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Fellows Gear-Shaper Cutter (US 579,708): The 3D Models
3DBonanza

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3DBonanza

1. жовтень 2026US
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Fellows Gear-Shaper Cutter (US 579,708): The 3D Models

Seven 3D models from Edwin R. Fellows's gear-shaper patent, US 579,708 (1897): the gear-shaper cutter of Fig. 11 with the 40-tooth gear and the 60-tooth internal ring gear it cuts, the sprocket-wheel cutter of Fig. 20 with its sprocket wheel, and the four-lobed cutter of Fig. 21 with the square bar it cuts.

Each model has its own step, after the step that explains it. The last step covers printing all seven.

Середній
Several hours of printing; the slicer reports the exact time

Інструкції

1

The cutter in Fig. 11

Fellows's cutter c is "a gear-shaped body of hardened steel" with alternating projections 2 and recesses 3. The ends of the projections form a series of metal-planing teeth. Its outer end 4 is "slightly recessed or beveled", so each tooth's cutting angle is slightly acute, which gives it rake. Clearance comes from inclining the cutter's axis relative to the blank's axis, not from relieving the teeth, so the teeth run straight. In Fig. 11 the body is one piece with a tapered shank and has a tapered hollow in its cutting end.
2

The gear-shaper cutter (Fig. 11) in 3D

Its proportions are scaled from Fig. 11. The patent gives no dimensions, so the tooth count, module and pressure angle are stated standard choices. It is a display and teaching model, not a working tool.

Spin the cutter in the viewer and look at the dished cutting face and the tapered hollow. It was built in FreeCAD from an exact involute tooth profile and saved as one joined .blend mesh. It opens in free Blender.

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How the cutter made these teeth

In Fellows's machine the blank "is rotated step by step in unison with the cutter" while the cutter reciprocates across it, and each stroke planes away a little metal. His specification lists the result: "The cutter generates the form of the curve of each gear-tooth cut on the blank, so that each tooth cut is theoretically correct," and "One size of cutter for any given pitch will cut any size of gear." This model was made the same way. The 24-tooth cutter was rolled one full turn around a 105 mm blank in 2,400 positions, and each position was subtracted from the blank.
4

The 40-tooth gear it cuts, in 3D

No tooth was drawn by hand. The flanks came out as true involutes, and the cutter's tips left a curved fillet at the root, as on a real shaped gear. The tooth count, face width and bore are stated choices; the patent gives no dimensions.

Spin the gear in the viewer and look at the curve where each flank meets the root. The cutter's tips made that curve, and no one drew it. It was built in FreeCAD and saved as one joined .blend mesh, editable in free Blender.

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One cutter, inside and out

Fellows's specification: "The same cutter will cut either external or internal gear-teeth with equal ease and correctness. This is an important advantage, it being very difficult to cut internal gears correctly by any of the gear-cutting machines now in use." To make this model, the published 24-tooth cutter was rolled one full turn inside a ring blank in 3,600 positions, and each position was subtracted. Inside a ring, the cutter and the blank turn the same way.
6

The 60-tooth internal ring gear, in 3D

Fellows counted this among his machine's advantages: one cutter cuts internal teeth as well as external ones. The flanks came out as true internal involutes. The tooth count, rim and face width are stated choices; the patent gives no dimensions.

Spin the ring in the viewer and look at the teeth on its inside. The cutter generated them, and no one drew them. It was built in FreeCAD and saved as one joined .blend mesh, editable in free Blender.

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The cutter in Fig. 20

Fellows: "In Fig. 20 I show a cutter c3 formed to cut a sprocket-wheel, the teeth being longer than the intervening recesses." The drawing shows c3 from its cutting end, rolling against a sprocket rim on its arm. Earlier teeth of the rim are already shaped, and the one in front of the cutter is being generated. The same machine and the same rolling motion that cut gear teeth cut sprocket teeth. Only the cutter's profile changes.
8

The sprocket-wheel cutter (Fig. 20) in 3D

It has seven broad teeth with narrower recesses between them, as his text says: "the teeth being longer than the intervening recesses." The patent gives no dimensions and no mathematical tooth form for this cutter, so its profile was traced off the patent drawing. The body behind the teeth is therefore an assumption: the shank, hollow and dished face are copied from the gear cutter of Fig. 11. It is a display and teaching model, not a working tool.

Spin the cutter in the viewer and look at its cutting face. The seven teeth follow Fellows's own outline: it was traced from the patent drawing, not drawn anew. It was built in FreeCAD and saved as one joined .blend mesh, editable in free Blender.

