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Articles related to CNC Setup and Machining Techniques
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Shop made CNC lathe bar feeder/puller

March 12, 2013, 7:47 am by Eldar Gerfanov (Admin)

 

An attachment like this is sure to save you some time and money running your lathe unattended

And here is a sketch that i used to make it

drawing 136309494441101697049931.jpg Side view 136310728559201697049931.jpg Front view 13631072952201-631193174.jpg

One more way to Resharpen a chewed up endmill

March 10, 2013, 9:02 pm by Eldar Gerfanov (Admin)

Some time ago an unknown colleague had borrowed an end mill from me.

Have i had been there i would have stressed that it was aluminum specific cutter and that it should not be used on steel.
Unfortunately i was not and it did not occur to him to ask somebody who would have known better.

Next time i look into my drawer i see this.(first picture)

Now we have a tool and cutter grinder to sharpen the OD of an end mill, but chips were so big, i would have to grind off maybe 20 thou of the diameter on order to get rid of them.

Our TC grinder does not allow to re-flute end mills, so i had to do it holding end mill in my hands.

First i picked up correct angle, and then i slide end mill upwards, turning it at the same rate as to follow flutes.

It came out better than i thought.
I was not planing to use it for finishing anyway.

And it lost only 5 thou in diameter after this hack-regrinding.

Before 13628531447330.jpg during 13628543442911.jpg after 13628543295750.jpg

Shop-Made Toe Push Clamps

January 25, 2013, 12:34 am by Eldar Gerfanov (Admin)
dXBsb2Fkcy9JTUFHMDU0MC5qcGcuZmlsZTMyMHgyMDA=.jpg

Anybody could use a pair (or more) of push clamps around their shop.

Those handy devices convert your machine' table into a huge vise.
They are pretty mush irreplaceable when machining plates and other oversized parts that no ordinary vise will fit.

Several vendors offer their clamps. But many of them tend to be pricey. And those that are not, lack in quality.

And to be honest with you, it does not look like they are worth the amount of money their seller is trying to get from you.

In the mean time their design is simple enough to fabricate in any shop.

Here is a picture of two of four clamps i made for myself on manual mill withing 2 hours- sure beats buying mitee-bitees for 175$ a pop!!!

Made out of 5/8" thick D2 plate

1" long Shoulder in the front is tapped to 3/8-16 NC.

Slot for 1/2-13 bolt is sloped towards the back to prevent clamp from sliding under clamping pressure.

A thick 1/4" washer is used to protect T-slot from damage by the socket head.

I ll try to get more pictures tomorrow.

IMAG0540.jpg IMAG0540.jpg Drawing ROckerCLamp.png

Pictures of Nested Parts

December 9, 2012, 5:10 pm by Eldar Gerfanov (Admin)

Here are some samples of nested parts i did recently

In both cases back of all pieces were machined at the same time, dowel holes milled so that there would be a way to align top and bottom.

Ealot of material was lost, but it was a scrap anyways, so all i gained was alot of saved man-hours.

Photobucket

And here are 4 more pictures:

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What to do when you can not clamp it

September 27, 2012, 11:51 pm by Eldar Gerfanov (Admin)
IMAG0019.jpg

If you cant, then dont clamp it at all!.
Skin it!

In here i have to program and machine several sets of roundish aluminum pieces with +/-0.001" outside tolerance. and within 0.002" thickness repeatability.
Instead if fixturing it one by one i decided to skim cut a 33" x 23" x5/8" to within 0.0015 flat. And then machine each piece completely leaving .005" outside to holt everything together.

Worked out great. 

for pics

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Shop-made indexing fixture

September 27, 2012, 11:32 pm by Eldar Gerfanov (Admin)

Needed to do alot of side drilling/milling/tapping on our moulds lately.

So I quickly designed and whipped up this custom indexing fixture that allows me to mount almost anything to it.

Face plate has several tooling dowel holes on front side to locate work piece.
On the back of face plate there are 36 3/8 dia reamed holes spaced 10 Degree apart.

Housing has a big 5.0"Dia pocket in the front into which the face plate's hub fits in with 0.001" clearance
Housing also has corresponding 3/8dia reamed holes spaced apart 9 degrees. This allows me to index the face plate with 1 degree increment.

Design time:2 hours, Machining time: 2 hours.

Pictures are here:

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FS Wizard: Dormer Drill test on T6061 Aluminum

April 23, 2012, 7:22 pm by Eldar Gerfanov (Admin)

As part of FS Wizard's development. 2 drills were tested today on T6061 Aluminum.

0.312 Dia and 0.390 Dia Dormer A002 Drill Jobber Drill with TiN coated tip.

Helix:30Deg

Point:Split, 118Deg.

Hole depth for both was 3.0"".

Peck equaled 1xDia

Speeds and Feeds for 0.312 Dia drill were

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Drilling Hardox 500 55RC: 0.281 dia .75 deep

April 20, 2012, 12:47 am by Eldar Gerfanov (Admin)

Tool:0.281 dia 0 helix TIN coated carbide drill

Peck:0.125

Coolant: Air

RESULT
SFM: 49 f/min
RPM: 663
APT:  0.00070 in/rev
Feed: 0.93 in/min
MRR: 0.1 in^3/min
HP: 0.2
Torque: 19.4 in-lb
Max Torque: 22.9 in-lb

 

Test of NIAGARA 3FL HP End mill for Aluminum

February 27, 2012, 10:02 pm by Eldar Gerfanov (Admin)

Recenty ordered a 3Flute High Performance End Mill From NIAGARA.
Was very glad and slightly surprised that when punched in all of the endmill's data into my Calculator nothing broke down.I had a rason: At 5000RPM and 3/8" Deep slot cut. The feed came to around 92.0IPM. Chips were making this nice ringing noise that sounds like money.

Setup:
HAAS VM-3
Hudrolic Tribos Holder
3/4" 45DegHelix 3Flute 1.625FluteLen, 2.375"Overhang TICN HP End mill

S:5000RPM
F:92.0IPM
DOC: 0.375" Slotting
Coolant:FLOOD

The calculation was pretty much dead on.

Tapping Hardox Rc 45-50

February 27, 2012, 9:43 pm by Eldar Gerfanov (Admin)

A need arouse to drill and tap lots of blind 1/4-20 holes in 3/4" thick hardox 45-50RC hard plate.

So if you ever need to do this use:

1) DRILL
Tap hole: >0.202" or bigger.  5/8 deep.
Drill used: Tialn coated carbide drill.
S=1418 RPM
F=2.6 IPM
NO Peck, No Coolant

2)TAP

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