Author Topic: diy sheet metal pinch rollers (Read 35110 times)

Andrew Wildman · « **on:** September 02, 2015, 02:42:00 PM »

I am starting a project to build some pinch rollers for the shop. I have looked at some for sale and they are either very lightweight, to the point of uselessness for my needs, or vastly over the wife's shed allowance.

The build is based on the materials that I had kicking about in the shed and also the length of the rollers is limited by the capability of my lathe.

The first bits to be made were the side plates. I used a rota broach to drill the holes:

The two plates were tacked together to ensure that they were symmetrical when machined:

side plates machined and gears bought from hpc (hopefully the only project expense)

ieezitin · « **Reply #1 on:** September 02, 2015, 05:47:35 PM »

Andrew

nice work. Did you side mill with that Rotobroach? the pictures make it appear you did.

Anthony.

SwarfnStuff · « **Reply #2 on:** September 03, 2015, 02:05:51 AM »

OK Lead on McDuff, I await the next installment

as this looks like I wanna make one too. So, thanks for posting so we can follow your adventure. Oh, and the cost limitations sound very familiar.

John B

Andrew Wildman · « **Reply #3 on:** September 03, 2015, 07:59:39 AM »

Anthony, Firstly the sides of the slot were sawn out on the vert bandsaw (see second picture) then the holes were drilled with the rotabroach and then the slots were cleaned up with an endmill. a lot of steps but it means that you get a nice clean radius at the end of the hole and you do not have to hog out all the waste.

John, Having 2 kids means time is also a bit of a limitation so posts may be a bit slow coming! We shall see...

jcs0001 · « **Reply #4 on:** September 03, 2015, 11:57:17 AM »

Andrew:

That looks good. I'm looking forward to seeing the finished product.

John.

Andrew Wildman · « **Reply #5 on:** September 05, 2015, 01:52:05 PM »

I completed the lathe work on the brass bushes.

The brass was a bit I got from the scrapyard when you could go to scrapyards to get stuff. The od was turned down:

Then the centre hole was bore and bushes turned and parted off:

parts ready for milling and drilling processes:

SwarfnStuff · « **Reply #6 on:** September 06, 2015, 03:26:08 AM »

Looking good, Thanks for the update. Yeah, not much luck getting into scrap yards here in OZ now either - UNLESS you happen to know the boss or someone. Sadly, I don't.
John B

SteveT · « **Reply #7 on:** September 06, 2015, 04:34:42 PM »

Interesting project, something I need to make one as well soon looking forward to seeing the rest of the build

NeoTech · « **Reply #8 on:** September 07, 2015, 04:33:20 AM »

*posting to follow* Awesome been thinking of building this myself once.. never figured out how tho.

rythmnbls · « **Reply #9 on:** September 07, 2015, 09:03:30 AM »

Quote

*posting to follow* Awesome been thinking of building this myself once.. never figured out how tho.

NeoTech, Perhaps this attachment will help.

Regards,

Steve

Andrew Wildman · « **Reply #10 on:** September 14, 2015, 03:31:18 PM »

Milled a slot around the bush to sit in the side plate. The slot did not go all round the edge. To speed up the process all the bushes were done in one go:

Picture showing alignment method of bushes for top and 45 deg 'slots'. Two parallel ones were done using parallels (most critical)

Andrew Wildman · « **Reply #11 on:** September 14, 2015, 03:34:13 PM »

after a bit of filing:

bushes in position on side plate:

next job drilling holes for the threaded adjuster, keep screw and oiling hole....

ausdier · « **Reply #12 on:** September 19, 2015, 10:49:26 AM »

Just a quick CAD model from the plans supplied by Steve, thank you very much Steve.
Drawn with Inventor 2012 Pro.
Rendered with Inventor and Keyshot 5.

Also added a 3D PDF so people can have a look around it.
Hope someone likes or finds this useful.
Cheers.

Andrew Wildman · « **Reply #13 on:** September 19, 2015, 04:01:51 PM »

wow I wish mine was going to look that good! Thanks ausdier.

