MetalworkingFun Forum
Todays Project - What did you do today? - Printable Version

+- MetalworkingFun Forum (http://www.metalworkingfun.com)
+-- Forum: Machining (http://www.metalworkingfun.com/forum-5.html)
+--- Forum: Projects (http://www.metalworkingfun.com/forum-7.html)
+--- Thread: Todays Project - What did you do today? (/thread-727.html)

Pages: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241 242 243 244 245 246 247 248 249 250 251 252 253 254 255 256 257 258 259 260 261 262 263 264 265 266 267 268 269 270 271 272 273 274 275 276 277 278 279 280 281 282 283 284 285 286 287 288 289 290 291 292 293 294 295 296 297 298 299 300 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320 321 322 323 324 325 326 327 328 329 330 331 332 333 334 335 336 337 338 339 340 341 342 343 344 345 346 347 348 349 350 351 352 353 354 355 356 357 358 359 360 361 362 363 364 365 366 367 368 369 370 371 372 373 374 375 376 377 378 379 380 381 382 383 384 385 386 387 388 389 390 391 392 393 394 395 396 397 398 399 400 401 402 403 404 405 406 407 408 409 410 411 412 413 414 415 416 417 418 419 420 421 422 423 424 425 426 427 428 429 430 431 432 433 434 435 436 437 438 439 440 441 442 443 444 445 446 447 448 449 450 451 452 453 454 455 456 457 458 459 460 461 462 463 464 465 466 467 468 469 470 471 472 473 474 475 476 477 478 479 480 481 482 483 484 485 486 487 488 489 490 491 492 493 494 495 496 497 498 499 500 501 502 503 504 505 506 507 508 509 510 511 512 513 514 515 516 517 518 519 520 521 522 523 524 525 526 527 528 529 530 531 532 533 534 535 536 537 538 539 540 541 542 543 544 545 546 547 548 549


RE: Todays Project - What did you do today? - dallen - 12-05-2014

(12-05-2014, 09:59 PM)f350ca Wrote: Good job on the gear. It seams to mesmerize the average person when you show them a gear you made.

Greg thanks, I've made a couple, nothing fancy. I usually have to do make the one I'm working on a couple times cause of getting lost in the turns and sweeps of the index head.

if this one works I plan on making a two or three out of bronze to have on hand. This damn lathe likes to eat them for some reason. wouldn't surprise me if the next thing I have to make for the old gal will be the worm that drives this gear.

DA


RE: Todays Project - What did you do today? - Sunset Machine - 12-06-2014

I keep a couple of gears on my desk at work for show-n-tell. My in-tray is actually full of junk (broken stuff), it has surprised me how many people dig through it to play with those gears. Conversation pieces. Helical, left and right hand, one is cross ground for a pretty pattern. They sparkle, people like shiny things. They have been good advertising.

Your worm wheel, it doesn't look worm-ish to me. Normally they envelope the worm somewhat. More of an acme than involute, but it's hard to say. Many mysteries are involved. The bottom line is that you need specific instructions (and tooling) at to how they were originally made, or make both the worm and wheel as a pair yourself. Make two worms, one to become the cutter. Those worms will likely require a custom lead, which means making custom change gears for your lathe unless you have one of those electronic CNC hoohaws.


RE: Todays Project - What did you do today? - dallen - 12-06-2014

(12-06-2014, 09:21 AM)Sunset Machine Wrote: Your worm wheel, it doesn't look worm-ish to me.

The worm is still in he lathe hiding behind the apron which I don't plan on pulling out until I get ready to see if this gear will fit. and yes the worm is an Acme Thread.

And no it doesn't drive the leadscrew, it drives the carriage feed.

Biggest thing is that if this doesn't work all I've lost is some time, but if it does I've save myself a hundred bucks cause that's about what it would cost me to get one shipped in from Grizzly with their crazy shipping schedule where they now charge you on the shipping based off what the amount of purchase is or some such crap. Anyway 70 bucks for a gear that was made in China they can stick that one where the sun doesn't shine.


DA


RE: Todays Project - What did you do today? - Sunset Machine - 12-07-2014

I was addressing the rapid wear. A straight sided screw running against a curved gear face means a tiny contact point.

Btw, that same shipping scam is also used by other companies too - a wiring harness cost $1500 to ship, the harness itself like $3500 and 10-15 lbs. They inflate the price and charge more to ship?! Really, just a wad of wire in a cardboard box. And not even a kiss..


RE: Todays Project - What did you do today? - dallen - 12-07-2014

The thing that ticks me about the shipping is that they would probably ship it in a padded envelop from Springfield Mo which is about a 5 hour drive from my front door, with the actual weight of the part and the padded envelope being well under 8 OZ.

