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Edmonton- Small lathe/milling work; Advice, insight, recommendation?
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<blockquote data-quote="John Conroy" data-source="post: 44247" data-attributes="member: 56"><p>Andrew dropped off the armature, sun gear, snap ring and key for me yesterday. I got at the job this afternoon. First I had to grind a HSS tool to cut the snap ring groove. They are only .029" thick so I ground a 1/4" blank to .030" wide and have 1 degree rake on all the faces and tested it on a piece of cold rolled scrap and it cut well. I was happy as I've never ground a cutter this small before, it was a test for my eye sight.</p><p></p><p><a href="https://johnconroy.smugmug.com/Metal-working-projects/n-K3vBdX/i-CCnSPXg/A" target="_blank"><img src="https://photos.smugmug.com/photos/i-CCnSPXg/0/381d534e/XL/i-CCnSPXg-XL.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></a></p><p></p><p><a href="https://johnconroy.smugmug.com/Metal-working-projects/n-K3vBdX/i-QDMT3kn/A" target="_blank"><img src="https://photos.smugmug.com/photos/i-QDMT3kn/0/8e85dc03/XL/i-QDMT3kn-XL.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></a></p><p></p><p>I wanted to mount it in a 4 jaw so I made some copper shims from 1/2" pipe to prevent marring the shaft.</p><p></p><p><a href="https://johnconroy.smugmug.com/Metal-working-projects/n-K3vBdX/i-kc8Std2/A" target="_blank"><img src="https://photos.smugmug.com/photos/i-kc8Std2/0/25c93d3f/XL/i-kc8Std2-XL.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></a></p><p></p><p><a href="https://johnconroy.smugmug.com/Metal-working-projects/n-K3vBdX/i-GRLgfbW/A" target="_blank"><img src="https://photos.smugmug.com/photos/i-GRLgfbW/0/de45c398/XL/i-GRLgfbW-XL.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></a></p><p></p><p><a href="https://johnconroy.smugmug.com/Metal-working-projects/n-K3vBdX/i-QQKczKL/A" target="_blank"><img src="https://photos.smugmug.com/photos/i-QQKczKL/0/d9d6450e/XL/i-QQKczKL-XL.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></a></p><p></p><p><a href="https://johnconroy.smugmug.com/Metal-working-projects/n-K3vBdX/i-CxzLNht/A" target="_blank"><img src="https://photos.smugmug.com/photos/i-CxzLNht/0/fa03223a/XL/i-CxzLNht-XL.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></a></p><p></p><p>The original shaft OD was .375 and the ID of the new gear is .355 so there was not much to take off. My goal was a hand push interference fit and it took quite a while to get that, the last .0003" removed with 400 grit sand paper. the groove cutter worked flawlessly and I cut the 2 grooves to .045" smaller OD than the shaft OD.</p><p></p><p><a href="https://johnconroy.smugmug.com/Metal-working-projects/n-K3vBdX/i-4qZTkz7/A" target="_blank"><img src="https://photos.smugmug.com/photos/i-4qZTkz7/0/ad9fd832/XL/i-4qZTkz7-XL.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></a></p><p></p><p><a href="https://johnconroy.smugmug.com/Metal-working-projects/n-K3vBdX/i-2jfPqq5/A" target="_blank"><img src="https://photos.smugmug.com/photos/i-2jfPqq5/0/b7141610/XL/i-2jfPqq5-XL.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></a></p><p></p><p>I parted the shaft off at the end of the original key slot.</p><p></p><p><a href="https://johnconroy.smugmug.com/Metal-working-projects/n-K3vBdX/i-jbm6KQx/A" target="_blank"><img src="https://photos.smugmug.com/photos/i-jbm6KQx/0/d9c6998c/XL/i-jbm6KQx-XL.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></a></p><p></p><p><a href="https://johnconroy.smugmug.com/Metal-working-projects/n-K3vBdX/i-Sd3jWqF/A" target="_blank"><img src="https://photos.smugmug.com/photos/i-Sd3jWqF/0/a5f8b1d5/XL/i-Sd3jWqF-XL.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></a></p><p></p><p>Then over to the mill where I used 3/32" end mill to cut the 3mm key slot.</p><p></p><p><a href="https://johnconroy.smugmug.com/Metal-working-projects/n-K3vBdX/i-LPN5ZdG/A" target="_blank"><img src="https://photos.smugmug.com/photos/i-LPN5ZdG/0/8dadd9c0/XL/i-LPN5ZdG-XL.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></a></p><p></p><p><a href="https://johnconroy.smugmug.com/Metal-working-projects/n-K3vBdX/i-ZtnkSjq/A" target="_blank"><img src="https://photos.smugmug.com/photos/i-ZtnkSjq/0/07975ad7/XL/i-ZtnkSjq-XL.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></a></p><p></p><p>The magnets are so strong that you almost don't have to clamp it in the vise, it just sticks there.</p><p></p><p><a href="https://johnconroy.smugmug.com/Metal-working-projects/n-K3vBdX/i-BkG8LxS/A" target="_blank"><img src="https://photos.smugmug.com/photos/i-BkG8LxS/0/ea822ac1/XL/i-BkG8LxS-XL.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></a></p><p></p><p><a href="https://johnconroy.smugmug.com/Metal-working-projects/n-K3vBdX/i-mwccvxB/A" target="_blank"><img src="https://photos.smugmug.com/photos/i-mwccvxB/0/55338db4/XL/i-mwccvxB-XL.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></a></p></blockquote><p></p>