I am a professional engineer so I spend a lot of my day in front of calculations and CAD (no greasy machines I am afraid!). So when I get home I try not to spend too long on the computer hence this is a close to cad as I get on home projects

Bit of an update. Holes drilled and tapped in bushings. Holes drilled in a jig of sorts:

complete parts (although I may counterbore the top)

Andrew Wildman · « **Reply #14 on:** September 19, 2015, 04:05:04 PM »

started on the rollers. Roller length is limited to the material I had. The useable length will be 470mm.

I would be finishing off the rollers tonight but I am looking after the kids while my wife is on a hen doo

ausdier · « **Reply #15 on:** September 22, 2015, 11:37:40 AM »

G'day Andrew,
Just wondering what the holes in the bushes are for.
I don't mean the big one in the middle, I presume that is for the roller. LOL....

Cheers and keep up the good work.

Andrew Wildman · « **Reply #16 on:** September 28, 2015, 04:54:15 PM »

ausdier, The holes are to locate the screws that move the bushes in and out. the small holes are for oiling and also to put pegs in to locate the screws so when the screw is retracted the bush comes with it rather than being stuck in the slot....if that makes any sense

I finished the turning on the rolls and could not resist a trial assemble. The bit of ready brek packet (can you tell I have kids!) represents a bit-o-sheet metal

next job screws...

SwarfnStuff · « **Reply #17 on:** September 29, 2015, 02:57:58 AM »

Andrew, I am really enjoying your build but will you please resize your photographs in future posts? 800 x 600 pixels seem to work best for most web sites. As it is I find that by the time I zoom out to see the whole picture, the text is minuscule - too small for my old eyes to read. Thanks for your most interesting build log.
Thanks again
John B

Andrew Wildman · « **Reply #18 on:** September 29, 2015, 02:11:19 PM »

No problem John. I will see what I can do for the next pics. Glad you are enjoying the build

NeoTech · « **Reply #19 on:** September 29, 2015, 03:41:36 PM »

And 800x600 i need to zoom in so much i need to squint my eyes instead...

800x600 is a veeery old standard.. 1024x768 is prob. bare minimum for most modern computer. and 1280x<whatver> is the more common one on forums.

SwarfnStuff · « **Reply #20 on:** September 30, 2015, 04:34:00 AM »

Well NeoTech an old standard for an old codger I guess. Ok stay with as is, I am pretty slick with the scroll wheel.
John B

Andrew Wildman · « **Reply #21 on:** October 03, 2015, 05:23:11 PM »

not sure what the outcome of the picture size discussion was but as it is what seems to squirt out of photobucket as standard I will keep with the original size. Sorry scrolling may be required!

So today I mostly machined keyways for 3/16 keys.
External keyways on rollers done on the mill

Internal keyways marked out on gears to centre. The gears were rested on the plate on two of the teeth. These two teeth were later used to line them up in the shaper.

Andrew Wildman · « **Reply #22 on:** October 03, 2015, 05:27:20 PM »

The shaper was set up with the clapper replaced with a fixed slotting bar. the part was sat up on parallels (and a shim) in the vice so that the gear could be clamper but still be aligned to the parallel and the gear was set vertical vrt the marking out using the two teeth and a square.

Andrew Wildman · « **Reply #23 on:** October 03, 2015, 05:44:19 PM »

I found this picture of me grinding the 3/16 slotting bit when I was doing another project (actually rebuilding the quill power feed on the Omnimil, which I will post a thread on at some point)

I must have been grinding the back relief here.
This was ground on the oldest tool in my shop, I recon a 1940's cutter grinder. I remachined and scraped it as it had about 0.02" wear on the x axis.

ausdier · « **Reply #24 on:** October 04, 2015, 11:27:22 PM »

I thought the holes were for that.
It is just that in the plans that I have you can swivel the tops off to get the top roller out then you can get the sheet out.
It just means that if you need to do that you will have to completely unbolt the top brackets, all god.
Keep up the good work it is looking good.
Cheers.

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Author Topic: diy sheet metal pinch rollers (Read 35110 times)