I need to cut chamfers into x64 pieces of mild steel – any advice?

[John HaineParticipant @johnhaine32865]

Not many people on here will use laser cutting for small thicknesses – in fact I think the main ME use of external cutting services is of thicker material for things like loco frames. Even fewer would want a chamfer, so I think you are unlikely to get a personal recommendation. On the other hand a Google seach on laser chamfer cutting uk (without quotes) brings up about 538000 results, many of which may be companies that do chamfered laser cutting. A few emails or phone calls could confirm if they can do chamfering and how much a batch might be. This would get you results faster than hoping for a recommendation I suspect.

[John Smith 47Participant @johnsmith47]

Posted by John Haine on 30/09/2021 16:22:44:

Not many people on here will use laser cutting for small thicknesses – in fact I think the main ME use of external cutting services is of thicker material for things like loco frames. Even fewer would want a chamfer, so I think you are unlikely to get a personal recommendation. On the other hand a Google seach on laser chamfer cutting uk (without quotes) brings up about 538000 results, many of which may be companies that do chamfered laser cutting. A few emails or phone calls could confirm if they can do chamfering and how much a batch might be. This would get you results faster than hoping for a recommendation I suspect.

Sure. Interesting. I spent a while doing exactly that about 1 year ago, but they were all eye-wateringly expensive. In the end I got about 150 parts cost for less than £1 each but had to put the chamfers on myself. Hence this thread! Luckily my requirement this time is not urgent.

[Robert ButlerParticipant @robertbutler92161]

Moderators this topic has been aired ad nauseum without satisfactory conclusion and respectfully suggest the topic thread is closed

Robert Butler

[John Smith 47Participant @johnsmith47]

Posted by Robert Butler on 30/09/2021 17:03:49:

Moderators this topic has been aired ad nauseum without satisfactory conclusion and respectfully suggest the topic thread is closed

Robert Butler

 

Up to you. Does the existence of this thread cause inconvenience?

I have learned a lot, but if so I'm happy shut up.

 

Edited By John Smith 47 on 30/09/2021 17:14:35

[John HaineParticipant @johnhaine32865]

Might I just add a point. I have previously suggested that if the chamfer is essential to the operation of the invention then it would be the job of a production engineer to work out how to make them in volume. If it isn't essential then if manufacture proves difficult it would be best designed out I agree with Robert that this correspondence has gone round the houses in two versions without closure. The basic issue is that there is a simple and obvious way to make the things which is to use a milling machine but John doesn't have the resources or space for one that is suitable.

If this was the letters column of ME or MEW I suspect that the editor would long since have rule "this correspondence is now closed".

[John Smith 47Participant @johnsmith47]

Posted by John Haine on 30/09/2021 17:15:03:

Might I just add a point. I have previously suggested that if the chamfer is essential to the operation of the invention then it would be the job of a production engineer to work out how to make them in volume. If it isn't essential then if manufacture proves difficult it would be best designed out I agree with Robert that this correspondence has gone round the houses in two versions without closure. The basic issue is that there is a simple and obvious way to make the things which is to use a milling machine but John doesn't have the resources or space for one that is suitable.

If this was the letters column of ME or MEW I suspect that the editor would long since have rule "this correspondence is now closed".

John Haine to answer your points:

1. Yes, the chamfer is essential to the device. No, it can't be designed out.

2. No, the problem isn't manufacturing parts in medium/high volume – that is emphatically NOT a problem – the problem has been the generation of a smallish number of prototypes. I have already made about x10 prototypes and will probably need to make a further x10 or x20 before I'm through. Each product involves x16 small steel parts. No, that number can't be reduced.

3. Yes, I have now bought a milling machine. Yes, it does the job with the tool suggested. Moreover following advice in this thread I have also bought a more appropriate tool that will almost certainly work better. Further experimentation required.

4. Yes, following the advice here, I have also bought a disk/belt sander which now also does the job – (albeit after some heavy modifications to correct poor build quality) – quite a lot faster than my milling machine, albeit with quite a lot of ongoing skill being required to make each one correctly.

5. Yes, I have been evaluating the purchase of a compact but broadly more appropriate second hand milling machine, which has recently been suggested. Sadly £850 on a (second hand) machine will require careful thought, but I haven't completely ruled it out.

Although the main purpose of this exercise is to get this particular job done, an important part of the point of this exercise is for me to come out with some good general-purpose tools, both so that I can quickly and easily do some small fine-tuning iterations to the core designs, and also for use on future projects.

I remain extremely grateful for everyone's input into this thread and feel that I have learned a lot. However if this thread has been irritating anyone or causing inconvenience of any sort, I suggest you don't read it. If that is not an option, by all means go ahead and close it.

I am entirely happy to shut up at any point.

J

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