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What Fig. 20 shows, and what was measured

Fig. 20 shows cutter c3 rolling against a sprocket rim on an arm. One tooth of the rim is finished, one sits in a recess of the cutter, and a dashed line marks the next before it is cut. Measured on the 300 dpi scan at the cutter's scale: two adjacent drawn teeth are 20.5 to 21.0 degrees apart about the rim's centre, depending on how each tooth's centre is taken, which gives 17.2 to 17.6 teeth. Both 17 and 18 were generated and fitted to the drawn teeth. The 18-tooth wheel lies closer: its median distance to the drawing is 1.0 mm, against 1.4 mm for 17. The cutter's centre is 119.4 mm from the wheel's. The uncut rim surface is at a 93.6 mm radius. With those numbers, rolling the cutter cut a root at 81.95 mm, against the drawn root line at 82.26 mm.
10

The sprocket wheel it cuts, in 3D

Its tooth count, centre distance and rim come from measurements on the drawing. The drawing shows the rim and one broken-off arm, so the arm count, hub, bore and thickness are stated choices.

Spin the wheel in the viewer. Its eighteen teeth were cut by rolling the Fig. 20 cutter against the rim, not drawn. Overlaid on Fellows's drawing, they sit on his finished tooth, on the tooth in the cutter's recess and on his dashed outline. It was built in FreeCAD and saved as one joined .blend mesh, editable in free Blender.

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11

The cutter in Fig. 21

Fellows: "In Fig. 21 I show a cutter c' having curved teeth or projections shaped to form four plane surfaces c2 on a blank presented to it." The drawing shows c' as four rounded lobes meeting in cusps, turning against a square blank with its four faces marked c2. The arrows show the two turning in opposite directions, like a meshing pair: four lobes for four faces, one turn for one turn. The same rolling that generates gear teeth here generates a square.
12

What the drawing measures, and what the simulation found

Measured on the 300 dpi scan: the four lobes are 90 degrees apart within about 1 degree, and each is a true circular arc. The arc radius is 116.7 px, its centre 110.9 px from the axis, and the arc fits within 0.11 px. The drawn square has a side of 292.4 px. Rolling this cutter 1:1 against a round blank in a simulation tests the claim. It does cut four faces, but each dips inward slightly, by about 2% of its width, so they are nearly plane rather than exactly plane. At the drawn centre distance (381 px) the lobes cannot reach the drawn square's faces, and the result is 13% too large in area. At a centre distance 2.8% shorter (370.25 px), the cutter cuts Fellows's square to within 2.5% of its area. The drawing is close, but not exact.
13

The four-lobed cutter (Fig. 21) in 3D

The size is a stated choice. Fig. 21 shows the cutter only from its cutting end, so the body behind the lobes is copied from the Fig. 11 gear cutter.

Spin the cutter in the viewer and look at its cutting face. The four lobes are four circles in Fellows's proportions. It was built in FreeCAD and saved as one joined .blend mesh, editable in free Blender.

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How the square was cut

Fig. 21 shows cutter c' turning against a square blank whose four faces are marked c2. Four lobes meet four faces, so the two turn one for one, in opposite directions. To make this model, the cutter traced from the drawing was rolled one full turn against a round blank. The blank's radius was the drawn square's half-diagonal. Each of the cutter's positions was subtracted. The centre distance used is the one that best reproduces Fellows's drawn square, 2.8% shorter than drawn, as found on the cutter's own blueprint.
15

The square bar it cuts, in 3D

Fellows called the faces "plane surfaces". The simulation shows them as very nearly plane: each has about 1 mm of gentle waviness across a 47.6 mm face. The bar's length is a stated choice, because Fig. 21 shows only its cross-section.

Look at the bar end-on in the viewer. Each face is very nearly straight, with a gentle wave the four lobes leave behind. The rolling motion cut every face, and none was drawn. It was built in FreeCAD and saved as one joined .blend mesh, editable in free Blender.

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Print them

The three cutters: stand each on its cutting face with the shank up. The dished face is a near-flat overhang and the hollow has a 24 mm flat roof, so turn on supports from the build plate. The real cutters are hardened steel.

The 40-tooth gear: lay it flat on one face. It needs no supports. Two copies at 100 mm centres have no tip clearance and no backlash, which leaves no room for printing tolerance, so a printed pair is for studying the tooth form.

The internal ring gear: lay it flat on one face. It needs no supports, but the bed must be at least 180 mm across. Because of the interference stated above, it is not a working ring for the 40-tooth gear as drawn.

The sprocket wheel: lay it flat on one face. It needs no supports, but the bed must be at least 187 mm across.

The square bar: stand it on one end. It needs no supports. Hold a straightedge across a face to see the slight waviness the cutter leaves.

PLA is fine for a display model.

Матеріали для цього кроку:

PLA-пруток — чорнийPLA-пруток — чорний1 набір

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