Have you looked at geargen11 it is an old DOS program should still be 
available someplace.


At 09:34 AM 5/20/2009, you wrote:
>On Wed, 2009-05-20 at 04:44 -0500, Ray Henry wrote:
>... snip
> > I dropped in on the folk at Synergy the other evening and they demoed
> > gear design for me.  Answer a few questions like number of teeth and so
> > forth and it draws it up and then writes the g-code depending on your
> > cutter.
> >
> > They don't have a rack gear routine (yet) but we played with that a bit
> > and it looked like the sides of the teeth are flat faced where the exact
> > angle and distance between are a product of the nature of the gear
> > running in them.  The rack's tooth profile is certainly not a simple
> > negative of the involute tooth of the gear that runs in it.
> >
> > It was an interesting thought and drafting experiment but I stayed well
> > short of the real math to make 'em.
> >
> > Rayh
>
>The rack tooth form is the basis for involute gears, everything else
>comes from this. The rack form is described in Machinery's handbook and
>here:
>http://www.sdp-si.com/d785/html1/D785T007_2.html
>
>The straight sides are at the pressure angle (20 or 14.5 degrees
>usually). This trapezoidal shape, as a hob, fly cutter, or standard #8
>gear cutter, can be used with an A axis to cut all of the gear diameter
>sizes with the corresponding pitch. The other key feature, is the base
>circle which is derived from the pressure angle lines placed with their
>intersection on the pitch circle.
>http://www.sdp-si.com/d785/html1/D785T018_1.html
>
>The diagram shows one pressure angle line, the other is just a mirror of
>it. The point(s) of contact are on this line and since the line and
>contact point can be thought of as an unwinding string, the sum of the
>contact points forms an involute of the base circle.
>
>I have Synergy, but I am trying to come up with an open-source gear
>utility. I have a way to go.
>--
>Kirk Wallace
>http://www.wallacecompany.com/machine_shop/
>http://www.wallacecompany.com/E45/index.html
>California, USA
>
>
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