Making & Testing HEAVY DUTY Button Tool Holder | Shop Made Tools
how you going guys Kurtis from Cutting Edge engineering today's job we're going to be making a pair of heavy duty button tool holders for our big lathe so if you've been watching our videos for a while you'll know I love using button inserts or round inserts for removing weld off components like barrels and rods in order to separate them so they can be repaired they're also great for doing weld prep and just bulk material removal because they are so robust and heavy duty and versatile they are just a great tool to use for those sorts of jobs but one of the ongoing problems that we have is clearance between the tool holder and the job because of the size of the components that we do it is quite difficult to be able to machine all the way to the base of a weld joint the tool holders just don't have enough length in them and the manufacturers only make them to reach a certain distance so the standard working depth of a tool holder is about 35 mil and when you're talking a 230 mil diameter rod that is just not enough so I have modified tool holders and machined a relief in the side of them so I can extend their working depth but that only gets me so far so we're having to slide the tool past its point of where it works comfortably in order to reach those depths but that causes vibration and rigidity issues so then I have to take relief cuts on either side of the tool in order to give it clearance to get deeper to get to the bottom of the weld joint any material that I have to remove from the component I'm trying to save I then have to put back by welding it so that creates extra work which means extra time and as you can see the tool holders do suffer quite a bit of damage because of the clearance issues they end up contacting the job which damages the holder so I thought it was about time we made our own tool holders to eliminate all of those problems and our new shop made tool holders are going to have a working depth of 115 mil so the material we're going to be using is Biz 80 high tensile plate and I've had that plasma cut to a rough profile of what we need and we're going to be machining those to a 32 mil tool height which will suit our big lathe and our frontline tool master lathe before I get them set up in the mill I am going to take them over to the linisher and remove any of the surface rust before we get them set up now that we've got that set up I'm going to go through with a boring head that I use as a fly cutter just to clean up the top surface so I've got that set to point three of a mil depth of cut so that didn't clean up so I'm going to take another pass at point five of a mil depth of cut while I've got it set up like this I'm going to use a 16 mil roughing end mill just to clean up and true both the ends now with that done I'm going to clean up these sharp edges there are many different ways you could do that but I'm just going to use my linisher with a conditioning belt on it now that I've got those flipped and set back up I'm going to use the end mill just to clean up the face that the cutter couldn't reach now with that done I need to finish machining the shanks to 32 mil to suit the tool height on the lathe so I am going to machine a true spot zero out my dro and take a measurement to how much material needs to be removed to finish off the shanks so that's measuring 35.5 which means I need to take off 3.5 mil before I fly cut that to depth I am going to come into this corner and machine the two faces and that's also going to give me clearance for the fly cutter yeah right we're good so you could definitely use a shell mill or an end mill to machine all these faces but the problem with that is they generate quite a bit of heat and you would have to run coolant and when you're trying to film when there's coolant getting around it makes it quite difficult so we've done this using a fly cutter it does take a little bit longer but we don't have to run coolant and it does leave a nice surface finish now with that machine to depth I'm going to do a clean up cut on the face that's is going to be the bottom of the tool holder so that's all the machining we can do with the tool holders together I'm going to separate them so we can do the next step now we've got the first holder set up the first thing we're going to be machining is the extension or the working area of the tool holder so because I've got a machine 10 and half mil off both sides I will be using a shell mill and I am going to need to run coolant I'm going to be using a 5 insert 60 mil indexable shell mill righto so I'm not totally impressed with the surface finish that shell mill is leaving so for the final cut I'm going to go back to the fly cutter and make it all nice and pretty so while it's set up on this side I'm going to use a 12 mil ball nosed endmill to put a nice radius through that corner now that that side's done we can flip it and repeat on the other side now with that done I can set the tool holder up so I can machine the pocket for the insert now I'm just going to use the edge finder to locate the position for the inserts pocket to mill the pocket into the tool holder I did get a custom endmill made up that has the exact same geometry as the button inserts do because the inserts I'm going to be using they are not parallel they are tapered just using a standard endmill that only cuts a parallel hole would not give the insert enough support so all I need to do is drill this down 5 mil but I don't have a digital readout on the quill so I'm going