An experimental V-4 wobbler

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Brass_Machine:
Very cool. Will be watching this one.

--- Quote from: spuddevans on May 09, 2011, 12:52:12 PM ---Edit, Dang it, managed to upload the same file twice, sorry Eric, just delete one as I cant seem to delete it myself.

--- End quote ---

I will fix that today

spuddevans:

--- Quote from: Brass_Machine on May 10, 2011, 10:50:29 AM ---I will fix that today

--- End quote ---

Thanks Eric :thumbup:

I got another couple of hours in the playroom workshop today, and started by mounting my new vice onto the mill, and then clocked it square with a dti, I didnt go crazy, but just got it down to +/- 0.05mm :lol:

I then mounted all 4 cylinder blanks on some parallels and with two pieces of ali at the front and back to compensate for the minor differences of thickness on each cylinder. If you dont put some soft material between the jaws and the workpieces then the slight differences will cause the multiple pieces to not all be gripped the same, which is perfectly fine unless you actually want to machine any of them. The Ali not only protects the brass from the steel vice jaws, but also will squish a little to compensate for the minor differences.

Anyway, I then I worked back and forth with a flycutter to get all 4 to the same length, 20mm.

I then turned the cylinders on their sides, gripped them in the same manner, and made a few more passes with the flycutter. Here's a shot after I cut the flat down until the required thickness ( 14mm ). Others might prefer to switch to an endmill to get the bulk removed, but as there was only 2mm to remove, and on brass I am able to take 0.25mm depth of cuts with this flycutter, it was quicker to keep using the flycutter. Plus it leaves a lovely silky smooth finish. Don't let the curved lines fool you, they cannot be felt by my fingernail.

Not having a lot of time left I started to set up for the next machining processes. The next thing will be to bore out a 2mm deep, 10mm diameter recess in the center of the flat section, and I will probably drill the inlet/exhaust holes at the same time. Because this has to be done on all 4, I'm going to use my sophisticated vice stop system shown below.

And for making sure that the cylinder flat is positioned true and flat I use another patent-pending system...

It wasnt until I had released the vice after flycutting all the flat sections that I realised that I should have kept them in place and just drilled and bored all the relevant holes using my edge finder on each cylinder and then moving to the right coord's for the holes :doh: :bang: :doh: :bang: :doh:

Oh well, you live and learn.

So next will be a boring post ( oh come come! this post has been boring anyway :lol: :lol: ) and then some silver soldering.

Tim

saw:
Nice work :thumbup:

spuddevans:
I've made a little more progress on the cylinders.

According to my plans I have to drill the 2 inlet/outlet holes, and also a central 10mm diameter hole. The small inlet holes pose no problem, but the 10mm diameter hole is a little more tricky for me as I found that I do not have a 10mm endmill, and this hole must be flat bottomed. (wasnt that a queen song, "flat bottomed something-or-other" :lol: )

I could've made a 10mm D-bit, but I figured out another way. I do have a 3/8" endmill which is 9.51mm approx in new money, and I also have a boring head that I can set to 10mm.

So here are my tools for this task,

Center drilling the holes,

Boring out the majority with the endmill,

Drilling the 1.5mm steam passages,

Then I swopped the ER32 chuck and mounted the boring head in the mill and then bored out to 10mm, I left the boring head locked at the needed diameter.

Repeat the above steps another 3 times, til you have this.

Then I turned the cylinder upright in order to bore out the bore :D

Using my expensive vice-stop to position the cylinders to make a little production line, first up after centering up was center drilling all 4 cylinders,

Then following through with drills up to 7.8mm,

Then I reamed all 4 out to 8mm, I was going to bore them with my boring head but I realised I didnt have a slim enough boring bar for it ( something for the shopping list )

Next I turned up 4 little rings of brass, 10mm OD, 8.1mm ID x 3.5mm depth.

And this is where they fit,

And here are the pieces all together with 4 8mm x 2mm neo' magnets sitting in place.

The magnets will be epoxied in place, and I am considering leaving the rings unfixed, they will fit into corresponding 10mm recesses in the main frame, and the magnetic attraction should keep them all in place.

While I have the vice stop set up, I will probably next drill the 4 holes on each end of the cylinders for fixing the endcaps or glands, then that should be all the cylinder machining operations done.

All that and maybe more (or less) on next weeks show.....

Tim

arnoldb:
Well sir, that was a lot of boring, but not at all boring :thumbup:
Good progress!

Kind regards, Arnold

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