Elmer's Kimble engine

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foozer:

--- Quote from: arnoldb on December 21, 2011, 12:54:20 PM ---Thanks Robert :beer:
:lol: You're giving me way too much credit there for being "clever"...

couple of day's 37C+ and humid heat :D Sometimes it's nice to just mellow out...

Did get a quick snap of a rather battered arachnid though -

Arnold

--- End quote ---

Still looks the useful kit, gonna have to cobble up something similar, just snapped a 0.250 bit while boring a hole, too much unsupported.

Here its 37F - 2C or so, just warm enough to avoid the coat and cool enough to wish one was worn.

No spiders, they all sleeping. I give em names, the bride makes the funniest screech owl sounds when she shes one :)

Got me another bag of chips awaiting the next installment

Robert

Rob.Wilson:
Nicely done Arnold :clap: :clap: :clap: :clap:

That spider could only be a few mill cross nothing for scale ,, :coffee:

Rob :)

DMIOM:

--- Quote from: arnoldb on December 21, 2011, 12:54:20 PM ---.....

Did get a quick snap of a rather battered arachnid though - this one must have lost a fight somewhere... This is a species of spider that I actively encourage to inhabit my house and shop, as they prey on all kinds of ants, insects, other spiders, does not spin webs and are completely harmless to household pets and other humans :D:

:beer:, Arnold

--- End quote ---

shouldn't that be harmless ???? :beer:

(reminds me of the pseudo-science tale that did the rounds when we were kids (or maybe it was in Viz..) Did you know that spiders have their ears in their knees? - here's how to prove it. Take one spider - make a noise and it will run away. Remove legs then make the same noise and it won't run away! No spiders were hurt in recording this anecdote .....

arnoldb:
:beer: Robert, it works :D. :scratch: Snapped a 1/4" bit ? - that sounds like a tiny bit of over-enthusiasm was used :palm: - best lighten up a bit on the cuts :coffee: :D. At 2C without a coat you're getting on to Geordie territory - are you sure you're from the States ? :poke: :D -- :thumbup: Just poking a bit of fun at you; I know you're making chips other than the kind one eats :beer:. PS I'm glad I'm not close enough to hear the "owl" :D

:lol: Rob, cheers mate :beer: - I'll have to get the wee 'un to climb on a scale the next time I see it... might measure 0.5 gram across the top and bottom legs :coffee: :D :D.

DMIOM (I wish I had a more conventional first name to address you with :)) At least it's not packing any "heat", so it's in effect un-armed completely... I refrained from offering it a sip from my drink; that would turn it completely legless though... :D

After a very merry week :beer:, it was nice to get to the shop today.

I first did a C-o-C, then decided on an end mill size and then added a's, b's, thetas and so on, then used sines, cosines and other stuff to make some calculations:

:Doh: Yes, yes, I know... Boring math stuff; I'm a sucker for punishment :whip: - but then again, it's really not that hard to do, and very useful :ddb: :ddb:

On to machining then. I screwed the chuck to the rotary table and centered it on the mill with a 6mm bar chucked up - close enough for machining flywheel webs:

The X and Y hand wheels were zeroed here, and I just kept notes on the "boring maths page" (BMP from now on!) to remember which way I was cranking to compensate for backlash.

Then I drilled a bunch of 3.5mm holes according to the BMP:

I want to finish off the webs with a 4mm end mill, so I used the 3.5mm drill as it leaves a bit of lee-way for error, and can just be drilled without using a center drill (or even better a spotting drill) for each location. If the 3.5mm drill wanders a tiny bit, that's OK.

Next I marked out the sections that must be milled out - just to help prevent a brain-fart later:

And a-milling-we-went. First the insides radial edges closest to the hub, with Y offset for the radius and feeding the rotary table between angles - taking the readings off the BMP; 1mm deep Z for each pass requiring 4 passes per slot; no use to hog things out, as that could just end in heartache or lots of "bad" words from a variety of different languages - or both:

The outside radial edges followed using the same method:

Up to now, everything was done from the mill table's X zero point with only Y feeds for offsets. For the next step, I once again referred to the BMP, offset the mill table in X and Y accordingly, dialed in the needed angle on the rotary table, and started on the straight sections of the webs - with feed on Y only:

More reference to the BMP, other offsets on the mill table, and the last cuts were done:

One side of the flywheel rim was still sharp from previous machining, so I mounted a bit of 6mm silver steel in the collet chuck on the lathe, pushed a bit of cardboard over it to protect and drive the flywheel hub, and then used a cone center with another bit of cardboard on the revolving tailstock center to mount the flywheel:

A quick lick with a file cleared off the burr on the rim, and then I just did some light file-work to get rid of burrs on the flywheel web. A final rub with some emery paper rolled into a cylinder removed some more toolmarks, and I ended up with this:

An OK-sort-of-looking flywheel. I wanted lightly tapered spokes, but not too lightly tapered either. Unfortunately, this is toward the "too lightly" side, so a lesson I can take forward. 4 degrees taper is too little on relatively short spokes like these :(. I'm not about to use some form of put-on-tool to correct this; in fact the only put-on-tool I have that is suitable for this application is called "re-make" :coffee:.

The BMP did get some additional scribblings on it through the process... Yes, I KNOW... It's still a "Boring Maths Page", but it did help :med::

In fact, if I had to be more mathematically precise, there would have been a lot more calculations involved - but this was good enough for the job on hand.

The flywheel does fit on the base though, and looks OK. I was thinking about painting the webs, but I have a hunch that will not be done; I'll decide about that once the base is painted:

Merry Christmas Everyone!

Kind regards, Arnold

saw:
Beautifully work of art Arnold :thumbup: :thumbup:

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