Cutting Internal Keyways in Manganese Bronze Gears on the Vertical Slotter - Manual Machining
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- เผยแพร่เมื่อ 26 พ.ค. 2023
- The Morey Vertical Shaper or Slotter as some call it, keeps earning her keep. This particular job came in due to one of my other videos on cutting keyways with this machine. The customer was push broaching these, and it was not going well. They told me the last set they cut, the broach exploded, making a very dangerous situation.
As this is the first test run of these parts for a potential new customer, I need to do my best. Not that I would ever put out anything other than perfect parts.
The Kool Mist unit was purchased from KBC Tools and I am very pleased with it. Their products and pricing are great. Here is the link to the Portamist. www.kbctools.com/itemdetail/1...
Topper Machine LLC is an entirely manual machine shop located in Spooner, WI. Our videos will highlight some of our shop work.
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#machineshop #machinistlife #manualmachinist - แนวปฏิบัติและการใช้ชีวิต
I love these old machines . In the 70's I worked in a foundry that had a Turret lathe with a 10" bed next to
my work station. After a few discussions with my supervisor I was relocated because I was so distracted
with the setup and operation of the machine .😉
These old machines sure do a good job and keep on keeping on after decades of use.
Love that old machine. Maybe it was just the camera angle, but it looked like the second cut was a goo 60 thou off center of the first one.
I thought I was the only one who saw the difference between the cutters. Looking at the tool when I it is screwed to the holder, you can see the edges are offset from the centre, which is shifting the cut. Obviously there is enough clearance for the key to still fit.
I got a vivid mental picture of that exploding push-broach fragmenting across the customers workshop. Not surprised they decided to outsource that step in the process. Looks like you have the right machine and tooling for that job. Hopefully the customer brings in more work.
Glad you mentioned the flaws with force broaching. I was curious about how that would work. I agree that using a coolant misting system is a lot less messy. I have to say though that I did get annoyed with the constant hissing when I was working as a machinist.
Does it matter where the key way is in relation to the gear?
Yes it does. I had full drawings and specs to follow.
This is like the earliest asmr haha. It's something the cnc machinists miss out on. Hitting your number is like getting a hole in one, sinking a half court shot or catching a 50 inch musky. The simplicity of the machines action hides it complexity and sturdiness of build. I'm gonna have to start looking for one. Great vid and channel. Thanks again
Spray system seems to be a great idea. Thanks for another great video, machining without CNC done right.
My back hurts so bad just watching you leaning over to run that.
Thanks for the video keep on keeping on.
That is a magnificent machine.
MR. TOPPLER
THE AUDIOS ARE MUCH IMPROVED ON THIS ONE. ON YOUR OTHER VIDEOS I WAS HAVING TO GO TO 50 VOLUMES. THIS ONE I WAS AT 26 VOLUMES. AVERAGE VIDEOS ARE 8-12 VOLUMES. SO IF YOU COULD JUST GET THEM A LITTLE BETTER IT WILL KEEP BARB OFF MY BACK ABOUT BEING TOO LOUD ON THE COMMERICALS. LOVED THE SLOTTING LOOKS LIKE A REALLY NICE MACHINE. KEEP UP THE GOOD WORK. GOD BLESS BORTHER
Excellent work. Those chips are cool like coil springs.
You did a nice job on the video and the part. It is interesting to watch you. What a great idea to cut it in two steps. I was thinking of you and the tractor show but that is next month. Thanks for making and sharing the video. I am glad that you are finding new customers. I wish that I could stop by and see you sometime.
Great video , need more.
Nicely done
Morning Josh,
Another great video......machining was spot on as usual and the videography superb...LOVE all those neat toys you have to work with...soo soo jealous.....finally finished MY shop expansion.....cleaning up the construction mess now and reorganizing into the new space....pics soon when its presentable.
Don
Very cool machine!
Great video I always wanted to learn how to do machine work like you can do never had a good opportunity thanks for sharing hope everyone has a wonderful memorial weekend
good stuff Josh Thank you for sharing
Good call on using the mist coolant, neat cutting oil is expensive on total loss application.
Nice set up and machining.
Thanks for sharing 👍
I can totally understand you like this machine so much. I'ts a very nice piece of equipement.
Well done Josh with the keyways ❤❤it. Thanks for the video take care of yourself and family and be Blessed ❤️❤️👍.
Nicely done. Is there a reason you don't have a threaded thru hole on the arbor and use a jack screw to remove the cutters?That's one hell of an angle plate you have sitting against the wall!
Never thought about a jack screw, might be a good addition to the tool. That angle plate is sure nice.
Most Excellent.
I see a base plate jig indexed and bolted to the table with a precision bore the same as the part but cut outs where the broching head as to pass thru so a plug could index the centerline. Adjustable stops to hold the clock position of the part while you clamp it down. If you could get a chunk of the worm gear. You could make pivoting indexing locks. So you clock the part to seconds of arc everytime in seconds while clamping the part.
The concept is good if there is enough repeat work to justify. Some of these jobs are 1-2 pieces a year. It doesn't justify spending time making fixturing for that low of a quantity.
@@TopperMachineLLC Maybe a sleeve that fits over the tool holder and into the workpiece will do?
Good stuff
I would be interesting to know what inspection methods/equipment you have to check the parts you produce before sending the components to the customer.
Josh, these videos are so interesting, it is good to see that your old tech machines can still do the job...heck they could alwys do the job! Great content! TY
I really enjoy seeing the work you do with the trains. And I like to see you using the old machines in your shop. The kids now days would be at loss if they had to try to make anything with them.
There probably won't be much more railroad videos. The FRA has already made some threats of fining me.
@@TopperMachineLLC can you share why?
