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  1. #1
    Join Date
    Jun 2011
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    gold coast
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    Default Fly Cutter for Sieg X2 mill

    Hi Guys,
    I'm soon to become the proud owner of a used Sieg X2 mill (H and F brand).
    I have an AL250g lathe already and have enjoyed myself using it for simple turning.

    When I lurked around the toolmakers in another life, I recall seeing fly cutters, and most of the old hands had ones they had made in their apprenticeship.
    Could anyone suggest a design which I could make, and which would be suitable for the small capacity of the X2, please.
    I can usually read engineering drawings as well as being fairly adept at understanding sketches on the back of bus tickets and used paper lunch bags.
    I don't have a specific use for this tool at this stage, but I'm assuming it might be fairly useful.
    I'm assuming I would not need to face anything wide than 75mm, but that's just a guess. I usually work in mild steel.
    Thanks in advance for any advice
    regards
    Brian

  2. #2
    Join Date
    Oct 2009
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    Upwey VIC
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    Default

    Brian,

    Be vary wary of using a fly cutter on this mill... the plastic gears can very easily strip with the intermittent cutting action, especially if you crash the fly cutter into the work.

    That said, plenty of people have successfully managed this, including me (well, I did strip one set of gears...).
    The easiest type of fly cutter is just a bar similar to a boring bar with an angled piece of HSS ground as it would be for a lathe boring/internal facing operation. Just don't get to ambitious with the cutting depth or radius, as the X2 doesn't have a lot of power at the speeds you would use at a useful radius for facing. I would suggest that a 75mm width of cut would be near the absolute maximum you would try on this mill.

    Modification of the X2 to using belt drive would overcome many of the above limitations.

    Andrew

  3. #3
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    Jun 2011
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    Default

    Thank you Andrew,
    you have identified my concerns well, and it's why I'm seeking advice from those more aware and experienced than me.
    I understand the need to take things gently, and I will be grateful for any specific suggestions on speed and diameters of cut as well as design of a suitable fly cutter.
    regards Brian

  4. #4
    Join Date
    Sep 2012
    Location
    York, North Yorkshire UK
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    Default

    Hi Brian,

    These are pictures of one of two fly cutters that I made. The flywheel effect of the quite heavy disc is an advantage on a light machine.

    New_Flycutter-1.JPG New_Flycutter-2.JPG New_Flycutter-3.JPG

    I don't remember the exact dimensions but the shaft is 1/2" diameter press fitted into a 3" X 5/8" steel disc. The toolbit is 1/4" or 5/16" square and is secured by a grub screw through the side. I think I used 1/4" whit. Not that anything is that critical.
    All the bits of metal were from the scrap bin and the toolbit was a broken lathe tool just ground to suit.

    HTH.
    Best Regards:
    Baron J.

  5. #5
    Join Date
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    Southern Highlands NSW
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    1,894

    Default

    That's almost identical to the first flycutter I made.
    It's the cheapest milling cutter you'll have. Mostly mills use many different and expensive tools.
    The large sweep of a flycutter results in a nicer finish than you get with several passes with a smaller diameter end mill.
    Having just one cutting point means slower progress compared to multi teeth.
    I'm not so sure that an intermittent cut matters too much, as long as depth of cut isn't excessive, and the job is firmly clamped.
    Always lock the axes that aren't moving during the cut. So if progressing the X axis, lock Y & Z to prevent play.

    Jordan

  6. #6
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    Default

    Thanks very much HTH and Jordan.
    That's exactly what I needed both in design and usage.
    I appreciate your time in contacting me
    thanks again
    Brian

  7. #7
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    HTH: The simplicity of design belies the elegance of this tool.
    Your finish is far better than the 'blacksmith' outcomes I often get, and it encourages me to take more pride in construction.
    Thanks again
    Brian

  8. #8
    Ueee's Avatar
    Ueee is offline Blacksmith, Cabinetmaker, Machinist, Messmaker
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    Default

    HTH- Hope that helps.....

    Don't worry, i see some acronyms and have to go googling......
    1915 17"x50" LeBlond heavy duty Lathe, 24" Queen city shaper, 1970's G Vernier FV.3.TO Universal Mill, 1958 Blohm HFS 6 surface grinder, 1942 Rivett 715 Lathe, 14"x40" Antrac Lathe, Startrite H225 Bandsaw, 1949 Hercus Camelback Drill press, 1947 Holbrook C10 Lathe.

  9. #9
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    Brian, should you need spares or upgrades I go to Little Machine Shop in the USA, they can supply the metal gears and or the belt drive kit.
    If you want to be game and do it yourself, Model Engineers Workshop had a write up on how to do it and what was involved. A handy magazine to get anyway for things to make and do.
    Regards
    Kryn

  10. #10
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    Thanks Kyrn,
    I really appreciate your input

    regards
    Brian

  11. #11
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    Hi Ueee,
    Hope you have success---I LOVE Google!!!

  12. #12
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    Hi Brian,

    I've found some photographs of the tool bits that may be of interest to you. Sorry about the quality.

    2nd_Tool-03.JPG Initial_Grind-02.JPG

    This is the round nose tool side and then front views. The other end is exactly the same except that the cutting edge is a straight line, roughly parallel to the shoulder in the right picture.

    HTH.

    PS. HTH means "Hope this Helps"
    Best Regards:
    Baron J.

  13. #13
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    A flycutter specifically made for very light milling machines is the one sold for the EMCO Unimat and Compact 5. It is a very lightweight flycutter, thus minimizing imbalance effects if used in light mills. Being lightweight it is also more forgiving to mistakes that may happen to a beginner. The tool can be adjusted to cover a large or a small surface, depending on the job at hand. I reckon it is the "ideal first tool" for a small mill owner. These can easily be bought for small money, or you can easily make your own. As I recall, the whole thing is only about 70mm long, using 6x6mm toolbits. I have used on of these for many years and can recommend it for beginners with a small light duty mill:
    emco_FC1.jpg

  14. #14
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    I've made similar tools from hex head bolts and broken drill bits, for both fly cutting and hole boring. They can be very effective and economical using bits of what would otherwise be scrap !
    Best Regards:
    Baron J.

  15. #15
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    Thanks Baron and cba.
    I think I'm capable of cobbling something up with all these details--thank you both. All I need is for the weather to cool down a tad
    regards brian

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