Lodge and Shipley, heavy turning

jakes_66

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Here's a project I thought might interest the L&S crowd. We don't get a lot of heavy machining projects like this anymore, but once in a while we fire up the old Model G 25/35 and the Model X.

The material: 15" dia 4140 QT, approx 41" long
2018-04-30 11.32.02.jpg 2018-04-30 14.10.21.jpg
The setup: Model G for machining the center for the tailstock
2018-04-30 14.48.13.jpg
Model X ready to do the finish turning.
2018-04-30 14.48.26.jpg
This project is in the shop as I'm typing. I'll post some more photos as the process goes along. I can't guarantee I'll catch every step, but I'll try!

Enjoy!
 

jakes_66

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Here's the center cut now. I switched cameras, so I hope these photos show some more detail.

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IMG_3197[1].JPG
 

jakes_66

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I'll wager that workpiece weighs something- what's it for?
Mark
It's the main input shaft for a large feed pellet extruder at one of the local poultry feed mills. The assistant shop manager tells me the electric motor is several hundred horsepower (I think he said 600?).

The mill plant manager says that electric motor uses more electrical power on startup than the average American household uses in a month...

:disillusion:

The workpiece weighs in around 2,100 lbs before machining. The reason for such a large piece is an attempt to solve a problem. We used to make a smaller shaft for them that got a flange welded, but that was not holding up. They have decided to try making the flange integral with the shaft.

$$$$$$$$$$$$

The taper roller bearing that installs on the one end of this shaft is $$$ 5 figures $$$
 

RandyM

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I see a huge pile of chips in your future. ;)
 

Ray C

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It's the main input shaft for a large feed pellet extruder at one of the local poultry feed mills. The assistant shop manager tells me the electric motor is several hundred horsepower (I think he said 600?).

The mill plant manager says that electric motor uses more electrical power on startup than the average American household uses in a month...

:disillusion:

The workpiece weighs in around 2,100 lbs before machining. The reason for such a large piece is an attempt to solve a problem. We used to make a smaller shaft for them that got a flange welded, but that was not holding up. They have decided to try making the flange integral with the shaft.

$$$$$$$$$$$$

The taper roller bearing that installs on the one end of this shaft is $$$ 5 figures $$$

All that to feed chickens! Wow!



FYI: Amazing that Sam's club sells roasted chickens for $5 each. BTW: The Sam's club in my area sells 600 chickens a day, M-F and about 750 per day Saturday and Sunday.

Ray
 

jakes_66

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Jay is the machinist doing the work. He has decades of experience and has been doing machine work since he was in the Airforce (working on a maintenance crew on F-100 Super Sabres when they were the newest fighter in the fleet).

Jay has been working here since 1971, he's old school and runs a tight ship. No nonsense, shows up every day and out-works most of our other employees.

IMG_3201.JPG
 

jakes_66

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Get that guy some duck boards, or a stall-mat at least.
Of the (2) machinists we employ, Jay does not like the mats. It baffles me that he can put up with that hard floor for hours everyday, but there are mats in front of every machine he does not normally operate. Flustered

 

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Tony Wells

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Good boots/tough feet or both lol. Jobs like where there is a large amount of material to come off I either find a stool to perch on, or once it's running well, I don't babysit it. I've done my share of heavy iron. The roughouts get kind of old.
 

markba633csi

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Too bad the video wasn't longer, but I'm guessing Jay doesn't like having folks watching over his shoulder :cool 2:
Mark
ps ask Jay if he wouldn't mind more video of the part being made- I'm sure a lot of us would enjoy seeing it
I know I would
 

Silverbullet

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Reminds me of the steel mill rollers we repaired , they were about 5' x 12" x 6" journals on each end. I must have machined a ton of weld off all those in the 70ts. Weld em up machine to size and repeat. It was work and happy to do it all over if I could. Love those lathes , nice shop.
 

BtoVin83

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We had a similar situation with a two piece crankshaft in a cement plant. They wanted one made from billet, we started with 24" 4140 about 10' long. We were cutting about 200 pounds per hour rouging it.
 

jakes_66

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This project is not in a rush. Jay has been working on it as other priorities permit. Today's progress includes lots of roughing as you can imagine.

 

jakes_66

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Here's the Model X doing the finish turning. Sorry for the delay, I was getting errors for a few days saying the server could not upload my images.

20180510_084245[4].jpg
20180510_084256[1].jpg

 

RandyM

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Here's the Model X doing the finish turning. Sorry for the delay, I was getting errors for a few days saying the server could not upload my images.
That problem was on our end and we believe that it has been resolved.
 
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