A heads up if broaching key ways the best cutting aid to use is Trefelex tapping compound. Not the oil but the green paste Always get an excellent finish with a big reduction in cutting load. You are probably aware now but the bush must always go beyond the end of the bore for one cut broach square key ways. Also a good idea to make the bushes to make a rectangular key way. Then all you need to do is shim for square.
Cheers, yeah there are only so many ways you can show turning a shaft before it becomes a bit boring. It's why I like projects with lots of parts that need to come together, it's far more interesting
Thank you, that was great. I really like the fast pace. Nothing more tedious that watching manual machines work in real time. I don't know why the broaches were breaking, have you sorted that out? Thank you again.
Thanks! I think the broach guides were too short, lubrication could have been better, potentially taking too deep cut, not backing off enough and not having enough feel with the press are all too blame
When hydraulic pressing the broach always back off a few times on the way down to relieve any anomalies to perfect perpendicular linear pressure to broach.
Tips for broaches: touch the top of teeth with a stone, this will avoid tooth dig in and broach not going straight. Arbor press sizing is about 1T for 5mm broach in steel.
How did you break that parting tool? Did you accidentally move your longitudinal feed? Also, a broach needs to have oil on all faces, and to make sure the broach is not tipping outward at its bottom, because if it starts to dig in, it will run away and take a deeper cut at the bottom of the keyway than at the start. I amke sure to let off the pressure on the press, and re check to make sure the broach is still square.
I was awkwardly working around my camera, kinda hugging it to get the lathe controls, and accidentally plunged the parting blade in quickly Yes I should have used different oil and a longer bush to keep the alignment
I didn't even get through the first pass on the spacer though, and it didn't even start engaging teeth until halfway down. So I think the broach was not vertical and was digging in too much at a guess
This is a brilliant way TH-camrs can earn extra income to fund their channels. Make parts and sell them online! The effort required to make a single gear was nearly the same as it takes to make one.
Doubt it, it's a 40t pess so it's slooooow. But being so strong there is less feel. The part was also quite long, and therefore multiple teeth would all be cutting simultaneously and increasing the overall load. I'm also not convinced I was broaching straight either
Not the speed. Made a hydraulic broach press that is slow on the way down and fast return ( fed by power pac). On the very large broaches I use my self made 100ton press. Made every part, cylinder, piston, press frame. Made the power pac for it as well, including the coupling, coupling bolts, even the O ring fittings.
Oh, it is variable pressure. Wouldn't use all its 100 ton for broaching. Also made it with remote control so I can hide around the corner if things look dicey.
I know. I quickly made it up and then realised I only extended the tool mounting shaft and didn't move the shoulder. So the sleeve was my solution without making the part for the 3rd time!
My mate I reckon is the best machinist in the world. He used to get paid a fortune for on site machining in Dubai, India, Indonesia, China ( 3-6mth stints ea). My smallest lathe is a Colchester Master top of the range but it doesn't matter to him which of my lathes he used when he worked for me, his jobs were always perfect, ( I would give him a 8 hr job but he would finish it in 2hrs). Btw he's 48yo and I'm 75yo. Don't need a new lathe, just get used of its idiosyncrasies.
Very nice work T...
2 things I wished I had learned when I was younger, to weld, and operate a lathe.. Tom thx for sharing...
Yep I still wish I started earlier
Thanks for watching
A heads up if broaching key ways the best cutting aid to use is Trefelex tapping compound. Not the oil but the green paste Always get an excellent finish with a big reduction in cutting load. You are probably aware now but the bush must always go beyond the end of the bore for one cut broach square key ways. Also a good idea to make the bushes to make a rectangular key way. Then all you need to do is shim for square.
Good tip. I probably should have used my usual sutton cutting paste. Yes my bush was too short in this case
I love the quick edits. Too many youtubers loose the story by too much machining. Thanks!
Cheers, yeah there are only so many ways you can show turning a shaft before it becomes a bit boring. It's why I like projects with lots of parts that need to come together, it's far more interesting
good job. With a bit of tumbler it will have a factory made look.
Tom. Please make more videos. We all miss you 🎉
A very good idea actually. Hmm might make a good project 😁
I want to make more, but workshop time is limited with work and home projects
Excellent! I’ve just ordered one.
Cool I see it. I should be able to send off before the weekend once I sort postage
Thank you, that was great.
I really like the fast pace.
Nothing more tedious that watching manual machines work in real time.
I don't know why the broaches were breaking, have you sorted that out?
Thank you again.
Thanks!
I think the broach guides were too short, lubrication could have been better, potentially taking too deep cut, not backing off enough and not having enough feel with the press are all too blame
Happy holidays Tom, great idea making a small batch, I wish more TH-camrs did that and offered up made parts for sale!
Thanks yeah I might look into making a few more. Already looking at putting that money back in to make it easier to make more gears for people
Nice work 👌🏻👌🏻
Cheers!
