Hey John, are you familiar with Gearotic ?
Art had a Tool Wizard utility in there at one time, (not sure of it's current state), that would generate the Gcode to machine a profile to match a selected gear form using a mill with a 4th axis.
I'd thought about entering the lathe tool tip rad(dia) in place of the endmill dia., generate the code, then delete all but the one side and the tip of the finished profile. Then by replacing the X and Y with Z and X. Using a few G52 offsets for the roughing, then a smooth finish pass.
Should be a perfect form with the too tip rad. comp. all taken care of.
But, never got around to trying it.
Seemed like a relatively easy task at the time though.
Thanks john,
Russ