Author Topic: Making a Cutter Holding Block (Read 23460 times)

Bernd · « **on:** February 16, 2009, 03:21:45 PM »

You know how it goes. You plan on making some tooling. Only it's a piece of complicated tooling. I'm talking about the South Bend headstock I'm using to make an indexing device. Here's the link to it.

I've wittled out the piece of aluminum for making the clamp plate that will clamp the spindle tight after indexing. The clamp will incorporate a cotter clamp. I learned about this clamp from Guy Lautard's "Bed Side Reader #1". I'd seen them before but didn't know what they were called.

Well I designed the part with a 3/4" (19mm) diameter cotter clamp. Unfortunately I don't have any kind of drill that large. Now I have several options to make that hole. First is use a faceplate and angle plate to bore out the hole. Here's a representation of how it would be set up.

The other method would be to use a boring head in the mill. Since I don't have a boring head I'll have to use a third method. Make a cutter that will cut a 3/4" (19mm) dia. hole.

Home made cutters a fun to make and you can learn something in the process. I'm going to make a three bladed cutter to drill the hole for the cotter key clamp. But wait a minute I need my index tool finished before I can do that. Kind of a catch 22 here, right. Not really. A very simple tool is going to be made from a piece of 1.875" (47.6mm) hex stock. Hence the name cutter block.

Here's a pic of it in the lathe with center drilled hole in it. When done it will have a 1" (25mm) dia hole through the center.
Since everybody likes lots of pics I figured two would do here.

The reason I scribed the lines on it was I was going to do it in a 4 jaw chuck. Anybody see why it can't be done in a four jaw chuck. Yup, it's six sided. If it were 4 or 8 sided it would work in a four jaw chuck.

Next will be drilling the hole using several different size drills to get up to a hole dia. were I can get the boring bar in. Then the hole will be bore to 1" (25.4mm) dia.

I should have a few more steps done in the next couple of days.

So in one days time I've regressed 3 steps to making my index tool. This how it goes sometimes when making stuff. Could I buy all this equipment?. Of course I could, but fun would that be. Remember you won't have any pics to look at if I had bought all the equipment. You might even learn a trick or two for your next project.

bernd

Divided he ad · « **Reply #1 on:** February 16, 2009, 05:11:53 PM »

Well you have got my attention Bernd

If not only to ponder the limitless uses of pink Mark out dye

I will honestly be interested in the engineering side of it too though

Ralph.

Bernd · « **Reply #2 on:** February 16, 2009, 05:30:37 PM »

Quote from: Divided he ad on February 16, 2009, 05:11:53 PM

If not only to ponder the limitless uses of pink Mark out dye

Ralph.

Ralph,

We need to talk about you getting an eye exam. It's a deep dark shade of green. You only think it's pink.

Bernd

SPiN Racing · « **Reply #3 on:** February 16, 2009, 08:12:09 PM »

It looks like the pink was dying to escape the bottle as well!!!!

:P

Cant wait to see where this is going.. Im gonna keep an eye on the cutter design...

sbwhart · « **Reply #4 on:** February 17, 2009, 02:34:18 AM »

Nice one Bernd

great use of Green mark out die

A bit

of how final job will look like but it will all become clear in time

Cheers

Stew

Bernd · « **Reply #5 on:** February 17, 2009, 10:08:10 AM »

Stew,

Perhaps I should rephrase the subject line to "Making a Cutter Holding Block".

Mmm...that makes more sense doesn't it?

Bernd

Divided he ad · « **Reply #6 on:** February 17, 2009, 11:35:17 AM »

Doesn't that bottle in the first picture say "Dykem girly pink" on it???

I was sure it did??

Must be my eyes..... Oh, did I forget to mention that I was medically examined in my infancy and found to be indeed colour blind

But it's still pink

Ralph.

Divided he ad · « **Reply #7 on:** February 17, 2009, 11:37:20 AM »

Any more on the holder design?

I am intrigued about the engineering of this more than the colours used...... Honest

Ralph.

Bernd · « **Reply #8 on:** February 17, 2009, 04:39:13 PM »

If your in that much of a hurry to see how it functions when complete take a read HERE.

It's not as a detail description as I'm going to do here but should satisfy your curiosity.

And I'm starting to really worry about your Ralph. Likeing PINK and have no lady to keep you on the straight and narrow. One begins to wonder.

Dam, my sides are hurting from laughing to much. Your a trip Ralph.