Good one, Tom. Don't know why you beroke so many tools, but s**t happens :)
@Rustinox I'm a bit out of practice. Haven't been in the workshop a lot recently
At a guess, the supports under the part in the press were flexing allowing part to shift slightly and the tool to dig into the part .
@@wktodd I'd say so yep
When hydraulic pressing the broach always back off a few times on the way down to relieve any anomalies to perfect perpendicular linear pressure to broach.
I did, but I don't think my bushing was long enough to guide the keyway
Tips for broaches: touch the top of teeth with a stone, this will avoid tooth dig in and broach not going straight.
Arbor press sizing is about 1T for 5mm broach in steel.
Good tip. I wonder if the sleeve was too long, is there normally a depth limit on broaches?
New sub, plus i bought the AL960B a couple of weeks ago. So I just ordered your gear.....I'm in Melbourne too!😊
Awesome, it's a great lathe!
about time!
😛 Hey I put a video up last month too! Now I'll take a 3 year break *Flies away*
If you held the broach guide endways it dosen't crimp in when milling the slot.
How did you break that parting tool? Did you accidentally move your longitudinal feed?
Also, a broach needs to have oil on all faces, and to make sure the broach is not tipping outward at its bottom, because if it starts to dig in, it will run away and take a deeper cut at the bottom of the keyway than at the start.
I amke sure to let off the pressure on the press, and re check to make sure the broach is still square.
Correct.
I was awkwardly working around my camera, kinda hugging it to get the lathe controls, and accidentally plunged the parting blade in quickly
Yes I should have used different oil and a longer bush to keep the alignment
You should have made you broach die deeper and use a shim. Do it is two pass's.
Absolutely right, but frequentely 4 or 5 passes (more safe😉❤)
I didn't even get through the first pass on the spacer though, and it didn't even start engaging teeth until halfway down. So I think the broach was not vertical and was digging in too much at a guess
Could you debur the gears with the laser?
@davers1610 interesting thought. I might experiment. Possibly not though, it only etches about a micron deep per pass, but repeated passes may work
Hmm cutting oil on the broach?
Yep, used it. It was a thin waterbased oil, but it still seemed to cling to the teeth
@@TomMakeHere Was weird I did not expect it to brake must have been skew or stuck somewhere
Put slideway oil on the broach sides and back and cutting oil or compound on teeth.
Hi from John ( Boom Engineering Sydney)
Olumsuzluklar için üzüldüm. Ama yaşadığım sorunları başkasında görmek kendi adıma teselli.😀
İzlediğiniz için teşekkürler. Hatalardan ders almak iyi olabilir
This is a brilliant way TH-camrs can earn extra income to fund their channels. Make parts and sell them online! The effort required to make a single gear was nearly the same as it takes to make one.
Yep it's something I am looking at getting more heavily into!
RIP expensive broach😢 I thought you had a slotting head?
Regards, Preso
@Preso58 I do but I thought I'd experiment. The slotter can be a pain to set up and then realign everything afterwards
Sehr schön 😊😊😊
Danke schön!
Anyone who knows what went wrong with the broaches?
Was it the speed of the press?
Doubt it, it's a 40t pess so it's slooooow. But being so strong there is less feel. The part was also quite long, and therefore multiple teeth would all be cutting simultaneously and increasing the overall load.
I'm also not convinced I was broaching straight either
Not the speed.
Made a hydraulic broach press that is slow on the way down and fast return ( fed by power pac).
On the very large broaches I use my self made 100ton press. Made every part, cylinder, piston, press frame. Made the power pac for it as well, including the coupling, coupling bolts, even the O ring fittings.
Oh, it is variable pressure. Wouldn't use all its 100 ton for broaching. Also made it with remote control so I can hide around the corner if things look dicey.
LoL what is this gear thing you talk about ? 😂 Time for an ELS mate
Ha ha I dabble in a bit of electronics and automation, but an ELS is more hassle than I want!
Thanks for watching
Wouldn't need a sleeve if you left a small step on the shaft
I know. I quickly made it up and then realised I only extended the tool mounting shaft and didn't move the shoulder. So the sleeve was my solution without making the part for the 3rd time!
👍👍😎👍👍
😁😁😁
Du hättest mit Hinterlagen arbeiten müssen und in mehreren Zügen die Nute herstellen.
Dies war der erste Durchgang und es war kein tiefer Schnitt. Ich glaube, die Raspel war nicht ganz gerade
Really buy a better lathe that can do the job.
That's fair.
Just like when my car is due for an oil change I buy a new one to save the hassle 😂
My mate I reckon is the best machinist in the world. He used to get paid a fortune for on site machining in Dubai, India, Indonesia, China ( 3-6mth stints ea). My smallest lathe is a Colchester Master top of the range but it doesn't matter to him which of my lathes he used when he worked for me, his jobs were always perfect, ( I would give him a 8 hr job but he would finish it in 2hrs).
Btw he's 48yo and I'm 75yo.
Don't need a new lathe, just get used of its idiosyncrasies.
Glad retired from the trade
Making things is fun though
@MattysWorkshop