2014 POTD Thread Archive

A long boring job, rough out the pocket the gear case for my Z-axis CNC conversion. Not really very interesting.

I should have used a bigger end mill to rough it out, took a long time, but I used what I had. It took about 1 hour per pass, at 0.125 deep and 6.5 IPM, 1600 RPM with a 0.5 roughing endmill. I think it would have taken more depth, but I didn't want to chance breaking a $35.00 endmill. Using WD-40 in my home brew mist coolant system, the red pressure tank, just visible on the left. I'll do a write up on the coolant system one of these days. WARNING: Do not pressurize flammable liquids with air, it can explode!! (like I'm doing here, but then I'm half crazy anyway.)

The nice thing was: No chatter, even when profiling at the full depth of about 1 1/4 inches to finish out the inside. I had my spindle rebuilt by C & M PRECISION SPINDLE, INC. I am very happy with the job they did.

Converting a perfectly good piece of aluminum into chips

gearcasepocket1.jpg

After pocketing to depth, I took a light cut around the outside profile to check the position of the clamps, don't want to run the cutter into them.
An interesting visual effect in the pocket bottom, it looks rough in the picture, but it is as smooth as a baby's behind.

gearcasepocket2.jpg

Next is to pocket the shaft holes..... stay tuned for more!
 
today I finished my cnc lathe, installed the ball screw covers.
the test part I cut was the first inside tread I have ever done on any lathe. It came out perfect on the cnc lathe.
I also installed a high speed spindle on my zx45 cnc mill. I haven't tried it yet.
steve

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Today I built a spider fixture so I could machine the fuel rails off my boat engines. It's an oddball shape that had to be bored, faced and threaded on one end.
After suspending the fuel rail in the spider I got it dialed in and one fuel rail machined.
One down, one to go.

The first shot shows the fuel rail that had to be bored, faced and threaded. (part to be machined is on right end)
The second shows the spider built out of black iron 3 inch pipe. There are 2 sets of 4 bolts @ 90 degrees holding the fuel rail so it can be dialed in.
The last is the finished end. After the parts are anodized, I'll make the matching male fitting out of brass.
Ed P

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I agree with Marco on this. It does look like a dachshund and its a very cool set up. Thanks for posting. I can see using this idea in the future.

Jeff
 
Engine on the fly. Two cylinders, and block made. May never run, but the pieces go together.


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epanzella said:
Today I built a spider fixture so I could machine the fuel rails off my boat engines. It's an oddball shape that had to be bored, faced and threaded on one end.
After suspending the fuel rail in the spider I got it dialed in and one fuel rail machined.
One down, one to go.

The first shot shows the fuel rail that had to be bored, faced and threaded. (part to be machined is on right end)
The second shows the spider built out of black iron 3 inch pipe. There are 2 sets of 4 bolts @ 90 degrees holding the fuel rail so it can be dialed in.
The last is the finished end. After the parts are anodized, I'll make the matching male fitting out of brass.
Ed P
Click to expand...


How did you dial in the chuck end of your part?
 
outsider347 said:
How did you dial in the chuck end of your part?
Click to expand...
I centered both ends as close as I could with calipers on the bench. When I built the fixture I made sure there was enough clearance to chuck it on either end. I put the fixture in the lathe with the dead end out so I could dial it in. Then I reversed the fixture so I could dial in the end I needed to machine. I wasn't too fussy on the dead end (.005) as I figured it was 14 inches away from the action. I got the business end down to .001 because of the thin wall on one side.
 
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