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  1. #1
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    Jul 2016
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    Melbourne
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    Default Punching small copper discs

    The new project lathe is missing about 30 little copper discs that go underneath the setscrews all over machine so i need to make 30-40 4 and 6mm copper discs, will a good sharp wadding punch do the job or should i look to making myself a shim punch and die? any other ideas welcomed. they seem to be 1.25 mm thick on average. One can be seen in the below photo.
    20170227_213407.jpg

  2. #2
    Join Date
    Oct 2011
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    Norwood-ish, Adelaide
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    59
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    I think you will struggle with a wad punch.

    Michael

  3. #3
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    Jan 2011
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    Far West Wimmera
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    I did a couple with a wad punch recently. Michael is right. I would not try it for 30. I used the wad punch after about the third one flipping off across the shed trying to cut it with snips. I still had to make about 4 or 5 with the punch to end up with 2.

    Dean

  4. #4
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    May 2011
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    Murray Bridge S Aust.
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    71
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    Default

    I'd look at making a simple punch and die set to suit the sizes required. I've done similar, not punching discs but sheet metal handles, I used a 20 tonne garage press. Will put up a pic shortly.
    Kryn
    To grow old is mandatory, growing up is optional.

  5. #5
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    Jul 2016
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    Melbourne
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    Default

    Unfortunately, one of the main things im lacking here is a press, so I imagine im going to have to use percussive force, I do have a few things at my disposal that could be useful. There is a big pneumatic jigging table here which has 4 realllly big pneumatic rams, maybe 6" dia 8" stroke, they may be able to be used for this, though a little rough on the die. We shall see.

    What is the most convenient way to put draught on the ejector hole, will a taper reamer be acceptable? or should i just make the punch long enough that it forces the disc all the way through, Ill try for some crappy ralph-cad asap.

  6. #6
    Join Date
    Oct 2010
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    melbourne, laverton
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    1,910

    Default

    Um I wonder if you could experiment with a hole saw

  7. #7
    Join Date
    Sep 2012
    Location
    York, North Yorkshire UK
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    6,439

    Default

    Hi Guys,

    I've made little plastic discs for just this purpose, using a leather belt hole punch and the 1.25 mm thick plastic strapping as used around packaging. Works a treat and you can just drop one into the hole, or two if you need.
    Best Regards:
    Baron J.

  8. #8
    Join Date
    Apr 2012
    Location
    Healesville
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    2,129

    Default

    I would get copper rod, turn to size and part them off.

  9. #9
    Join Date
    Apr 2012
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    Healesville
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    2,129

    Default

    Or use brass....

  10. #10
    Join Date
    Nov 2007
    Location
    Melbourne
    Posts
    26

    Default

    Quote Originally Posted by caskwarrior View Post
    The new project lathe is missing about 30 little copper discs that go underneath the setscrews all over machine so i need to make 30-40 4 and 6mm copper discs, will a good sharp wadding punch do the job or should i look to making myself a shim punch and die? any other ideas welcomed. they seem to be 1.25 mm thick on average. One can be seen in the below photo.
    20170227_213407.jpg
    caskwarrior,
    Where in Melb are you? I'm at Main Ridge on the Mornington Pen.
    This my disc cutter, we could punch them out in a few minutes.
    There are any number of wineries, cafes and even a brewery within minutes ... worth a trip just for that!
    Cheers,
    Peter

  11. #11
    Join Date
    Oct 2007
    Location
    Sydney
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    3,112

    Default

    Quote Originally Posted by azzrock View Post
    Um I wonder if you could experiment with a hole saw
    Could you please post some photos of using a hole saw to make 4/6 mm disks in 1.25 mm sheet stock. I'd like to see that.

    Quote Originally Posted by lightwood View Post
    caskwarrior]
    This my disc cutter, we could punch them out in a few minutes.

    Peter
    Is that a commercial punch/die set or one that's been made? It looks excellent and very useful. What thickness of materials can you reliably punch?

    FWIW I've just hacksawed off brass slugs from solid rod and dropped them in the holes before running the steel fastener down. They would obviously be thicker than 1.25 mm, but only take a few seconds to saw off and there's so much thread available that 5 mm wasn't going to be missed.

  12. #12
    Join Date
    Oct 2010
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    melbourne, laverton
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    Default

    A challenge . No hole in the middle right?

  13. #13
    Join Date
    Nov 2007
    Location
    Melbourne
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    26

    Default

    Quote Originally Posted by Pete F View Post

    Is that a commercial punch/die set or one that's been made? It looks excellent and very useful. What thickness of materials can you reliably punch?
    Pete,
    it's a commercially produced Jewellery Disk Cutter. I bought it more than 30 years ago, and have used it VERY often.
    It is used on non ferrous metals up to 2mm. I've used it to cut Platunum, gold, silver, brass, copper.
    It starts at 12mm then 1.0mm steps to 9, then 0.5mm steps to 2.0.
    Common scene is required .... I'd never put 2mm stuff in there under about 5mm.
    Most of what I use it for is around 0.5 - 1.5mm thick yellow and white golds...and that is where it excels.
    Here is another option I've used sometimes for light weight non-ferrous metal stamping.
    The "R T Blanking System"
    You can see what I've used, imagine how it would go if a better steel was used!
    Cheers,
    Peter





  14. #14
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    Dec 2005
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    South Australia
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  15. #15
    Join Date
    Sep 2012
    Location
    York, North Yorkshire UK
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    Default

    Hi Peter,

    I've seen that technique used before. If I recall it was used for making steam whistle reeds.
    Best Regards:
    Baron J.

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