Whats really funny is a buddy of mine has and Enco 14X40 which probably has the same gear setup in it that mine does and he's never had a problem. I even added a line to put lube directly onto the gears, of course I also had to make from scratch the bracket that holds the worm in place behind the apron. I found that it was loose and floating around and when I took it off a couple years ago found that it had cracks in it, Grizzly was out of stock so I made one out of a hunk of 4140 that was laying around here.

Guess I could take some measurement when I tear the thing apart and use the rest of the hunk of 4140 Annealed round bar to make a Hob by cutting the Acme Thread on it then putting in a bunch of relief cuts for chip clearance and harden it.

Now if I can just remember where the Shop Monster put that 4 MM broach at when I told him to stop chewing on it that it wasn't a Rib Bone I'll be doing ok.

DA


RE: Todays Project - What did you do today? - PixMan - 12-07-2014

Yesterday was a gathering of my wife's side of the family, so no shop time. I got oover there today for about 4 hours of work and a half-hour of cleanup.

First order of business was to add a detail I'd forgotten on the last part I'd made for dallen (David.) It was a flat measuring .094" x .125", only .0079" deep in the Ø1/2" round. It's for an index mark of the sight assembly, so I also added that using the tip of a 1/32" (0.0312") ball mill I have.

[Image: IMG_2558-r_zpsdaba7e3f.jpg]

Now on to the tougher part, the "sight leaf". It's challenging to make (as discussed earlier), but I got a good start on it. I found a piece of tool steel about 5 feet long and 13/16" x .525", which I believe is A2 air-hardening steel, a very stable material. It won't be heat treated, I just needed something that wouldn't warp like a banana when I mill and grind down to .151" thick x .562" wide and over 4" long. All the 1018CRS I have would definitely get a bow in it.

Just two photos. One of the part roughed out, the other with the "easy" machining of the long, thin section.

[Image: IMG_2560-r_zps9aaf5954.jpg]
[Image: IMG_2563-r_zps84ab07bb.jpg]

It'll be next weekend before I can finish it, but I have a plan. First, mill the fat end to the overall length required. Locate and drill for the 1/4'-40UNS thread through, and tap it. (I'll need David to send me his tap or I'll buy one.) Use a 5/16" (.3125") corner rounding cutter to form the bottom semi-circular cylindrical shape. Now move to the surface grinder.

Take one of the 1" wide Ø8" wheels I have, a Norton 32A60-LVBS and finally use the radius/profile dresser I bought a couple of years ago. With that I can create a form on the wheel with 60º of a .155 radius to a flat face. That will allow me to take off the .0035" per side that it's oversize as I creep into the corner and make the full 300º radius. Sounds easier than it will be, but I have the tooling. All I need to gather up is the patience!


RE: Todays Project - What did you do today? - dallen - 12-07-2014

pm me your address and I'll send the tap, and you can drop it in the box along with the parts

David


RE: Todays Project - What did you do today? - PixMan - 12-07-2014

Will do David!

I'm actually enjoying this challenge, very much. BTW, I need to get a set of good reamers. I didn't have a Ø.125" reamer for those two holes, so I used high quality 1/8" drill. Checking with the shank of a carbide end mill which measured (with my Mitutoyo 293-344 digital electronic micrometer) right at 0.12495, and it was a very snug fit. Perfect size!

I used a 6mm carbide end mill to rough out the slot, leaving about .001" per wall for the finishing end mill. For that I used a 3/32" (.09375") two-flute solid carbide end mill, and crept up of the final .251" width. It may be just a touch snug on that dimension, though a 0.2500" spotting drill shank slid up & down smoothly. I used a smooth face "safety edge" file to get the corners sharper, though may want to touch them up again before I ship the parts out.


RE: Todays Project - What did you do today? - Mayhem - 12-07-2014

Ken that sight looks fantastic and I'm glad you will finally get to use the radius/profile dresser. Are you going to be doing the graduations on your mill?

If you recall, the ToolMex reamers are reasonably priced and appear to be well made. The 6.5mm one I purchased was $14.48.


RE: Todays Project - What did you do today? - PixMan - 12-07-2014

Darren,

David and I will discuss the graduations on the "sight leaf" part. I can get the lines done, but my mill is too hard to program every little move for every number. I was talking with Russ, and he has a legal copy of BobCad that he's going to let me try. It's the only CAD/CAM software package available which has written a post processor and made a custom cable for the Prototrak Plus control on my machine. I think it would take too long for me to get the cable, relearn the software (I last used it about 10 years ago) and work out any bugs before the parts would be ready to ship off to David.

As for the reamers, I was thinking of contacting FHC about the reamers but I'm looking around. Holiday time and gifts for others are the priority right now, but to make matters worse my daughter's car is dead (she killed the motor) and I have to buy out my company car coming off lease (new one due in any day now) and give her my wife's 2009 Malibu. Money's getting tight, though I got lucky and sold off that De-Vi-Bar for $500 and made a little over $300 on the deal.