gears_nyu.md

Document about gear production at NYU

This document outlines how the gears were manifactured at NYU. The gears were machined using an automatic CNC milling machine.

Tools used:

1. Atrax 1/16", 3/16" LOC, 1/8" Shank Diam, 1-1/2" OAL, 2 Flute, Solid Carbide Square End Mill
2. Accupro 0.07" Diam 4 Flute Single End Solid Carbide 0.015" Corner Radius End Mill
3. Haas Super Mini Mill 2

Production outline

At each step, two gears are produced. The road is first cut and two basic blanks (see AT3_10_Teeth_pulley_lathe_blank.pdf) are created.

The steps are then as follows:

1. The blank is mounted in the cnc machine (IMG_20191217_153512.jpg)
2. For each gear teeth:
3. Using the Atrax tool, the main area of the gear teath is removed (see AT3_10T_pulley_Presentation Model.pdf, middle picture)
4. Afterwards, the Accupro tool is mounted and the part rotated by 25 degrees.
5. The gear teeths are cut as shown in AT3_10T_pulley_Presentation Model.pdf, 25 degree picture
6. Analogous, the tool is rotated back by 50 degree to do the -25 degree cut using tool Accupro as shown in AT3_10T_pulley_Presentation Model.pdf
7. Rotate the part and work on the next gear
8. After each gear teeth is done, rotate the blank and work on the second gear part
9. After both parts on the blank are worked out, cut the blanck to obtain two different parts

Code for CNC machine

The code used to run the cnc machine is provided in O40390.NC.

O40390.NC

%
O40390(AT3 10-TEETH PULLEY-ROTARY TABLE)
(PULLEY FOR ROBOTIC TEAM)
(CREATED 09/26/2019) 
(STARTED )(12/03/19)(11:55AM) 
(FINISHED)(12/04/19)(01:05PM) 
(CYCLE TIME)(20 MIN) 

( X ZERO SET AT THE FIXTURE FACE ) 
(Z=-0.925 AT THE LEFT FACE OF THE PART) 
( Y ZERO SET IN THE C/L OF THE TURNTABLE )
( Z ZERO SET IN THE C/L OF THE TURNTABLE )

( TOOL#02   0.062"  SQUARE E.M.   H02/D02  ) 
( TOOL#03   0.070"x0.015"R  E.M.  H03/D03  ) 
  
N0005
N0010 G17 G40 G49 G53 G69 G80 G90 
N0015 G00 G53 G90 Z0.0 
N0020 G00 G53 G90 X-6.0 Y0.0 
N0025 G90  

GOTO200 

N0200 T02 M06
(TOOL#02   0.0625" ENDMILL)
(ROUGHING 10 SLOTS)
N0205 S4500 M03
N0210 G54
N0215 G00 X-0.900 Y0.0 A0.0
N0220 G43 Z4.0 H02 D02 
N0225 G01 Z0.625 F150.0 
N0230 M08 
N0235 M97 P7100 (1)
N0240 G00 Z0.625
N0245 G00 X-0.900 Y0.0 A36.0
N0250 M97 P7100 (2)
N0255 G00 Z0.625
N0260 G00 X-0.900 Y0.0 A72.0
N0265 M97 P7100 (3)
N0270 G00 Z0.625
N0275 G00 X-0.900 Y0.0 A108.0
N0280 M97 P7100 (4)
N0285 G00 Z0.625
N0290 G00 X-0.900 Y0.0 A144.0
N0295 M97 P7100 (5)
N0300 G00 Z0.625
N0305 G00 X-0.900 Y0.0 A180.0
N0310 M97 P7100 (6)
N0315 G00 Z0.625
N0320 G00 X-0.900 Y0.0 A216.0
N0325 M97 P7100 (7)
N0330 G00 Z0.625
N0335 G00 X-0.900 Y0.0 A252.0
N0340 M97 P7100 (8)
N0345 G00 Z0.625
N0350 G00 X-0.900 Y0.0 A288.0
N0355 M97 P7100 (9)
N0360 G00 Z0.625
N0365 G00 X-0.900 Y0.0 A324.0
N0370 M97 P7100 (10)
N0375 G00 Z4.0
N0380 M09 
N0385 G00 G53 G90 Z0.0 
N0390 M05 
N0395 G00 G53 G90 X-6.0 Y0.0
N0396 G17 G40 G49 G53 G80 G90 
N0397 M01 

