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Fellows Gear-Shaper Cutter (US 579,708): The 3D Model
A 3D model of the gear-shaped cutter that Edwin R. Fellows drew in Fig. 11 of US 579,708 (30 March 1897). Rolled against a blank as if the two were already meshing gears, this one cutter generates true involute teeth on a gear of any size.
The model was built in FreeCAD with true involute teeth, then saved as a single-mesh .blend. 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.
Intermediate
Several hours of printing; the slicer reports the exact time
Instructions
1
1
The cutter in Fig. 11
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
2
The model in 3D
The model in 3D
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.
Tools needed:
Desktop Computer3
3
Print it
Print it
Stand it 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. PLA is fine for a display model. The real cutter is hardened steel.
Materials for this step:
PLA Filament - Black (1.75mm, 1kg)1 kitTools needed:
3D PrinterMaterials
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Tools Required
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