[Project 5] Low Profile Table Clamps

[oldveloParticipant @oldvelo]

Hi

Fly cutter with the tool stuck out flailing a large radius on a small width workpiece NBG on a gear drive train.

Keep the diameter of the cutting circle just a fraction wider than the job when flycutting to minimize the torque load on a chattering gear chain. Belt drive is infinitely smoother running on intermittent cutting

Three toolbits mounted on 52 mm cutting head will cut faster with one bit starting the cut and the previous one exits.

Setting up is a breeze take out the clamp bolt and fix the setup jig in its place to get all the tips equal by installing the toolbits to sit on the jig and do up the clamp screws.

Sharpen dull HSS tips with an oilstone for longer life and almost mirror finish.

[Lee Jones 6Participant @leejones6]

I do not currently have any plans to make new fly cutters.

In fact, I'm only using (playing really) this one until the new carbide inserts for my face mill arrive.

Not sure I can get any less stick-out than I already have. Maybe 5mm, but I've seen SO a lot further than mine.

Incidentally I have noticed a small flat spot on the base of my cutter. I think my grind needs to be improved.

[Ron LadenParticipant @ronladen17547]

Well done Lee, good that you have got a better finish. I am not used to the sound of your machine of course but the 600 rpm cut didn't sound that bad to me, sounded better than the slow cuts I thought.

Ron

[Lee Jones 6Participant @leejones6]

Recording on the mobile phone doesn't seem to pick-up the banging sound, which is a shame.

[Lee Jones 6Participant @leejones6]

Jason,

When cutting a shoulder, did you say it was better to come in from the side?

I have Harold's 'Milling A Complete Course' and he seems to suggest chewing away 2mm coming top down.

[JasonBModerator @jasonb]

I would indeed come in from the side so that you get to use more of the flutes otherwise you are just wearing the end of the cutter. That's for a HSS or carbide 2, 3 or 4 flute cutter, the facemills seem to work better the other way round on my machines.

Edited By JasonB on 26/05/2020 13:06:26

[Lee Jones 6Participant @leejones6]

Mmmm… Pretty!

[Martin ConnellyParticipant @martinconnelly55370]

I think fly cutting with HSS bits at RPM that result in a higher than recommended surface metres per minute are benefiting from air cooling over most of the revolution. Just to show that slower RPM with correct feed works here is an example. This is a piece of scrap hot rolled steel about 25mm across. RPM=166, DOC=0.1mm, feed=18mm/min.

Martin C

Edited By Martin Connelly on 26/05/2020 20:26:56

[Martin ConnellyParticipant @martinconnelly55370]

Lee, the low profile clamps mentioned earlier are here. They are priced for industry not home use but will give ideas on how to make your own.

WDS parts

Martin C

[Lee Jones 6Participant @leejones6]

Thanks Martin. For the video and the link.

[Lee Jones 6Participant @leejones6]

Sneaky nap-time session:

[Lee Jones 6Participant @leejones6]

Other side milled:

[Lee Jones 6Participant @leejones6]

Not sure how I'm going to do the vertical cuts yet.

[John BaronParticipant @johnbaron31275]

Posted by Lee Jones 6 on 27/05/2020 18:41:11:

Not sure how I'm going to do the vertical cuts yet.

Bandsaw !

[Lee Jones 6Participant @leejones6]

Never mind ​​​​​​

[Lee Jones 6Participant @leejones6]

Finished for the day:

[Lee Jones 6Participant @leejones6]

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