Cutting a gear with an angle grinder

[martik777]

This was an experiment but it worked out so well I thought I'd share it. Knowing the profile would not be perfect I used aluminum. Grinding wheel was 1/8" thick, worn just about right. I had to make a keyway on the shaft as the aluminum would not stay on tight with a friction fit only.




Here are the full size pics:
http://s1182.photobucket.com/albums/x445/martik777/Backgear repair/

 

[Fourjc]

Looks like something I would do.. The final result is what counts.
Gread job.
I made an aluminium timing belt pulley by drilling holes in an oversize blank then turning down to final size them forming the final shape on surface grinder. Grinding aluminium is difficult, the wheel packs up very quickly, it needs lot's of oil.
How did your cut off disk perform in aluminium.
Am I seeing a tooth missing on the big gear in picture 8.

 

[goldenchips2]

yes, i to am interested in how your wheel did not load up
did you use a special made for aluminum wheel?
Or just ALOT of coolant....:thinking:

 

[4R8]

looks like it came out well, congrats.

As Goldenchips2 has mentioned about the disc loading I'd like to back this up with a warning.

Std 3mm (1/8" inferial) cutting wheels can explode if utmost care isn't taken. The fine cut discs ie flexovit's "Megaline" series don't have this problem.
I've watched a cutoff wheel pretty much disappear from a grinder (bar the centre ring and a few pieces in my buddies leg) when cutting Aluminium.

Again, nice work and I'm sure you're aware of the risks but others may not be.

 

[bcall2043]

This was an experiment but it worked out so well I thought I'd share it.

martik777

The experiment turned out great. Do you plan to live with the aluminum gear or cut another using another method? Keep us informed about the next step if there is one?

I have a lathe with a busted gear but am still watching and learning. If I can get the tools and materials together I think milling the teeth will be my first step.

Benny
In middle Tennessee, USA

 

[martik777]

Yes, there are a few missing teeth on the bull gear. I plan to tap in some #10 screws and mill to shape. No welding equipment otherwise I'd braze it up.


The wheel did not load up at all, maybe cuz the cuts were so light? I made 3-4 passes for a depth of .100. It was just a cheapie depressed center grinding wheel not a cutoff.

Thanks for the words of caution, I was very careful with that wheel being near eye level, I stood way off to the right side.

I think I'll see how well this one stands up before considering using steel or CI.