;Involute spur gear free gcode wizard using O codes
;Cut outer involute spur gears with a slitting saw on a 4 )
;axis mill Wilfried Smekens SA-CNC-Club 21 June 2015 Beta 1.0)
(Touch off bottom of cutter to center of gear to be cut = Z )
(Touch off cutter to the side of the gear = X )
(Touch off cutter to outside diameter of the gear = Y )
(Gear width) #1 = 30
(Outer diameter) #2 = 120
(Base diameter) #3 = 107.12
(Root dia. ratio) #4 = 1.15 (% of undercut)
(angle to turn *) #5 = 32
(Cutter thickness**) #6 = 2
(Cutter diameter) #7 = 63
(Tooth quantity) #8 = 38
(Spindle speed) #9 = 1900
(Feed rate) #10= 400
(counter) #11= 0
(press. angle theta) #12= 20
(Calc angle alpha ) #13= [57.296*tan[#12]-#12]
(tooth angle at base) #14= [[180/#8]-[2*#13]]
(tooth hight) #15= [[#2-#3]/2]
(tooth undercut mm) #16= [#15*[#4-1]]
(max cut width) #17= [2*sqrt[[2*#15*#16]-[#16*#16]]]
(calculate cuts qty) #18= FUP[#1/#17]
(counter cuts qty) #19= 0
G17 G21 G54 G80 G90
S#9 M3 (M8) (clockwise splindle speed + coolant on)
G1 X-1 Y-2 Z0 A0 F#10
o100 do
G90 G0 A [360*#11/#8](turn gear to spline position)
G0 X [#7/2] Y-1 (move cutter to start position)
G1 Y [#15*#4] F#10 (cut spline to depth ) G1 X [#7/2+#1] (cut sideways ) G0 X [#7/2] Y-1 (move cutter to start position)
G91 G0 Z-#6 A-#14
G90 G1 Y [#15*#4] F#10 (cut spline to depth ) G1 X [#7/2+#1] (cut sideways ) G0 X [#7/2] Y-1 (move cutter to start position)
G91 G0 Z #6 A #14 o200 do
G90 G0 X [[#7/2]+[#1/[#18*2]]+[[#1*#19]/#18]] Y-1 G91 G0 Z [#3*3.1416*#5/360] A [#5]
G90 G0 Y #15
G91 G1 Z-[#3*3.1416*#5/360] A-[#5] F#10
G90 G1 Y [#15*#4] (make undercut) G0 Y-1 ( retract to safe position)
G91 G0 Z-[#6] A-#14
G91 G0 Z-[#3*3.1416*#5/360] A-[#5] G90 G0 Y [#15] G91 G1 Z [#3*3.1416*#5/360] A [#5] F#10
G90 G1 Y [#15*#4] ( same as spline depth ) G0 Y-1 ( retract to safe position )
G91 G0 Z [#6] A#14
#19=[#19+1]
o200 while [#19 lt #18]
#19 = 0
#11=[#11+1] ( add counter )
o100 while [#11 lt #8] ( repeat for all splines)
M5 M9 ( stop spindle and coolant)
G0 Y-2
G0 A0 X-1 Z0
M30 ( The end )
* to large a angle may cause you to cut some extra air, but
to small a angle could cause tool collision with workpiece
** select cutter thickness as near as possible to the tooth valley width
P.S. depending on your machine configuration or workpiece orientation,you may have to + or - the X and Y 's 4th axis setup 360mm=360degrees )
