around to be used again.


When you want to do the Ketchup song, but you only have lubricant oil


How come they're doing shaping instead of hobbing? Seems like it'd be a lot faster.


Nom nom nom


Wow, so if the timing of the rotation is off.... profile is destroyed??


Seems like an egregious amount of oil


Matches. https://music.youtube.com/watch?v=1o0CtxZ_Cbo&feature=share


This needs sound. Love the sound of these type of metal cutting machines. So satisfying


Forbidden gravy


Forbidden soy sauce


Is that like some pre-hardened gear or something? That is the slowest gear machining I have ever seen.


Why so much oil? What’s it actually do here? I apologize for my engineering ignorance.


Annnnnd that's where babies come from






I have stabilized the video for you: https://gfycat.com/QualifiedBackGazelle It took 77 seconds to process and 49 seconds to upload. ___ ^^[ how to use](https://www.reddit.com/r/stabbot/comments/72irce/how_to_use_stabbot/) | [programmer](https://www.reddit.com/message/compose/?to=wotanii) | [source code](https://gitlab.com/juergens/stabbot) | /r/ImageStabilization/ | for cropped results, use \/u/stabbot_crop


Must be a chinese factory since the piece is cooled with soy sauce?


Having done this exact job I can say that it seriously sucks in my often inaccurate opinion. That lubricant/coolant you see permeates your skin and caused deep blisters and skin peeling for me. Also these machines are really annoying to calibrate and set up for a production run. Many of them are quite old and worn out meaning that even if you set them up as tightly as you can, they will begin to drift and get out of spec, leading to, yep, you guessed it, readjusting it again. *sigh* Ok, rant over.


Oh hell yeah those lubes smell awful. So many questions: are the smells just nasty or are there serious VOC hazards? What IS that smell? Are there viable alternatives?




Sorry, your submission has been automatically removed. Not enough karma, spam likely. *I am a bot, and this action was performed automatically. Please [contact the moderators of this subreddit](/message/compose/?to=/r/EngineeringPorn) if you have any questions or concerns.*


Anyone else notice the rhythm of the machine matches the Haddaway song “What is Love”?


Why the soy sauce?