MadModder

The Shop => Tools => Topic started by: DaveH on April 13, 2011, 09:07:58 AM

Title: Insert Fly cutter
Post by: DaveH on April 13, 2011, 09:07:58 AM

Here's a Fly cutter with an insert tip I made.

(http://www.nam-engineering.com/cm/albums/userpics/10008/normal_FC1%20%2812%29.JPG)

DaveH

Title: Re: Insert Fly cutter
Post by: marfaguy on April 13, 2011, 09:14:09 AM

Dave,
Nice!! How did you secure the cutting-head to the taper? Just loc-tite or is it pinned somehow?

Title: Re: Insert Fly cutter
Post by: DaveH on April 13, 2011, 10:34:21 AM

Kenneth, Marfaguy,

No and No, I take it you didn't see the whole post before some bugger nicked it. :(

Not to worry I will put it back on, just need a couple of hours :D

DaveH  :nrocks:

Title: Re: Insert Fly cutter
Post by: DaveH on April 13, 2011, 12:38:53 PM

Insert tip Fly cutter.

This is a repeat posting from the other day.

Here are some pics showing a fly cutter with replaceable tip.
(http://www.nam-engineering.com/cm/albums/userpics/10008/normal_FC1%20%2812%29.JPG)

The major problem I had was holding the Morse taper 3  suitable for milling. However John (Blogs) came up with a solution “screw it together”. So I made it that way, however it can be made by a “force fit” or loctite it together.  

Started with a Morse taper 3 with a blank end.
(http://www.nam-engineering.com/cm/albums/userpics/10008/normal_FC1%281%29.JPG)


Ready to start the threading. The thread was cut about 60% and finished with a die.
(http://www.nam-engineering.com/cm/albums/userpics/10008/normal_FC1%20%284%29.JPG)


Finished threading. ½’ UNF
(http://www.nam-engineering.com/cm/albums/userpics/10008/normal_FC1%20%285%29.JPG)

I used a piece of EN8 50mm dia for the part to hold the insert. This was basically a disc (17mm thick) with a threaded hole in the centre.
Here it is worth mentioning whether screwed or fitted together another way, take it back to the lathe to make sure it runs true.

Here the whole assembly after some milling, was screwed together and mounted in the lathe
The thickness is reduced to allow the insert to protrude about 1mm (0.040”), at the bottom.
(http://www.nam-engineering.com/cm/albums/userpics/10008/normal_FC1%20%287%29.JPG)

It is unscrewed and further milling is carried out. Although only one insert is used keeping it symmetrical helps with the overall balance.
(http://www.nam-engineering.com/cm/albums/userpics/10008/normal_FC1%20%2810%29.JPG)

Some aluminium ‘faced’
(http://www.nam-engineering.com/cm/albums/userpics/10008/normal_FC1%20%2815%29.JPG)

(http://www.nam-engineering.com/cm/albums/userpics/10008/normal_FC1%20%2814%29.JPG)


Just to note these round inserts come in different sizes 8, 10, 12, 16, 20 mm dia.  I used 12 so a smaller or larger fly cutter is possible.

DaveH

Title: Re: Insert Fly cutter
Post by: DaveH on April 13, 2011, 12:43:40 PM

Kenneth,

Boy you are quick :D

DaveH

Title: Re: Insert Fly cutter
Post by: saw on April 13, 2011, 03:10:38 PM

This is a very nice flycutter  :thumbup:

Title: Re: Insert Fly cutter
Post by: JimM on April 14, 2011, 06:25:24 AM

Nice flycutter Dave

I'm intrigued by your threading tool as well, are they commercial inserts or something you've ground up yourself ?

Cheers

Jim

Title: Re: Insert Fly cutter
Post by: DaveH on April 14, 2011, 06:51:03 AM

Hello Jim,

I did answer your post but it all disappeared  :scratch:

The tips and the holder I bought from Iscar about 12 years ago. (They are still available)

The holder is: GHSR 12-2.

If you have a look on their web site you will see the holder can take various tips. (Shapes and sizes)

Hope that helped a bit.
Dave

Title: Re: Insert Fly cutter
Post by: DaveH on April 14, 2011, 07:38:09 AM

Hi Jim,

This will take you to the web page

http://www.iscar.com/Ecat/familyHDR.asp/fnum/183/app/6/mapp/TG/GFSTYP/M/type/1/lang/EN

DaveH

Title: Re: Insert Fly cutter
Post by: No1_sonuk on April 14, 2011, 07:45:05 AM

Quote from: DaveH on April 14, 2011, 06:51:03 AM

I did answer your post but it all disappeared  :scratch:

There have been server problems in the past day or two, and a restore from backup was done, meaning some posts were lost.

Title: Re: Insert Fly cutter
Post by: lordedmond on April 14, 2011, 07:50:46 AM

Should that insert be in a pocket to support the rear like the commercial profiling cutter are , instead of relying on the screw along to take the load ?




Stuart

Title: Re: Insert Fly cutter
Post by: DaveH on April 14, 2011, 09:03:34 AM

Hello Stuart,

Quote from: lordedmond on April 14, 2011, 07:50:46 AM

Should that insert be in a pocket to support the rear like the commercial profiling cutter are , instead of relying on the screw along to take the load ?
Stuart

You are correct, I should have mentioned it :doh:
Here it a pic showing the pocket
(http://www.nam-engineering.com/cm/albums/userpics/10008/normal_FC1%20%2811%29.JPG)

DaveH

Title: Re: Insert Fly cutter
Post by: Blade on April 14, 2011, 02:24:49 PM

That is nice, great job!

Title: Re: Insert Fly cutter
Post by: j45on on April 14, 2011, 05:34:24 PM

Great tool Dave I have ordered a blank arbor to have a go at making one  :thumbup:

Title: Re: Insert Fly cutter
Post by: DaveH on April 15, 2011, 07:29:28 AM

If you are considering making this fly cutter the only real critical part is the seating of the insert within the pocket.

The sketch shows the basic idea, the hole centre in the insert is slightly offset to the tapped hole centre in the holder by about .005” - .009”. This offset makes sure that the insert (top) is forced against the top side of the pocket. A small radius is required (as shown), the depth of the pocket should be such that no force is exerted at the cutting edge of the insert. In other words if the insert thickness is 4.8 mm the pocket depth needs to be in the region of 3.5 – 3.8 deep.

 Hope that is understandable  :scratch:

DaveH