Author Topic: 3D Printed Quorn Tool & Cutter Grinder  (Read 22323 times)

Offline Joules

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Re: 3D Printed Quorn Tool & Cutter Grinder
« Reply #50 on: December 21, 2015, 06:23:05 PM »
Thanks for that John, but when I first started it was hellishly frustrating getting through the early learning curve.  I see what guys here do in metal and realise I won't achieve what they can.  I am just happy to have found something that fits my skill set, and that my craft skills can compliment it.  I can design stuff I don't have the skill or tools to machine.



« Last Edit: December 22, 2015, 11:21:33 AM by Joules »
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Offline Joules

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Re: 3D Printed Quorn Tool & Cutter Grinder
« Reply #51 on: December 22, 2015, 10:45:28 AM »
Next step,  I have remodelled the other end supporting the bars, and moved its mounting position into the middle of the casting.  Nothing jumps out at me that may cause any issue here and I have recessed the fixing.  Rather than split the casting I have gone for an 8mm pin that will pull and wedge the bar in order to lock it.  Again, if anyone see's a fault in my logic please pipe up.



Let me also know if this style of representation is easier than the rendered images.  Once I finalise this part and get it printed we should be ready to assemble as per below.



The eventual plan is to re-print the castings in a suitable colour, but for now translucent works well as I can shine a light and see where parts are.
« Last Edit: December 22, 2015, 12:14:24 PM by Joules »
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Offline RobWilson

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Re: 3D Printed Quorn Tool & Cutter Grinder
« Reply #52 on: December 22, 2015, 11:12:32 AM »
Have to say, I'm very impressed with the quality of the 'printed' items....  :dremel:

I'm also more impressed at your ability in mastering this technology.... :bow: :bow: patience at learning a new skill such as this is not one of my strong points...  :(

Plus one  :thumbup:  :clap: :clap: :clap: :clap:


Rob

Offline awemawson

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Re: 3D Printed Quorn Tool & Cutter Grinder
« Reply #53 on: December 22, 2015, 11:28:40 AM »
Looking good Jules  :thumbup:

Prof Chaddock would have been highly amused, I don't think he was shy of using new materials and techniques.
Andrew Mawson
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Offline Fergus OMore

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Re: 3D Printed Quorn Tool & Cutter Grinder
« Reply #54 on: December 22, 2015, 01:42:27 PM »
Ah well, but at the end of the day- you have grit. 

And the answer to  the obvious question- neither have I.

Norman

Might I re-iterate the grit problem which is part and parcel of many tool grinders of which the Quorn is no exception. Otherwise, a most interesting exercise.

Norman

Offline Joules

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Re: 3D Printed Quorn Tool & Cutter Grinder
« Reply #55 on: December 22, 2015, 01:50:12 PM »
Not worried about the grit at the moment, more interested in at least getting it working.  If parts are cheap to make once its completed I will just wear them out and replace.   :thumbup:
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Offline Fergus OMore

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Re: 3D Printed Quorn Tool & Cutter Grinder
« Reply #56 on: December 22, 2015, 03:14:13 PM »
It is not the question of replacement  but binding when in use which  is the problem.

I got so fed up with grit that I settled for Stent or Clarkson which avoided most of the confounded problems which I had with the Worden and then the Quorn.

I'm afraid that it is fact of life and the Worden- in my case- is 'infill' somewhere.


Offline Joules

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Re: 3D Printed Quorn Tool & Cutter Grinder
« Reply #57 on: December 22, 2015, 03:30:23 PM »
What about seals wiping the bars ?  I will give the felt a go, but can't imagine that being great at keep grit off, but I thought rubber seals might keep it at bay.

As the next major part is a 10hr print and will wait till tomorrow I have got a quicker 1hr job on the printer.



