Ognibs other deuce

[Ognib]

Swapped out the centering device for a drill bit & bored the center hole for the part.

Then swapped the drill chuck for a collet & cutter bit & started rounding off the corners.
I'm getting a beautiful polished sheen to the machined surfaces...dig it!!...light cuts & moderate feed rate, as I begin to get a feel for the machine & it's capabilities & limitations.

[Ognib]

I can't get in there with my calipers to read the wall thicknesses.

Eyeballin it says that both sides are close to being the same thickness.
This tells me that my setup was pretty tight & well lined up.

Probably not rocket science tight...but I'm ok with it for my first attempt.

[LaughingIndian]

Congrats on the rig Ray ... I can feel your enthusiasm way over here          .... 

 

[Twokidsnosleep]

Really cool, I am excited for you too you are dealing this in to perfection

Just remember to keep safe and wear some eye protection. Stupid things happen really quickly, especially when one is excited about a new tool...don't ask me how I know

[Ognib]

Thanks, guys.

Scott, eyes covered & full face on top of that.

I worked in metal shops all my life & have had metal chips dug out of my eyes on a couple of occasions.

Not fun at all!!

 

[Ognib]

Time to source some small bits for drilling the bolt holes...also need to order a slitting saw blade & arbor to separate the part from the stock.

I can see it's not perfectly concentric around the bore...it's ok for my first piece...aaand there'll be a brake rotor in front of it, sooo...
But do need to tighten up my setup skills.

[Ognib]

Took the part off the machine so I could get on it with the caliper.

At one point, the wall thickness on one side is .010" greater than is the wall across from it.

Going to set up the dial indicator again & start at the bottom...re-read everything...get the setup tightened up to where I want it.

Ordered a slitting saw & arbor, yesterday.

[Ognib]

I jigged up another block & found the results I got...interesting.
Both blocks cut from the same piece of stock.
Both shaped with the same bit.

By the time I got this far on the second piece, the quality of the finish had deteriorated to the point that there is galling & actual shards of aluminum stuck to the sides of it...almost like the material is being torn rather than cut.

Talked to a guy I know in the trade & he made a couple of suggestions.
Going from a 3 flute bit to a 2 flute...stepping up in size to a 1/2" bit...trying carbide vs hss.

It's interesting, the amount of thought as well as the type of thought that has to go into successful results in this type project!
Diggin it!!

[Ognib]

I'm becoming aware that a significant part of becoming a good machinist is learning to do a good tight setup.
I've read where guys will say they frequently spend more time in setup than they do in the actual machining process.

I'm ordering this today.
It will allow me to move in & do my setup off of the inner bore of each of the fixtures rather than the outside diameter...closer to the center line...runouts should be smaller...allowing a tighter setup...

Diggin the learning process.

[Ognib]

Added another dial indicator to the collection.This one has a lever activator which allows me to reach into & read runout on the center bores of my rotating fixtures.

Has a slick dovetail mount...nice.

 

[Ace-Garageguy]

I'm becoming aware that a significant part of becoming a good machinist is learning to do a good tight setup.
I've read where guys will say they frequently spend more time in setup than they do in the actual machining process.

Exactly. 

And try to keep your measuring rig as simple and short as possible. The object is to keep it entirely rigid. If the measuring setup can move at all in relation to the work, all the measuring in the world is useless.

[Ognib]

Good advice, Bill.  Thanks. 

Sometimes I find I overlook the obvious...

Rigid now.

 

[Ognib]

I spent 2 full days on the setup...measure 14 times, cut once...you know...

Cut another hub. Happy with this one. Average on the total runout is .0015.

Learned some stuff.

Got the bolt hole positions dimpled with a centering bit.

[Twokidsnosleep]

Ahh cool

the blue contrast marking is smart, now I see what you are making 

[Ognib]

Ya, first usable part. 

 

Drill chuck on the machine won't secure the small bit for the bolt holes.
Have to drill those with the dremel.

Need 2 more just like this one.

[Ognib]

 

[Ognib]

Progress.

[Twokidsnosleep]

Nice SWARF!!!

 

[Ognib]

 

  subtle insight into whats actually going on here...

[Ognib]

Got this plug squared up & faced on both ends for consistant seat in the chuck & for a smooth surface for layout work.



Finally, I'm back on these pieces that I tried, unsuccessfully, to cut on the drill press last summer.

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Edited June 23, 2016 by Ognib

[Ace-Garageguy]

Ah, this is fun to watch. The QC is coming along nicely. 

[Ognib]

 

Practice makes better, Bill.

Interesting...there's a pattern in the metal but when I run a finger over it, can't feel anything...just smoooth.

[Twokidsnosleep]

Watching in awe

[Codi]

Ray, you might setup a shop vac and point the nozzle close to your work piece while your machining.  It will help keep the mess down and make clean up much easier for you while drawing air across the work piece which has some additional benefit. I took that tip immediately from Dave and have used it ever since.  cheers, tim

[Ognib]

Good Idea Tim, thanks.

Also going to find a larger cardboard box & set up a containment wall that'll help keep the mess localized.

Also want it to cover the vertical dovetail & keep it clean while in use.

 

So far I've been going in circles.

Watched a guy cut a set of chess pieces on an old school manual machine...spinning all the knobs at the same time, freehand...impressive.

I've been visualizing similar techniques regarding some of my pieces that are odd shapes.

Thought I'd give the back cover for the QC a whirl using the X & Y tables along with the rotary table.