[QUOTE="John Conroy, post: 44247, member: 56"] Andrew dropped off the armature, sun gear, snap ring and key for me yesterday. I got at the job this afternoon. First I had to grind a HSS tool to cut the snap ring groove. They are only .029" thick so I ground a 1/4" blank to .030" wide and have 1 degree rake on all the faces and tested it on a piece of cold rolled scrap and it cut well. I was happy as I've never ground a cutter this small before, it was a test for my eye sight. [url=https://johnconroy.smugmug.com/Metal-working-projects/n-K3vBdX/i-CCnSPXg/A][img]https://photos.smugmug.com/photos/i-CCnSPXg/0/381d534e/XL/i-CCnSPXg-XL.jpg[/img][/url] [url=https://johnconroy.smugmug.com/Metal-working-projects/n-K3vBdX/i-QDMT3kn/A][img]https://photos.smugmug.com/photos/i-QDMT3kn/0/8e85dc03/XL/i-QDMT3kn-XL.jpg[/img][/url] I wanted to mount it in a 4 jaw so I made some copper shims from 1/2" pipe to prevent marring the shaft. [url=https://johnconroy.smugmug.com/Metal-working-projects/n-K3vBdX/i-kc8Std2/A][img]https://photos.smugmug.com/photos/i-kc8Std2/0/25c93d3f/XL/i-kc8Std2-XL.jpg[/img][/url] [url=https://johnconroy.smugmug.com/Metal-working-projects/n-K3vBdX/i-GRLgfbW/A][img]https://photos.smugmug.com/photos/i-GRLgfbW/0/de45c398/XL/i-GRLgfbW-XL.jpg[/img][/url] [url=https://johnconroy.smugmug.com/Metal-working-projects/n-K3vBdX/i-QQKczKL/A][img]https://photos.smugmug.com/photos/i-QQKczKL/0/d9d6450e/XL/i-QQKczKL-XL.jpg[/img][/url] [url=https://johnconroy.smugmug.com/Metal-working-projects/n-K3vBdX/i-CxzLNht/A][img]https://photos.smugmug.com/photos/i-CxzLNht/0/fa03223a/XL/i-CxzLNht-XL.jpg[/img][/url] The original shaft OD was .375 and the ID of the new gear is .355 so there was not much to take off. My goal was a hand push interference fit and it took quite a while to get that, the last .0003" removed with 400 grit sand paper. the groove cutter worked flawlessly and I cut the 2 grooves to .045" smaller OD than the shaft OD. [url=https://johnconroy.smugmug.com/Metal-working-projects/n-K3vBdX/i-4qZTkz7/A][img]https://photos.smugmug.com/photos/i-4qZTkz7/0/ad9fd832/XL/i-4qZTkz7-XL.jpg[/img][/url] [url=https://johnconroy.smugmug.com/Metal-working-projects/n-K3vBdX/i-2jfPqq5/A][img]https://photos.smugmug.com/photos/i-2jfPqq5/0/b7141610/XL/i-2jfPqq5-XL.jpg[/img][/url] I parted the shaft off at the end of the original key slot. [url=https://johnconroy.smugmug.com/Metal-working-projects/n-K3vBdX/i-jbm6KQx/A][img]https://photos.smugmug.com/photos/i-jbm6KQx/0/d9c6998c/XL/i-jbm6KQx-XL.jpg[/img][/url] [url=https://johnconroy.smugmug.com/Metal-working-projects/n-K3vBdX/i-Sd3jWqF/A][img]https://photos.smugmug.com/photos/i-Sd3jWqF/0/a5f8b1d5/XL/i-Sd3jWqF-XL.jpg[/img][/url] Then over to the mill where I used 3/32" end mill to cut the 3mm key slot. [url=https://johnconroy.smugmug.com/Metal-working-projects/n-K3vBdX/i-LPN5ZdG/A][img]https://photos.smugmug.com/photos/i-LPN5ZdG/0/8dadd9c0/XL/i-LPN5ZdG-XL.jpg[/img][/url] [url=https://johnconroy.smugmug.com/Metal-working-projects/n-K3vBdX/i-ZtnkSjq/A][img]https://photos.smugmug.com/photos/i-ZtnkSjq/0/07975ad7/XL/i-ZtnkSjq-XL.jpg[/img][/url] The magnets are so strong that you almost don't have to clamp it in the vise, it just sticks there. [url=https://johnconroy.smugmug.com/Metal-working-projects/n-K3vBdX/i-BkG8LxS/A][img]https://photos.smugmug.com/photos/i-BkG8LxS/0/ea822ac1/XL/i-BkG8LxS-XL.jpg[/img][/url] [url=https://johnconroy.smugmug.com/Metal-working-projects/n-K3vBdX/i-mwccvxB/A][img]https://photos.smugmug.com/photos/i-mwccvxB/0/55338db4/XL/i-mwccvxB-XL.jpg[/img][/url] [/QUOTE]
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Edmonton- Small lathe/milling work; Advice, insight, recommendation?
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