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Thread: Bit of direction needed
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9th Mar 2020, 08:01 PM #1
Bit of direction needed
IMG_20200309_164957.jpg
Firstly,...the sum total of my milling experience is what you are looking at.
Secondly, the only way I can mill at the moment is with the lathe, and on that tool post.
Thirdly, the only milling tools I have is a small set of cheap end mills.
In hindsight I probably should have run the first cut with the 10mm, and the second cut with a 12mm, leaving me with a very thin web,....maybe the next time.
What is left is about 2.8mm thick. I might be able to break it out, or grind a hacksaw blade down enough to fit in there and cut it out, but I was hoping there was a better way?
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9th Mar 2020, 08:43 PM #2Member
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9th Mar 2020, 09:09 PM #3
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9th Mar 2020, 09:21 PM #4
If you want that middle web out just do what you have been doing and mill it out on the lathe.
If it breaks off it will save milling so much, then just clean up what's left as it won't break below the surface.Using Tapatalk
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9th Mar 2020, 09:46 PM #5Member
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It should be fine. I can see a lot of chatter marks in the existing cuts. How many passes did you take for each of those two cuts?
Based on the width of previous cuts I'm guess that they are about 20mm deep, and that web is about 5mm? (EDIT: sorry, you said it's about 2.8mm). Also assuming cold rolled mild steel?
If so, take it in 4 passes x 5mm deep each maximum and it should be fine - that's conservative as that setup doesn't look very rigid ... it's always hard to get a good setup when milling on a lathe. Anything you can do to buttress the part will help with the vibration. Ideally, an angle plate behind it with the part held to that with strap clamps. The shallower each cut, the less scary the cut will be.
Phil
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9th Mar 2020, 10:46 PM #6
Ok, I'll give it a shot tomorrow.
They are 20mm deep, and I started at 0.5mm per pass for a couple of mm, then upped it to 1mm per pass. Any more than that and things get very noisy and don't look good. At those depths I get a decent feed rate going,....75mm in 20 seconds or so. (At 1230rpm)
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9th Mar 2020, 11:33 PM #7Senior Member
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Phil,
Just to add another perspective seeing as the milling is done on the lathe, rigidity of setup is important, this is probably something that's not present, therefore I would suggest cutting the center piece with a thinned hacksaw blade or one of those round blades to about a 3-4mm stub and then mill the remainder. A cold chisel from both ends would also be a possibility and break off the remainder. Good luck with it. Alan.
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10th Mar 2020, 02:16 AM #8
Hi Phill, Guys,
You are a much braver man than I ! For me, milling on the lathe was a frightening experience.
OK I know that your lathe is bigger than mine, but from what little milling I've done on mine, rigidity is king. Anything you can do to make the workpiece more rigid will help.
As everyone has said, you have milled two slots, milling that bit in the middle should be a doddle.Best Regards:
Baron J.
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10th Mar 2020, 07:18 AM #9Philomath in training
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10th Mar 2020, 08:34 AM #10
Those round things are abrafiles.
Handy for holes in sheet metal if you have an original holder.(I have my dads).
If not there are adapters for a normal hacksaw.
H.Jimcracks for the rich and/or wealthy. (aka GKB '88)
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10th Mar 2020, 10:22 AM #11Diamond Member
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or, Remington "Grip Edge"s...
IMG_0542.jpg
Note that both of these types were standard hacksaw length?
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10th Mar 2020, 11:32 AM #12
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10th Mar 2020, 11:51 AM #13Member
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