N0400 T03 M06
(TOOL#03   0.070"x0.015"RAD ENDMILL)
(SEMI-FINISHING TEETH SIDES)
N0405 S4500 M03
N0410 G54
N0415 G00 X-0.125 Y-0.068 A25.0
N0420 G43 Z4.0 H03 D03 
N0425 G01 Z0.625 F150.0 
N0430 M08 
N0435 M97 P7200 (1)
N0440 G00 Z0.625
N0445 G00 X-0.125 Y-0.068 A61.0
N0450 M97 P7200 (2)
N0455 G00 Z0.625
N0460 G00 X-0.125 Y-0.068 A97.0
N0465 M97 P7200 (3)
N0470 G00 Z0.625
N0475 G00 X-0.125 Y-0.068 A133.0
N0480 M97 P7200 (4)
N0485 G00 Z0.625
N0490 G00 X-0.125 Y-0.068 A169.0
N0495 M97 P7200 (5)
N0500 G00 Z0.625
N0505 G00 X-0.125 Y-0.068 A205.0
N0510 M97 P7200 (6)
N0515 G00 Z0.625
N0520 G00 X-0.125 Y-0.068 A241.0
N0525 M97 P7200 (7)
N0530 G00 Z0.625
N0535 G00 X-0.125 Y-0.068 A277.0
N0540 M97 P7200 (8)
N0545 G00 Z0.625
N0550 G00 X-0.125 Y-0.068 A313.0
N0555 M97 P7200 (9)
N0560 G00 Z0.625
N0565 G00 X-0.125 Y-0.068 A349.0
N0570 M97 P7200 (10)
N0575 G00 Z1.625
N0600 G00 X-0.900 Y+0.068 A-25.0
N0605 G01 Z0.625 F150.0 
N0610 M97 P7300 (1)
N0615 G00 Z0.625
N0620 G00 X-0.900 Y+0.068 A11.0
N0625 M97 P7300 (2)
N0630 G00 Z0.625
N0635 G00 X-0.900 Y+0.068 A47.0
N0640 M97 P7300 (3)
N0645 G00 Z0.625
N0650 G00 X-0.900 Y+0.068 A83.0
N0655 M97 P7300 (4)
N0660 G00 Z0.625
N0665 G00 X-0.900 Y+0.068 A119.0
N0670 M97 P7300 (5)
N0675 G00 Z0.625
N0680 G00 X-0.900 Y+0.068 A155.0
N0685 M97 P7300 (6)
N0690 G00 Z0.625
N0695 G00 X-0.900 Y+0.068 A191.0
N0700 M97 P7300 (7)
N0705 G00 Z0.625
N0710 G00 X-0.900 Y+0.068 A227.0
N0715 M97 P7300 (8)
N0720 G00 Z0.625
N0725 G00 X-0.900 Y+0.068 A263.0
N0730 M97 P7300 (9)
N0735 G00 Z0.625
N0740 G00 X-0.900 Y+0.068 A299.0
N0745 M97 P7300 (10)
N0750 G00 Z4.0
N0755 M09 
N0760 G00 G53 G90 Z0.0 
N0765 M05 
N0770 G00 G53 G90 X-6.0 Y0.0
N0775 G17 G40 G49 G53 G80 G90 
N0780 M01 