I remember being around when my boss was trying out a new tool and his dad came in, He showed his dad the result of the tool on a fence post but his dad was more interested in the shavings that came off the cutter...picked a few up and because they were shiny smooth and spiralled said "that'll do" and walked off to do something else...
A very handy machine to have! You should get a lot of work in the future I hope. I don't think many people have those machines now.
Very interesting video liked the cool mist. Those curled chips were very nice and bright and smooth. Just curious did the keyway have to be located in a defined rotational location. Would have liked to see how to line it up with a certain outside rotational point.
Great Video 💯💯💯💯
Thanks, but how did you watch a 27 minute video in 16 minutes?
@@TopperMachineLLC . I finished the whole Video had to stop and feed my cats
Would it be possible to get/make a longer cutter with 2 or 3 teeth, each offset sideways so that each takes a small width but total is the full width? Most broaches use that technique to get full width sometimes with notches at different spaces across the teeth gets the same result. Seems your customer has proven the value of pull broaching over push by the Kablooie method!
Curious, 1) how did you setup the keyways in relation to the gear sector and 2) how did you verify they are dead nuts across from each other. we have several machine drive hubs with keyways at noon and 6 o'clock and always have to file dress the keys for the fit we want, usually a couple thou's because the keyways are not well clocked. (shaft keyway not equal to hub keyway) . good video watch u often
)
Good video
☹🇬🇧
I’m curious, in these old machines,
1. how do you determine the depth of cut and appropriate strokes per minute for the different materials?
2. are the cutters still commercially available or do you make them?
3. what is the cutting edge profile on these cutters?
Thanks for sharing, cool video.
Great video and nice work Josh. That must be a VERY expensive piece of material. The machine height forces you into a pretty brutal working posture; not something that I could hold all day, but then you are a much younger man than I......
Makes for a strong back. Lol
are the two cutters on the same centerline? it looks like the second, larger cutter, is taking more from one side than the other...?
The smaller one was ground to take out a chipped corner. They were not on the same center, but that didn't matter.
To save tool changes would it not have been better to do the narrow cuts on both sides before changing to the ¾” cutter?
What is the cutter made of, and how quickly does it go dull? Is it something that you can resharpen, or is it a throwaway item? It looks similar to a dado plane in woodworking.
They can be reground. They are m42. They cut a long time.
Need to drill and tap bar for a push bolt to remove cutter?
Would a standard horizontal shaper hold tolerances like your vertical shaper does? Just curious because the horizontal type has a clapper box that moves abd wondering if that causes it to not be a ridged as yours.
I know guys doing this kind of stuff on shapers. It is a lot more setup, but it's still gives great results
Looks like a part for a machine that makes napkins?
I have no idea. I just get to see the parts.
Does the orientation of the keyways matter in relation to the outer worm gear? Or is that set when the actuator is assembled?
It is a predetermined location.
No power feed on the table on that machine?
Yes, but it's not consistent under .003/stroke. I just hand feed for some cuts.
I tried to locate that company for the cutters but had know luck . I would like to get some cutters for my shaper . Do you have a web site Thank you
Keyseater.com
So this thing is sort of like what would happen if a broach and a shaper made a baby? I'm also guessing that smaller and larger tool holders are possible for other work?
You can build any size tool holder you want. I have several variations and sizes. You're only limited by your imagination and skill level.
How did you know where to put the slots in relation to the part gear? 73 dan
It was on the drawing supplied by the customer.
Is there any benefit to having two key ways instead of one?
Second one is for when it wears and you can flip the gear for more life.
Thank you for the response 👍🇦🇺
Does the keyway need to be clocked to the sector gear at all?
Yes, they are called out on the drawing. I couldn't show the drawing due to customer privacy
@@TopperMachineLLC Thanks Josh, I wondered
Why are the two cutters not aligned with each other?
One had a chipped corner and was ground down to still be usable. Does not affect the finished product.
did you use the kool mist at full strength or diluted?
It is diluted
@@TopperMachineLLC Mist cooling systems are wonderful. Very economical and effective.
... in enclosed systems. It is normal to breathe in various vapours, odors and emulsions throughout the working day in a workshop. But are you sure you want to multiply that by orders of magnitude?:). Of course, that depends on the size of the nozzle and the type of emulsion, which ultimately blows through the workshop as "fallout". Just as a side note and thought. Thanks for the great and entertaining video. subscribed! :)
@@dieSpinnt I use so little mist coolant that it really isnt a concern. This job was the first time ever in my shop. It will continue being used for these particular jobs, but again, very limited use. I also have a large exhaust fan in the shop for smoke/mist. For the most part, I run dry on everything but drilling and small milling. Sometimes a little oil goes a long way. I really hate the mess and smell of these things lingering in the air all day, and into the house on my cloths.
Why not use the Cold Gun?
I wanted the lubrication supplied by the coolant. The cold air gun is great with carbide.
👍😎👍
After cutting the keyways is manganese bronze difficult to deburr ?
Wasn't much burr with the Kool mist unit. More burr on the one I did with oil. Cleaned up quite easily
I've done some work with Mn bronze. It isn't too bad to finish, but it will load up files and sandpaper very quickly. Doesn't form much of a secondary burr if you're careful. I will say that getting good result with a whirlybird type tool was tricky; tends to catch and dig in at some point and skate off of others. It feels more "crumbly" then the other tough bronzes I've dealt with.
It looks like this machine is hard on the back always bent over.
All machines are this way. Just makes for a stronger back.
You might not have such a cavalier attitude in 20yrs time, just saying.
My father was a slotter by trade.
Every time you’re gone Two times speed. Why can’t you slow down so at least I can hear and know what you’re talking about. Otherwise I will quit watching you.
Hey Josh HRU ?
There shouldn't b Any Doubt that u'll get the job , let us no OK ?
Take Care
B Safe
🇨🇦