cylinder head milling machine indexable cutters

I made another attempt at carbide insert cutters for my friends Van Norman rotary broach today.
these 12 cutters use 10mm round high relief cutters (2 are spares)
we will try them tomorrow morning
steve

DSCF0584.JPG DSCF0587.JPG DSCF0588.JPG DSCF0606.JPG DSCF0608.JPG
 
today i went to install the new cutters and my friend had a new set of factory matched cutters there also ($300)
we installed mine first and they cut really well on high speed except an odd pattern in the finish, you could not feel it but it was visable. the slow cut was really good but takes 40 minutes.
i was too curious so i installed the factory cutters, they did not do as well as mine on fast or slow but i kept noticing the same pattern still. so checking the machine further i found a chunk out of the drive belt. i put a new belt on and the pattern was gone but the finish is still not as good as my set i made. the round inserts do a lot better on aluminum with the high rake angle. the speed of the cutter head is still too slow for a really good finish on aluminum so the last thing i'm going to add is another set of pulleys to move the head speed up 4x and bring the slow cut speed down to 10 minutes add mist coolant and i should be dont. i'll post finish pics when done. then he just flips the lever and changes the belt to switch from cast to aluminum. as far as my friend is concerned he is happy now but i know i can make it better with a little more work.
at least the cutter problem is solved and a new set of inserts from mitsubishi are $20 including shipping.
there isnt much interest in this topic but for me it wasnt fixing the machine as much as making 12 holders exactly the same. I'm not a machinist so making something perfectly the same was the challenge them working as I designed them to was nice also. i got a lot better understanding of cutter geometry that i could have never gotten without a friend who is himself an automotive machinist, trusting me a novice to fix his machine.
steve
 
today i went to install the new cutters and my friend had a new set of factory matched cutters there also ($300)
we installed mine first and they cut really well on high speed except an odd pattern in the finish, you could not feel it but it was visable. the slow cut was really good but takes 40 minutes.
i was too curious so i installed the factory cutters, they did not do as well as mine on fast or slow but i kept noticing the same pattern still. so checking the machine further i found a chunk out of the drive belt. i put a new belt on and the pattern was gone but the finish is still not as good as my set i made. the round inserts do a lot better on aluminum with the high rake angle. the speed of the cutter head is still too slow for a really good finish on aluminum so the last thing i'm going to add is another set of pulleys to move the head speed up 4x and bring the slow cut speed down to 10 minutes add mist coolant and i should be dont. i'll post finish pics when done. then he just flips the lever and changes the belt to switch from cast to aluminum. as far as my friend is concerned he is happy now but i know i can make it better with a little more work.
at least the cutter problem is solved and a new set of inserts from mitsubishi are $20 including shipping.
there isnt much interest in this topic but for me it wasnt fixing the machine as much as making 12 holders exactly the same. I'm not a machinist so making something perfectly the same was the challenge them working as I designed them to was nice also. i got a lot better understanding of cutter geometry that i could have never gotten without a friend who is himself an automotive machinist, trusting me a novice to fix his machine.
steve

Picture's worth a thousand words etc. I now understand what you're doing much more clearly.


M
 
Very nice cutters. From your first post I figured you were working on either the Van Norman or a Storm Vulcan.
I have the Storm vulcan 85 with variable speed drive added for head trasit.
Slowing the trasit speed way down does a good job on aluminum but takes a long time so I am very interested in how the 4x speed works on aluminun.
A different set of pullys on the Storm vulcan could probably be used to speed the cutter up. If it has the power to handle that....the 3pz motor is huge but rated 2 hp.

I your guy using alumicut spray or beeswax on the aluminum?

I use beeswax.....mostly in an attemt to keep a piece of aluminum from sticking to a cutter and leaving a mark in the surface.
 
thanks for your interest
he has read about using pledge spray wax but we have not tried it yet. now that i have the cutter issue and cheap inserts resolved we are moving on to feeds and speeds and mist coolant.
I have also come up with a system to feed the cutter seperate from the cutter rotational speed with a servos motor to feed the table. total investment to try the servo motor, belt and pulleys and all will be about $200 and it is a new 3/4hp reversable variable speed 0-3600 so it is worth doing. then all the belt change will do is increase the cutter rotational speed. the servo motor will arrive on the 2nd and we will build it then.
steve
 
Hey tony I as well have a van Norman broach. Are you willing to fabrcate and sell me some bit holders?
 
That's not me, that's jumps making the cutter inserts. Maybe he would be interested. I've just offered a few comments here.
 
You can send him a PM through our system here, or perhaps he will respond to this thread and contact you. He hasn't been here for a couple of weeks though, so if he doesn't respond promptly to a PM from you, I will send an email to him on your behalf.
 
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