N0800 T03 M06
(TOOL#03   0.070"x0.015"RAD ENDMILL)
(FINISHING TEETH APEX)
N0805 S5000 M03
N0810 G54
N0815 G00 X-0.900 Y0.0 A342.0
N0820 G43 Z4.0 H03 D03 
N0825 G01 Z0.625 F150.0 
N0830 M08 
N0835 M97 P7400 (10)
N0840 G00 Z0.625
N0845 G00 X-0.900 Y0.0 A306.0
N0850 M97 P7400 (9)
N0855 G00 Z0.625
N0860 G00 X-0.900 Y0.0 A270.0
N0865 M97 P7400 (8)
N0870 G00 Z0.625
N0875 G00 X-0.900 Y0.0 A234.0
N0880 M97 P7400 (7)
N0885 G00 Z0.625
N0890 G00 X-0.900 Y0.0 A198.0
N0895 M97 P7400 (6)
N0900 G00 Z0.625
N0905 G00 X-0.900 Y0.0 A162.0
N0910 M97 P7400 (5)
N0915 G00 Z0.625
N0920 G00 X-0.900 Y0.0 A126.0
N0925 M97 P7400 (4)
N0930 G00 Z0.625
N0935 G00 X-0.900 Y0.0 A90.0
N0940 M97 P7400 (3)
N0945 G00 Z0.625
N0950 G00 X-0.900 Y0.0 A54.0
N0955 M97 P7400 (2)
N0960 G00 Z0.625
N0965 G00 X-0.900 Y0.0 A18.0
N0970 M97 P7400 (1)
N0975 G00 Z4.0
N0980 M09 
N0985 G00 G53 G90 Z0.0 
N0990 M05 
N0992 G00 G53 G90 X-6.0 Y0.0
N0995 G17 G40 G49 G53 G80 G90 
N0997 M01 

N1000 T03 M06
(TOOL#03   0.070"x0.015"RAD ENDMILL)
(FINISHING TEETH SIDES AND ROOTS)
N1005 S5000 M03
N1010 G54
N1015 G00 X-0.125 Y-0.066 A25.0
N1020 G43 Z4.0 H03 D03 
N1025 G01 Z0.625 F150.0 
N1030 M08 
N1035 M97 P7500 (1)
N1040 G00 Z0.625
N1045 G00 X-0.125 Y-0.066 A61.0
N1050 M97 P7500 (2)
N1055 G00 Z0.625
N1060 G00 X-0.125 Y-0.066 A97.0
N1065 M97 P7500 (3)
N1070 G00 Z0.625
N1075 G00 X-0.125 Y-0.066 A133.0
N1080 M97 P7500 (4)
N1085 G00 Z0.625
N1090 G00 X-0.125 Y-0.066 A169.0
N1095 M97 P7500 (5)
N1100 G00 Z0.625
N1105 G00 X-0.125 Y-0.066 A205.0
N1110 M97 P7500 (6)
N1115 G00 Z0.625
N1120 G00 X-0.125 Y-0.066 A241.0
N1125 M97 P7500 (7)
N1130 G00 Z0.625
N1135 G00 X-0.125 Y-0.066 A277.0
N1140 M97 P7500 (8)
N1145 G00 Z0.625
N1150 G00 X-0.125 Y-0.066 A313.0
N1155 M97 P7500 (9)
N1160 G00 Z0.625
N1165 G00 X-0.125 Y-0.066 A349.0
N1170 M97 P7500 (10)
N1175 G00 Z1.625
N1200 G00 X-0.900 Y+0.066 A-25.0
N1205 G01 Z0.625 F150.0 
N1210 M97 P7600 (1)
N1215 G00 Z0.625
N1220 G00 X-0.900 Y+0.066 A11.0
N1225 M97 P7600 (2)
N1230 G00 Z0.625
N1235 G00 X-0.900 Y+0.066 A47.0
N1240 M97 P7600 (3)
N1245 G00 Z0.625
N1250 G00 X-0.900 Y+0.066 A83.0
N1255 M97 P7600 (4)
N1260 G00 Z0.625
N1265 G00 X-0.900 Y+0.066 A119.0
N1270 M97 P7600 (5)
N1275 G00 Z0.625
N1280 G00 X-0.900 Y+0.066 A155.0
N1285 M97 P7600 (6)
N1290 G00 Z0.625
N1295 G00 X-0.900 Y+0.066 A191.0
N1300 M97 P7600 (7)
N1305 G00 Z0.625
N1310 G00 X-0.900 Y+0.066 A227.0
N1315 M97 P7600 (8)
N1320 G00 Z0.625
N1325 G00 X-0.900 Y+0.066 A263.0
N1330 M97 P7600 (9)
N1335 G00 Z0.625
N1340 G00 X-0.900 Y+0.066 A299.0
N1345 M97 P7600 (10)
N1350 G00 Z0.625
N1400 G00 X-0.900 Y0.0 A0.0
N1405 M97 P7700 (1)
N1410 G00 Z0.625
N1415 G00 X-0.900 Y0.0 A36.0
N1420 M97 P7700 (2)
N1425 G00 Z0.625
N1430 G00 X-0.900 Y0.0 A72.0
N1435 M97 P7700 (3)
N1440 G00 Z0.625
N1445 G00 X-0.900 Y0.0 A108.0
N1450 M97 P7700 (4)
N1455 G00 Z0.625
N1460 G00 X-0.900 Y0.0 A144.0
N1465 M97 P7700 (5)
N1470 G00 Z0.625
N1475 G00 X-0.900 Y0.0 A180.0
N1480 M97 P7700 (6)
N1485 G00 Z0.625
N1490 G00 X-0.900 Y0.0 A216.0
N1495 M97 P7700 (7)
N1500 G00 Z0.625
N1505 G00 X-0.900 Y0.0 A252.0
N1510 M97 P7700 (8)
N1515 G00 Z0.625
N1520 G00 X-0.900 Y0.0 A288.0
N1525 M97 P7700 (9)
N1530 G00 Z0.625
N1535 G00 X-0.900 Y0.0 A324.0
N1540 M97 P7700 (10)
N1550 G00 Z4.0
N1555 M09 
N1560 G00 G53 G90 Z0.0 
N1565 M05 
N1570 G00 G53 G90 X-6.0 Y0.0
N1575 G17 G40 G49 G53 G80 G90 
N1580 M01 

