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  1. #16
    Join Date
    Apr 2012
    Location
    Healesville
    Posts
    2,129

    Default

    This sure looks like fun, my immediate thoughts are.
    Shorten the tool hang out,
    Cut with a nose radius,
    Feed rate less than nose radius,
    Trefolex

    cheers, shed

  2. #17
    Join Date
    Nov 2017
    Location
    Geelong, Australia
    Age
    57
    Posts
    2,651

    Default

    Thanks Shed.
    Nose radius, feed and Trefolex I can try easily.
    Tool hangout is more difficult, as currently those monster brazed-HSS tip ones I'm using are all I have that will get into the dovetail.
    I've got one of the multi-angle shaper toolholders that takes 3/8 HSS blanks, but its a large one and the castellated section that holds the HSS would be close to 50mm diameter so I can't get it far enough into the dovetail recess to cut the angle. A smaller version is definitely on the TODO list.

    Steve

  3. #18
    Join Date
    Aug 2011
    Location
    Melbourne
    Posts
    4,779

    Default

    I have only ever done cast iron and ms on my shaper. Certainly nothing like fork lift tynes!

    Maybe the rake or clearance angles need a tweak? Have you tried different ram speeds?


    Does your shaper have an auto lubrication setup on the ram? Neat!

    Simon
    Girl, I don't wanna know about your mild-mannered alter ego or anything like that." I mean, you tell me you're, uh, super-mega-ultra-lightning babe? That's all right with me. I'm good. I'm good.

  4. #19
    Join Date
    Nov 2017
    Location
    Geelong, Australia
    Age
    57
    Posts
    2,651

    Default Adventures with my Klopp shaper

    Yes, a different grind has improved things. I had a bit more success the other night after realizing I had virtually no rake on the tool.



    Ground in some more and it worked much better





    I'm not 100% convinced the ram oiler is working properly as the ram doesn't seem "oily" if just leaving it up to the oiler. When I had the ram gib out etc to free it up I didn't realize that the sight glass was actually a reservoir or I would have put some light oil in it and confirmed it was getting out where it should. Thought it was just a window to check for oil flow like on some mills.
    Since then I have put oil in it and it disappears over a couple of months so assume it's not completely blocked but really have no idea if it's doing its job correctly.
    Long story short - I still give it the odd squirt of oil on the ram ways when it's running

    Steve

  5. #20
    Join Date
    Nov 2017
    Location
    Geelong, Australia
    Age
    57
    Posts
    2,651

    Default Adventures with my Klopp shaper

    I've been running in the slowest gear (it has 3) as in second gear wanted to launch itself across the floor. Finally took a good look at the speed chart and worked out that it was only running about 25feet/min Seems the recommendation for alloy steel is more like 50.
    Scratched my head for a sec wondering how I could get a higher speed when the next gear wasn't an option - until I realized that the speed is a product of the rpm (i.e. Strokes per min) and the stroke - just like the chart was trying to tell me. Doh!
    So, increased the stroke by almost twice, and it cut a lot more cleanly.

    Proceeded to finish the dovetail off, but made the newbie mistake of not cutting the middle section to full depth first.
    End result - my first dovetail on the shaper - but ~2mm too wide to use as tool holders



    Steve

  6. #21
    Join Date
    Apr 2012
    Location
    Healesville
    Posts
    2,129

    Default

    Why don't you cut one tool holder off and try a 2mm shim on one side, if successful just put tack weld at each end to hold it there.
    It should work ok.

    cheers, shed

  7. #22
    Join Date
    Nov 2017
    Location
    Geelong, Australia
    Age
    57
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    2,651

    Default

    Quote Originally Posted by shedhappens View Post
    Why don't you cut one tool holder off and try a 2mm shim on one side, if successful just put tack weld at each end to hold it there.
    It should work ok.

    cheers, shed
    Good idea shed - thanks!!
    Have to admit that after measuring twice and realising I'd cocked it up I turned off the power and lights and walked away...