Bernd

Divided he ad · « **Reply #9 on:** February 17, 2009, 08:07:45 PM »

Quote

If your in that much of a hurry to see how it functions when complete take a read HERE.

Bu64£r.... You tricked me into HMEM!!!!

I'll wait for the full details, and the video of it working

Quote

And I'm starting to really worry about your Ralph. Likeing PINK and have no lady to keep you on the straight and narrow. One begins to wonder.

Don't you worry your pretty little head about me sweet heart .... I'll be just fine

(couldn't resist that!!

)

oh, I love this site

Ralph.

Bernd · « **Reply #10 on:** February 17, 2009, 10:18:26 PM »

Quote from: Divided he ad on February 17, 2009, 08:07:45 PM

Don't you worry you pretty little head about me sweet heart .... I'll be just fine (couldn't resist that!! )

oh, I love this site

Ralph.

Ok Ralph I just sprayed beer all over over my keyboard with that one.

Bernd

Bernd · « **Reply #11 on:** February 18, 2009, 06:16:11 PM »

Well it's time to get back on subject here.

After drilling the hole large enough a boring bar is used to bore out the hole. I'm going to make the hole 1.125" (28.57mm) in diameter. I was shooting for 1.000" (25.4mm) but went over. You don't want to make it to big because you won't have a place to put the set (grub) screws. I check how close I was with a digital caliber. These are not good for getting the bore right on size.

Here's why the calibers don't work very good for inside measuring. The blades on the end have a square surface. Although small you really can't get to the point at the which it should be measured. Here's a C-o-C of what I mean.
The points of the blades will touch the sides of the wall at "A" and "B", but not at "C" because of the small flat of the blades.

So in order to get a proper sized hole I made a plug. There are two diameters on it. It's kind of hard to see but the first dia. is .005" (.127mm) smaller than 1.125".

So I use the calibers until I get close to a bore of about 1.125" (28.57mm). When I'm close I use the plug gage.

Now in order to get that last few thousands or tens of thousands I use the top slide to put on a fine cut.

How's that done you ask? I set the top slide over to about 11 degrees from the parallel to the center line of the lathe. This gives a ratio of 5 to 1. In other words when I move the top slide .005" (.127mm) it will move the tip of the cutter .001" (.025mm). So I can put on a very fine cut to the point of being able to move the top slide .001" and move the tip of the cutter .0002" (.005mm). A nice way to be able to put on a real fine cut using a manual machine without a DRO.
Here's a pic of the set up. Although not much to see, you'll notice how far I've moved the top slide toward the lathe center line.

And the end result is that I get the gage to fit with a couple of very light cuts.

Next I had to make a plug that will eventually have a hole through the center to hold the cutter. The hole can be almost any size. I need one with a .500" (12.7mm) hole for the shank size of the cutter I'm going to make. Again note the angle to of the top slide. I moved it over to 10 degree to give about the same ratio as I did on the holder.

And here are the completed parts for the tool holder.

That's it for now. I need to get some set screws, grub screws for you foreigners, and drill some holes. Until next time.

Regards,
Bernd

Darren · « **Reply #12 on:** February 18, 2009, 07:14:56 PM »

Foreigners...bah!!

You spelt "colour" wrong earlier, well wrong for your part of the world, right for us.....

See you know we are right

Nice looking job btw, looking forward to seeing more....

Bernd · « **Reply #13 on:** February 18, 2009, 10:25:59 PM »

Ok I'm passing out two gold stars to Darren. I was wondering when somebody would catch on to my spelling of "colour".

Hopefuly I'll get to makeing the cutter this weekend.

Bernd

Divided he ad · « **Reply #14 on:** February 19, 2009, 12:28:00 AM »

Quote

Ok Ralph I just sprayed beer all over over my keyboard with that one.

Bernd

Drinking while in charge of a computer..... Isn't that an offence??

Now then.... Bad calipers, Plug guages, angled compound slides and ratioed cuts of some old measurement system...... I'm going to have to read this through a few times to absorb it all

Loads of stuff I never thought about before in there Bernd

Keep up the good work... (although I seem to think you have done much of the mechanical part of this post...... Don't know where I got that idea from???

)

Ralph.

sbwhart · « **Reply #15 on:** February 19, 2009, 02:15:42 AM »

Nice job Bernd

Now I see what your up to,

Followed that link to HMEN saw the posher more serious side of Bernd

Prefer the

side

Cheers

Stew

Stilldrillin · « **Reply #16 on:** February 19, 2009, 02:19:17 AM »

Angled topslide, Bernd? Nice one!

