To the OP, a WEDM is not what you want to cut gears, especially standard spur gears. While gears look like just straigh teeth,they are actually an involute shape that is mathmaticaly calculated for each pitch and diameter, in addition to taking forever with a WEDM. Standard spur gears can be cut with the proper involute gear cutter on a mill with a dividing head, its really not hard. Worm gears can be cut on a lathe with a ground cutter and gears can be hobbed on a lathe with a hob.
Where it gets tricky is spiral gears, bevel gears, spiral bevel, and so on and so forth.
Gears were also cut on shapers as the fellows gear shapers cut true involute forms.
More importantly , you can generally find a gear blank or standard gear from motion industries or Boston gear and bore it to whatever size of your shaft, often for cheaper than you can find the cutter.
Where it gets tricky is spiral gears, bevel gears, spiral bevel, and so on and so forth.
Gears were also cut on shapers as the fellows gear shapers cut true involute forms.
More importantly , you can generally find a gear blank or standard gear from motion industries or Boston gear and bore it to whatever size of your shaft, often for cheaper than you can find the cutter.