    Its still mounted in the vice at the moment, and the QCTP is easy to remove to test fit so I can try 2mm and have the option to open it up a bit more for 2.5 or 3mm shim if need be.

    I'll still be making more holders as I only get 3 out of this blank, but if I can salvage this somehow would be great - even if they need to be relegated for use with lighter tooling.

    Steve

  8. #23
    Join Date
    Apr 2018
    Location
    Drouin Vic
    Posts
    633

    Default

    The batch I made a while ago in exactly the same way produced one that was loose- a bit of shim stock in the bottom snugs it up. I only use it for an indicator holder though.

  9. #24
    Join Date
    Nov 2017
    Location
    Geelong, Australia
    Age
    57
    Posts
    2,651

    Default

    Good suggestion Pete - Thanks.
    At the moment I've only got 2 normal toolholders plus the usual cutoff and knurling ones - so will definitely employ one of these as an indicator holder.

    Steve

  10. #25
    Join Date
    Nov 2017
    Location
    Geelong, Australia
    Age
    57
    Posts
    2,651

    Default

    Needed a tool holder for internal keyway cutting so I could finish repairing my old chipper/mulcher.

    Found that 1" all thread was a good fit in the bore of my big toolholder, so made up a the keyway tool from that.
    Drilled a hole just slightly smaller diameter than the corner-corner dimension of the 1/4" square HSS cutting tool, then filed some corners into it so the HSS just slid in. Retained it with a cap screw drilled and tapped into the end of the bar. A grub screw would be better but I didn't have any at the time.

    Works OK, but has a couple of issues.
    Firstly, it's very hard to set such a short tool vertical. I plan to put a couple of flats on the holder to give a surface to align.
    Second, there is very little room for chips to evacuate from in front of the cutting tool. Think I'll try relieving the area under the bar in front of the tool so the chips don't pack in hard and get stuck.







    Steve

  11. #26
    Join Date
    Apr 2018
    Location
    Drouin Vic
    Posts
    633

    Default

    Nice work Steve. I must get me one of those multi-angle tool holders for the shaper.
    To set the orientation of the holder, you could put a longer piece of tool steel or key steel in the holder while you set up, then swap it out for your short toolbit.

    I made a slotting toolholder that goes in place of the toolpost in the clapper, so the cut happens directly in front of the clapper instead of below it. It solved the problem I was having, but now I can't for the life of me recall what the problem was! I think it was to do with the way the flex of the setup is magnified at the toolbit with the setup as yours is- any flex in the vertical part of the setup results in a massive increase in depth of cut at the bit, so I was either breaking toolbits or pushing the workpiece out of the vise and generally not getting a consistent depth of cut.

    With the chip clearance thing, I wondered when I saw your photo in the other thread of the keyway if you were cutting that with nowhere for the tool to run out at the end of the cut; the toolbit has to leave the job at the forward end of the stroke or the chip can't break off. For instance you would drill a hole at the forward end of a blind keyway so that the cut finishes in the hole.

  12. #27
    Join Date
    Nov 2017
    Location
    Geelong, Australia
    Age
    57
    Posts
    2,651

    Default

    A multi angled holder would be pretty easy to make Pete.
    My one has had a hard life and needs a bit of TLC.
    I'll probably make another smaller version at some stage that will take 5/16 tools as the large head has some access issues for tighter features.

    When I cut the shaft keyway you're referring to in the chipper thread it still had part of the old keyway that I could run into, so it wasn't blind.

    This internal keyway for the pulley is all the way through, but the issue is the chips compacting in front of the tool between the tool shaft and the bore.

    I don't seem to have any issue with the tool digging in during the cut, but the multi angle holder shank is massive compared to the lights cuts I was taking.
    I recall seeing one of Stefan Gotteswinter' videos where he had made a holder that mounted directly in the clapper, and had some function to index the cutting tool. Must find it again...

    Steve

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