hmm,maybe fly-cutter does not apply entirely. Anyway It's ground from broken end mill to create tooth profile or rather between-tooth-profile . My cutter rests safely and wait for next job .
Calculations worked for me:
pulleys PCD radius - 0.381mm gives you pulley radius.
then cut depth if 1.21mm.
However I found slight dimensional variations for pulley dia /doc. I used those from pic uploaded
I have only done XL series pulleys, so trapezoidal not round. Looks like it's easier to get it right with HTD. Should start replacing mine on the router.
JohnS' makes mine look a bit amateur:
As those went on my router they've had a lot of use and the pulleys under where the belt runs has got polished. Same is true for the bought ones. I wonder if it's worth anodising them to harden the surface? Would have to be careful not to change the dimensions too much in the process.
Very good job anyway. I like the side rings which I couldn't be bothered :whistling:
Doesn't fly cutter do job faster???
I ran 300mm/min @ 1.21mm doc and I would dare to do 500 easy. 2mm ballnose could be very flexible as well.
Again very good looking pulleys, John
Ball nose cutter puts less load on the spindle, so less wear? More likely reason is probably that it's harder to grind an accurate 3mm form tool (unless you've got the right equipment) than to just use a ball nose cutter.
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