to lock the quill in place and use the knee to lift the table the 5 mil right so this is probably the scariest part of the entire job I'm going to be drilling and tapping a hole for an 3.5 mil screw that holds down the insert so I actually had to order in the Taps and the drill for this I don't have anything that small what I'm going to do first is drill down with a 2.9 mil drill I'm also going to chamfer the top of the hole just to help the tap get started in the center so to thread the hole I'm going to be using two different types of taps one is a starting tap to get the thread started then I'm going to use a finishing tap to fully form the thread normally I would use a gun tap or a spiral tap unfortunately they are not available so I do have to do this in two step this tooling is extremely small this does make me very nervous I'm used to working on big equipment with big drills and big taps I am quite heavy-handed so I'm very concerned I could snap this tap in this hole pull it out n clear it [Karen] [anxious sigh] right so that was very successful we've got the hole drilled and tapped to depth the screw fits in very nicely I think we're good so the next thing I need to do is take this back out of the vice and set it up so I can cut a radius across the front to give the insert some relief [Karen] okay uh oh jeez no just wait wait hey oh you want that one hang on a minute sit ah ah ah good boy [chomp chomp] [nom nom nom] righto guys so that's our tool holders completed I've gone through and deburred them and also fitted the inserts the inserts fit perfectly and I'm really happy with how everything turned out I'm probably going to send these out to be Nitrided just so they've got a nice clean surface finish but there's one way to find out how well these work and that's to put one to the test and we're going to be testing it on removing the eye off an ex1900 bucket cylinder rod so this is 150 mil diameter rod with the standard tool I would have to relief cut either side of the tool in order to get the depth that I needed so this is going to be a really good test to see how this performs that's pretty solid [Karen] that's moving righto so that performed absolutely perfectly we didn't have any chatter or any vibration issues I was just plunging straight in I was moving it left to right about half a mil so I wasn't overloading the insert but that really ate that material and you could see there was plenty of clearance between the eye rotating and the top slide and the tool post when you're using a standard tool holder everything is much closer to the job and it could be a lot easier to have a collision if you're not aware about what's going on around it so by having that extra length that gives me a great deal more space where I don't have to worry about it so the tool hleer performed a lot better than I actually expected it to because of the length of it and what I'm asking it to do it is quite a lot of load to be putting on a tool there are a few things I would change if I ever remade these I would make it slightly longer so it was the exact same length as the tool holder and I would probably shorten the bottom of it just a little bit so it was level with the bottom of the tool holder but other than that I'm really happy with how they came out this is just going to make these sort of jobs that we do so much easier so for a couple of hours of time and about $60 in material these were well worth the investment yes I did have to buy in some specialized tooling but I am going to be using that on a big custom cutter that I need to make in the future so I still needed send these out for nitriding but that's this job done thanks for watching [nom noms] [burp] [Laughter] this performs very similar to a parting blade the way you can just plunge it in so I think I'm going to call this a button blade [Laughter] so I have modified two holders ughh so I have moditi oh moditide but an ongoing problem I've been ugghhh [giggle] but an ongoing problem that I've ugh [ __ ] but an ongoing problem that I seem oh [ __ ] [giggle] but an ongoing problem I've had oh [ __ ] [awkward pause] how' you say it so I'm gonna i'm MmmmMMM [Laughter] now with that done oh [ __ ] what' you say [Karen] Kurtis has got it what'd you say [Laughter] I was just able to plunge straight in just move left to right just a little just to give the tool [Karen] WOAH just using a twen ughh twanded just moving at [giggle] [ __ ] me [ __ ] off train you are sss mmmmm [even more awkward pause] [Karen] malfunction [Laughter] [Karen] you can see when it started to get hot pretty [Karen] that is bloody close no where near it [nervous giggle] [Karen] look how close that is ooooohh BANG [Karen] ohhh you're a wanker [giggle] [Karen] ooh was that it or one more I need to see OH ha ha [Karen] pfft hah oh that shirt is not in good shape [giggle] I think I'm due for some new ones [Karen] it even made a cute sound I feel like I'm making watches [Karen] did that do anything don't know I'm not willing to gamble anymore [Karen] [sigh] can't even see in there oh I can't even feel anything [Karen] what why would you go there you didn't give me direction oh jeez [Laughter] [Karen] spin it no no what what spin it what does that mean to you [Laughter] spin spin [squawk squawk] there's a [ __ ] bird they both up there I think oh yeah I can see the other one outside [squawking continues] here he comes where where'd the other one go I thought I saw him fly past [chirp] oh there he is he's right there come here hey oh you missed out [cute chirps]
2024-02-07 17:55