In this case the micrometer thimble.  Since knurling looks naff 3D printed, I have gone for something a little better suited to 3D printing.  It's been printed in black and I will try to put white paint in the numerals and graduation marks once it's done.  This part is printing at 0.1mm to capture the fine detail in the numerals.
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Offline RobWilson

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Re: 3D Printed Quorn Tool & Cutter Grinder
« Reply #58 on: December 22, 2015, 03:54:20 PM »
is it done yet !   :D



Rob

Offline Joules

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Re: 3D Printed Quorn Tool & Cutter Grinder
« Reply #59 on: December 22, 2015, 04:11:12 PM »
86%

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Offline RobWilson

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Offline RotarySMP

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Re: 3D Printed Quorn Tool & Cutter Grinder
« Reply #61 on: December 22, 2015, 04:42:18 PM »
That rendering looks cool. Which CAD SW are you using?
Mark

Offline Joules

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Re: 3D Printed Quorn Tool & Cutter Grinder
« Reply #62 on: December 22, 2015, 05:08:11 PM »
Hot on the printer...



It doesn't photo well under artificial light, I have just started the clean up of this part so it looks worse than it actually is.



But I hope this gives some sense of scale.

Mark the software is Rhino, and it's using the artistic view.
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Offline raynerd

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Re: 3D Printed Quorn Tool & Cutter Grinder
« Reply #63 on: December 23, 2015, 02:16:18 AM »
Great work. Can't wait to see it up and running - I'll stick my first parts order in  :wave: :thumbup:
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Offline PekkaNF

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Re: 3D Printed Quorn Tool & Cutter Grinder
« Reply #64 on: December 23, 2015, 02:37:35 AM »
Grit on TCG....

My experience shows two approaches:
* Nothing covered. Keep dry and vacuum everything out before moving anything :lol:
* All covered/pressurized. Still needs to be vacuumed before shutting down pressure.

Rubber covers + non pressurized or any grease/coolant on ways: Worse than anything else.

Think of rubber cover over a bar. You move the cover and increase/decrease internal volume of the bellow = differential air pressure and that surely sucks the grit inside the area that was supposed to be protected. And it is hard to clean the area inside the bellow.

I was thinking of fitting plastic "scrapers" on ways and pressurizing a small plenum right behind of it. Needs some trial and error, plastic "washer" pops out if too tight fit to rod and if too loose, uses a lot of air and blows the dust/grit around.

I would not worry bout the grit on MK I model, just keep it dry and clean.

BTW. Grit is going to be embedded on the plastic and wear out the steel rods. May actually make nice laps.

Pekka

Offline Joules

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Re: 3D Printed Quorn Tool & Cutter Grinder
« Reply #65 on: December 23, 2015, 03:21:36 AM »
LOL bars are going to be perspex, so running it dry.  The initial thoughts here are 3D print different vacuum shields for the various grinding operations as printing is relatively quick I should be able to make custom hoods to enclose the work and wheel as much as possible and attach vacuum cleaner to reduce dust/grit MAYBE...

Having just checked the parts this morning, they have changed shape a little  !!!  My close fit isn't quite as close now, this could be temperature/humidity related, we shall see.  Sorry guys not expecting metal casting precision here, but perhaps good/enough for sharpening small items and cutters upto 6mm.  The challenge is getting something that works, it would be nice to see what this casting would be like printed in polycarbonate, but that is beyond the capability of my 3D printers.  Now when we have desktop metal printing   :med:



Here you go Rob, if the rest of the project turns to crap this micrometer thimble will be worth the experimentation.  I have just applied Humbrol enamel with a toothpick, once it dries I can lightly rub down the surface and sharpen up the detail.  Little things like this make the printer soooooo  useful.
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Offline awemawson

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Re: 3D Printed Quorn Tool & Cutter Grinder
« Reply #66 on: December 23, 2015, 03:37:12 AM »
That thimble has come out very nicely.

When you say things have changed size/shape have you a guesstimate what sort of percentage? As the medium is squirted out at melting point, presumably the whole body of a print will get quite warm during the process. As the plastics are poor heat conductors they will take a long time to come to a stable temperature in the core of the object which I assume will tend to set up stresses which will probably take quite a time to come to an equilibrium. Not important if printing a Yoda or a small precision object, but more so as the size and mass increase.
Andrew Mawson
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Offline Joules

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Re: 3D Printed Quorn Tool & Cutter Grinder
« Reply #67 on: December 23, 2015, 04:01:58 AM »
Andrew, this is the largest part I have printed, it does look like the internal structure has pulled the print out of line.  Not easy to say how much, I just made up some paper feeler gauges and its looking like 0.010""  has opened up at the thin fillet on top where the vertical part of the print joins.  When I finally come to welding these parts they will be clamped to a surface plate and tacked together, very much like tig welding.   Once I get the bars in I can measure from them, it's all good fun.

