m_c:

I'll have a look at the Gearotic software. What I can do with it might be limited as I do not yet have a CNC machine. I have planned to build one since retiring and have decided that I AM going to start one in the new year (I guess I'll be posting many questions so please be prepared to be patient with me!). In my professional career, besides bespoke s/w, I used one from Kisssoft AG http://www.kisssoft.ch/english/home/index.php. It is totally trustworthy. I was using it for calculating gear tooth stress analysis, bending, deflections, optimising shape for low noise/wear etc. As we had many machines designed for hobbing/shaping and tooth grinding, we did not need CAD/CAM for producing tooth surfaces. Have just looked at Kisssoft and it is now owned by Gleason and looks to have gone up-market somewhat. There is a test/demo that will allow generation of reliable data.

Leadhead:

You have challenged me to a project for when I have built a CNC machine!. I will be following this thread with interest. I guess that by 32 tpi you mean "32 teeth per inch of PCD"? That would be 32 DP which is quite small (tooth depth of 1.78mm). Heck that is small. If you need any help with gear geometry, just shout.

Good luck

Martin