I`ve only just got the hang of only taking off half of what is required at each pass.....
It takes far more passes than usual, but unable to go oversize. (Usually).

David.

Baldrocker · « **Reply #17 on:** February 19, 2009, 06:03:04 AM »

Quote

but it will all become clear in time

sbwhart
Cant thick of anything more useless than
clear markout dye

BR

Stilldrillin · « **Reply #18 on:** February 19, 2009, 07:54:27 AM »

Quote from: Baldrocker on February 19, 2009, 06:03:04 AM

Quote
but it will all become clear in time
sbwhart
Cant thick of anything more useless than
clear markout dye
BR

I`ve not commented on the marking out colour........ It`s all been said before I`ve even thought of it........

BUT, after more than 50 years of using marking blue, engineers blue, always blue......
The thought of clear marking blue is hilarious.......

David.

Bernd · « **Reply #19 on:** February 19, 2009, 09:52:55 AM »

Ralph,

I've started to notice the more I write stuff the more little tricks I show that have never been seen or read about.

So, it looks like a small write up about the calibers and the us of a samll angle setting on the top slide to get a finer cut on the lathe is in order. I'll do that right after I finish this project.

Give me a

if nothing seems to be happening in that direction.

after some time has passed of course.

Bernd

bogstandard · « **Reply #20 on:** February 19, 2009, 11:22:10 AM »

David,

Part of my last job was printing, and the annaline inks that we used to use were meths based, and was exactly the same make up as marking out blue. For many years I used a bottle green one, then red, now all I have left is the normal blue. I found the green one was the best, hence it got used up first.
I knew I should have had a gallon bottle of each while it was available.
I suppose I will have to buy some one day.

Bernd,

If possible, in your posts, try to make the tips and tricks stand out by emphasising them. People always understand them better in a real life situation, rather than a set up explanation. Like my little sine tip to get the correct angle, showing how it is put to work in a real machining job.

BTW, do you use 5c collets?

If you do, this is another way to achieve what you are doing

http://littlemachineshop.com/products/product_view.php?ProductID=3190&category=

John

sbwhart · « **Reply #21 on:** February 19, 2009, 11:43:06 AM »

Hi Chaps

Bin hanging back on this one until I get back to work and check the facts out, we use galons of the stuff per week as a sealant make it up ourselves from Meths, Shellac and Caster oil with a die added for clour to diferentiate products, the colours we used was, blue, red, and green, but we've stopped using the red and green (I think but will check) as the die has been found canceragenic.

Stew

Bernd · « **Reply #22 on:** February 19, 2009, 06:23:27 PM »

Quote from: bogstandard on February 19, 2009, 11:22:10 AM

Bernd,

If possible, in your posts, try to make the tips and tricks stand out by emphasising them. People always understand them better in a real life situation, rather than a set up explanation. Like my little sine tip to get the correct angle, showing how it is put to work in a real machining job.

Good point. Have to rmember to do that next time.

Quote

BTW, do you use 5c collets?

You'd think with the size shop I have and the equipment that I have that I would own a set of collets. But I don't.

Why, becasue the Logan lathe uses those small 3C collets made by Hardage and the Bridgeport uses the Quick Change tooling. So I have no use for 5C YET.

Quote

If you do, this is another way to achieve what you are doing

http://littlemachineshop.com/products/product_view.php?ProductID=3190&category=

John

Call me cheap John. I guess I would rather do something like what I'm writing up than buy ready made. Kind of like using C-o-C verses 3D CAD to draw steam engines.

Bernd

bogstandard · « **Reply #23 on:** February 19, 2009, 06:27:37 PM »

Bernd,

I wasn't getting on at you about the tool holder, just informing the population that if they did have 5c, there is another method of doing it.

Before I got all my collets, I have been thru the exact process you are doing, to achieve the same goal.

John

Bernd · « **Reply #24 on:** February 19, 2009, 06:27:53 PM »

Quote from: sbwhart on February 19, 2009, 11:43:06 AM

but we've stopped using the red and green (I think but will check) as the die has been found canceragenic.

Stew

Scientist have disscovered that spit is caneragenic, but only if swallowed over a long period of time.

Bernd

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Author Topic: Making a Cutter Holding Block (Read 23460 times)

Baldrocker

bogstandard

bogstandard