I have started the print for the other end support, once its finished I will give it 48hrs to stabilise and see what we have.  I tried to keep the wall thickness the same so if it is distorting due to internal stress, it may distort the same way, two wrongs making the best right I can hope for.
Just get doing and make swarf, you can decide what its going to be later.   :thumbup:

Offline RobWilson

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Re: 3D Printed Quorn Tool & Cutter Grinder
« Reply #68 on: December 23, 2015, 04:28:45 AM »
 :clap: :clap: :clap: looking good Joules  :thumbup:



Rob

Offline Joules

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Re: 3D Printed Quorn Tool & Cutter Grinder
« Reply #69 on: December 23, 2015, 03:23:08 PM »
29hrs printing see's the base castings complete.



Guess it might be Boxing day the bars go in.  The rear bar will be press fit and the front bar a sliding fit (in theory).  The micrometer thimble actually made a good gauge to test the 25mm Perspex bar.  It does vary a little, so I hope to manage the two bar fits from the 1m bar I have.  Otherwise doodling, the rest of the micrometer adjuster and working out a plan  :scratch:.  Threads into PLA, not likely, might get away with it in Perspex though.  Will have to make some test parts and see how happy they are with 10lbs (4.5kg) load on them, otherwise its metal components in this area.

« Last Edit: December 24, 2015, 06:32:03 AM by Joules »
Just get doing and make swarf, you can decide what its going to be later.   :thumbup:

Offline nrml

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Re: 3D Printed Quorn Tool & Cutter Grinder
« Reply #70 on: December 23, 2015, 04:13:30 PM »
Slightly  :offtopic:.
Why not ABS-Polycarbonate blend instead of pure polycarbonate. It seems to be very highly rated by respected pioneers in the reprap movement. A tool grinder is not liklely to end up covered with oil and grease and the exposed areas could easily be given an appropriate protective coating.

Offline Joules

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Re: 3D Printed Quorn Tool & Cutter Grinder
« Reply #71 on: December 23, 2015, 04:36:01 PM »
No reason at all, my only concern PC/ABS mix, the ABS.  You're using it, admittedly in a blend, above ABS working temp.  Since ABS already stinks the place out off gassing, that is going to be worse at higher temperatures.  What happens to the ABS component at those higher temperatures ?   Bit like brass loosing its zinc, not sure I am happy getting a lower PC temp by burning off more ABS.
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Offline Baron

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Re: 3D Printed Quorn Tool & Cutter Grinder
« Reply #72 on: December 24, 2015, 05:47:46 AM »
Seasons Greetings Joules,

Nice work.  Watching with interest.

Just a comment: You might find that the perspex bar is not truly round.

Best Regards:
                     Baron

Offline Joules

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Re: 3D Printed Quorn Tool & Cutter Grinder
« Reply #73 on: December 24, 2015, 06:31:21 AM »
Cheers Baron, your spot on, but then my 3D prints aren't truly round in the bores  :lol:

I wonder if you can get ground and polished glass rod in 25 & 30mm diameter, would have to forget the spiral on 30mm glass, unless an angle grinder disk could put the groove in   :scratch:

(no I am not being serious, but...)
« Last Edit: December 24, 2015, 07:03:51 AM by Joules »
Just get doing and make swarf, you can decide what its going to be later.   :thumbup:

Offline Fergus OMore

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Re: 3D Printed Quorn Tool & Cutter Grinder
« Reply #74 on: December 24, 2015, 06:43:44 AM »
If the bed bars in the  bores are not truly parallel to each other  in every direction, you will run into all sorts of problems.  Well, that happened to me.

Meantime, Happy Christmas to one and all.


Norman