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Note that this is a very good way of designing any gear - just slow. Once you have that, you can array the cut profile… note, though perfect I do not suggest doing it as… it’s a really slow process.
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You then do a subtraction of all of the models along the movement curve into the blank. Take the gear that you’re going to be meshing with, locate it to where it’ll mesh, then array it so that the movement of the tooth against the blank gear matches the movement exactly. The other way to model it is more computationally costly but produces perfect results. You then have to apply a small bevel (say 2mm on one side and 0.4mm on the other) so that it narrows either end of the tooth profile and then, if you’re feeling fancy, round off the interface between the tooth and the bevel, but printing will do a bit of that too so you may not have to. You then will use a turned cut to select only the meshing portion of the gear. The first is to model your involute curve on a plane and loft it to a point, same as you’re doing. What the gear becomes is a compound sphere segment - okay, that’s just a fancy way of saying it’s rounded. In truth, the tooth model is very similar to an involute gear by fixed at 45 degrees and when the tooth is looked at on-end it’s curved in at either end of the tooth area. Okay, all that said as soon as you leave the bevel involute gear model, you can easily make one. If you were to replace the gears with rollers they would be two cones that come to a point at the same location.
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The correct way to make involute bevel gears like this is to make the two gears have the same vanishing point. The trouble with this gear is that it’s not actually a valid involute tooth profile due to the smaller gears meshing with a larger gear which already has it’s angles set by a 90 degree mesh with a gear of the same size.
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