Bearing Housing for Griffin

[Matt-Aburg]

Finishing operation # 2

This is done on a fixture. I am thinking about re-investing my pay form this job into 4 more billets and 1 new fixture plate that will cut 2 at once....

Anyway here is the almost finished product. I have side, end, and other holes to go in. Toughest will be the 6 deep 0.500 ream. I am thinking about getting my friend with real CNC's to help me out on the deep drilling....

This operation entailed using a band saw to begin with. I am strongly thinking about employing it on setup 1 also to keep the solids.
Next I finished the pockets .
Rough, finish.... etc... This is going to change on V3 to rmove time.... I found that roughing on the router is wayyyyy faster. I can feed 1/8 deep 0.4 wide with a 3/4 endmill at 60 inch / minute... not to mention the 400 IPM rapid.

Also note my social distancing screens. These add a layer between me and a shattering 6000 RPM carbide endmill. It also keeps the chips better contained. These can still be bought, for a short while, since Covid is mostly over...

https://www.amazon.ca/Mobile-Shield-Plexiglass-Distancing-Divider/dp/B08KWHKVDQ?pd_rd_w=08oXg&content-id=amzn1.sym.ccd66d6a-fd89-4716-b3af-012410ff4aa9&pf_rd_p=ccd66d6a-fd89-4716-b3af-012410ff4aa9&pf_rd_r=HCGSJJY0A7TJQGBN7KMV&pd_rd_wg=8WzzC&pd_rd_r=d8dfb262-bbf6-4d1a-8e58-1850a0cbccfd&pd_rd_i=B08KWHKVDQ&psc=1&ref_=pd_bap_d_grid_rp_0_1_i

 

[phaxtris]

So shiny!

 

[Matt-Aburg]

I decided to re-invest my pay to make 2 more sets. This time I am going to use the Bandsaw more on setup 1. I will not be trying to finish in two setups from top and bottom, because the matching is impossible with my equipment. I will surface cut top and bottom, but not wrap the radii until the sides operations. I have to bump the sides anyways now to get rid of the missmatch. I also have holes to put in both sides and one end... so a total of 5 ops.

Here are my billets!!!!!

 

[Matt-Aburg]

Yesterday and today I decided to move forward with the sleeve bushings. Both lathes are down right now, but I need to show progress. These parts are roughed side 1. I finished all heights, but left stock on OD and ID for finishing. I will be fixturing up now to continue roughing side 2. Total time to rough, and semi-finish is 45 minutes each.

 

[Matt-Aburg]

I have moved the bushings along. The OD's and long ID were completed yesterday. Note that I am using boring head on both OD and ID.... I also completed the tooling required to cut side 2. That will be a continuation. For now, progress is moving along. Improvising without the lathes working.... still need to get this job done and delivered on time.

 

[Janger]

DINE fine boring head

Matt - great project and posts. A few questions of course.
You have Cnc so I’d like to know your thinking on using a boring head. better concentricity? will that give better results than say a 3/4” EM with a boring op and then a spring pass? the casting has a bunch of paper(?) marked holes. what are those?

 

[Matt-Aburg]

Matt - great project and posts. A few questions of course.
You have Cnc so I’d like to know your thinking on using a boring head. better concentricity? will that give better results than say a 3/4” EM with a boring op and then a spring pass? the casting has a bunch of paper(?) marked holes. what are those?

Boring is necessary for two reasons. First is surface finish, Circular interpolation leaves little steps, bumps. I am showing a extremely blown up picture to show you. Bottom diameter is clearance dia... so circular is good enough. Note the difference.

Second, is to control the size and location 100 percent. I clock the hole and bore finished so everything is aligned. Also, the top bores on both sides are most critical. I did buy a Dine FBH for use on the Router. I have not got there yet. The convention boring head for the Bridgeport you see is only running 85 RPM with a feed-rate of 0.75 IMP. I had to buy a Dine system to be able to spin at least 1000 RPM on the router... This is coming up soon... I just roughed second side and have a few little details before it goes to the next part. So far, 1 hour to rough side 2. I will be boring the OD also for side 2... Future, much will be lathe, with Dine only for finish bore (critical sub micron level).

What you see on the casting are markers for the 3D scanning I did to reverse engineer this product.

 

[Matt-Aburg]

I never did put the scan data up. I made a V1 of the part that was very close to the scanned part. On V2, I changed it with approval to make manufacturing more friendly.

 

[Matt-Aburg]

I have semi finished side 2 of the sleeve bushings. I will need to outside bore the long OD and then finish bore the critical ID;s with the micron capable Dine boring head. I have a much better fixturing solution on its way... Note to my education... finish boring the fixture in a vice was incorrect. It became oblong after releasing the vice. For roughing fixture... I ended up opening it by a couple thou...

 

[Matt-Aburg]

I am onto making the next group. I still have side an end operations on the first two. I am hoping to really pull ahead with these and get the deep drilling (6 inch deep x 0.500 ream) over to my friend with 3 CNC's next week. I would like to do all 6 pieces while the fixture is up on his machine. He is not busy so time to get her done.

On these photos, I have used a bandsaw to take off 10 pounds of each block. I also put in starter hole on the drill press. Here are the 4 pieces lined up.

 

[PeterT]

I never did put the scan data up.

What kind of scanner/app was used? It looks like industrial strength stuff.

 

[Matt-Aburg]

What kind of scanner/app was used? It looks like industrial strength stuff.

The scanning was done with a Creaform scanner. The images are of the imported scans brought into the design platform I use.

 

[PeterT]

Thanks, often times I see the object in a purple blue color. Is that some kind of spray on detection coating or the beam itself or..?

 

[Matt-Aburg]

Thanks, often times I see the object in a purple blue color. Is that some kind of spray on detection coating or the beam itself or..?

View attachment 30533

Purple blue is the color of the laser or structured light (depending on type). That scanner in your picture is a laser scanner,

 

[Matt-Aburg]

Two machines at once... It is very noisy out in the shop.

 

[PeterT]

Maybe you mentioned elsewhere but what CNC system are you running on the Bridgeport/clone? Did you do the stepper/conversion yourself?

 

[Matt-Aburg]

Maybe you mentioned elsewhere but what CNC system are you running on the Bridgeport/clone? Did you do the stepper/conversion yourself?

The Bridgeport clone came in already modified from CNC Masters out of sunny California. This machine is called the "Supra". I bought that machine about 12 years ago. It is a bit slower that the router, but it can cut steel. The control is their software on a dedicated computer just for it.

 

[Matt-Aburg]

New Fixture for side # 2

I am making a new fixture to suit the router table. The other one was made for the Supra mill, and is too thick. I need to thin down on my setup or I am limited to short tools. I am going to start the back in a moment. The front will be completed while attached directly to the table.

 

[Matt-Aburg]

I am 1 part away from completing the 6 total housings. I still have the sleeve bushings to continue after, with new tooling and using the DINEX boring system (on the router).

Here is the one I finished yesterday. I ran the final program starting at 1:30 am till ??? (because I turned the lights out and went to bed !). This is by far the best one so far. I changed up how I was finishing the top slightly angled surfaces. Now I bump them at a 0.02 step over with a 0.500 ball cutter... Very little handwork required on this part. I hope the one that's being machined ends up the same, so my customer will get them on time (a slight dusting required).

I have made these pictures in order to show what is done on each operation.

 

[Janger]

The ball mill finishing made it look great Matt. They're not paying you enough that's for sure. :> but that's not entirely why you're doing this! Labour of love clearly.

Show us another picture of the fixture without the part? I don't follow how it works.