(END OF PROGRAM) 
N8888 G00 G53 G90 Z0.0 
N8889 M05 
N8890 G00 G53 G90 X-6.0 Y0.0 A30.5 
N8891 G17 G40 G49 G53 G69 G80 G90 G94
N9999 M30 

N7100 (ROUGHING SLOTS CENTER)
N7105 G01 Z0.163 F25.0
N7110 G01 X-0.125 F4.0
N7115 G01 Z0.146
N7120 G01 X-0.900
N7125 G01 Z0.625 F50.0
N7130 M99

N7200 (ROUGHING RIGHT SIDE)
N7205 G01 Z0.137 F25.0
N7210 G01 X-0.900 F5.0
N7215 G01 Z0.625 F50.0
N7220 M99

N7300 (ROUGHING LEFT SIDE)
N7305 G01 Z0.137 F25.0
N7310 G01 X-0.125 F5.0
N7315 G01 Z0.625 F50.0
N7320 M99

N7400 (FINISHING TOP)
N7405 G01 Z0.1797 F25.0
N7410 G01 X-0.125 F5.0
N7415 G01 Z0.625 F50.0
N7420 M99

N7500 (FINISHING RIGHT SIDE)
N7505 G01 Z0.1354 F25.0
N7510 G01 X-0.900 F5.0
N7515 G01 Z0.625 F50.0
N7520 M99

N7600 (FINISHING LEFT SIDE)
N7605 G01 Z0.1354 F25.0
N7610 G01 X-0.125 F5.0
N7615 G01 Z0.625 F50.0
N7620 M99

N7700 (FINISHING SLOTS CENTER)
N7705 G01 Z0.141 F25.0
N7710 G01 X-0.125 F5.0
N7725 G01 Z0.625 F50.0
N7730 M99
%

AT3_10_Teeth_pulley_lathe_blank.pdf:

AT3_10T_pulley_Presentation Model.pdf:

Mounted partd