09-26-2015, 11:28 AM
The big question is if you still have the original ram in order to copy the tooth shape. I'm going to assume you don't.
Plan "A" would be to read in Machinery's Handbook about how to measure the mating gear to determine the pitch, pitch angle and/or module of the gear, then select a correct gear cutter and then cut the rack on your mill.
Plan "B" would be -- and I've never done this, so take it with a grain of salt -- roll the mating gear in a carefully prepared bed of modeling clay which you would measure for pitch and use to generate the hand-ground fly-cutter tool as Ed describes. Then you'd cut the rack on your mill.
Plan "A" would be to read in Machinery's Handbook about how to measure the mating gear to determine the pitch, pitch angle and/or module of the gear, then select a correct gear cutter and then cut the rack on your mill.
Plan "B" would be -- and I've never done this, so take it with a grain of salt -- roll the mating gear in a carefully prepared bed of modeling clay which you would measure for pitch and use to generate the hand-ground fly-cutter tool as Ed describes. Then you'd cut the rack on your mill.