Tempering, aligning, and testing

Had a couple of hours in the shop while my dearest was out for her visitation in NUH as a church volunteer. Few things I would like to try out after reading and playing with the ideas in my mind.

First, is to make a center with straight shank - to be used with the ER16 collet. This was also my first time trying my hand at tempering steel.

I cut off a short section of 10mm steel rod and turn it down a little to descale it. The compound slide was set to an angle of 30-degree to allow an included angle of 60-degree.


After cleaning up with sandpaper, I heated the business end of the center with the Proxxon torch. This torch was bought quite a while back from Mike. So far it has only been used to burn some irritating black ants in the kitchen. I didn't manage to get it cherry red as described in some forum postings. Still went ahead to dunk it in a cup of water when I saw the change in colour.


Somehow, I like the darkish colour...


Tested it by using it to align the A2Z adjustable tailstock with a dead center mounted, a painful process but I managed.


The reason for this adjustable one is the drooping of the original tailstock when extended. I'll work on the repair I saw on the web when I have time.

With some time more to burn, I decided to test out the "follower rest"; using the A2Z QCTP and a brass finger mounted. The brass finger was taken from the fixed steady.


It didn't work as i thought it would. I experienced lots of chatter leaving ugly finishes on the stainless steel pin. The diameter was still bigger at the tailstock end though alignment on both end were done.


I'm hoping that this will not be the result I get from using the Sherline's follower rest, which I should be receiving on the 26th this month. The DRO kit and some other items I ordered should be in the same shipment of there is no screw up.

A bigger lathe is still haunting me. It's now seems that the Proxxon PD400 is the right one to go for. The Wabeco D4000E is my dream machine but the price is too daunting; it is quite a few thousands more than the PD400 but with slightly shorter bed 350mm vs 400mm.

With that being decided, The problem left is, how will I be able to smuggle it into my shop without being seen? Not an easy task as the PD400 is quite big to simple hide away from sight. Besides, the bright yellow (splash guard and chips collection tray) and green would stand out from the Sherline lathe and 2 mills, which are black. Sigh...


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New tools

I stopped the previous post frustrated. So thought of putting something more joyful today, being a Sunday - my new purchases. This always perks me up.


These were picked up from Mike the last 2 days. You can see the grooving tool at the far left with the 2 inserts next to it. The little inserts, smaller than the size of my finger nails, are USD23 each (excluding shipping and tax). I did a few tests of the thinner one (~0.79mm) on stainless steel. It "peels" off the metal like when you are peeling off an apple with a sharp knife. It cuts better than the HSS insert I bought earlier but it is also more than double the price of the HSS insert (USD10).

The round block is the raiser for Sherline QCTP. This will help, together with the tailstock raiser (the one below the round block) and headstock raiser (not shown), to increase the size of the stock I can turn on the lathe.



The above came in mid last week from Axminster UK. Took them a month to reach me as the parcel was returned due to unsuccessful delivery. But the service standard of the company's staff was so good that I don't feel a bit mad. There are 3 chatter free countersinks and a stop jig for the straightedge clamp in this shipment.

I'm always happy when I buy things for my hobby; just like a woman on their shopping spree.

Frustrating session!!!

Right after sending off the guests, I went straight to the shop to continue my work on the axles. With the best piece just done, I thought that I would be able to hold the 0.02mm tolerance I set for myself for the job, across the length of 54.1mm. Boy, I was wrong! very wrong! The next piece was out by 0.18mm. The piece after 0.19mm. What the hell went wrong?!

I clean up the lathe, put in a 10mm steel rod with about 75mm sticking out of the ER16 collet. Several light passes were taken with measurements taken at the 2 ends and the middle. After tapping the spindle with a dead blow hammer here and there, I managed to clock an error of 0.02mm across the 75mm. That is good enough for me.

I put in a new piece of 6mm stainless with only 20mm sticking out. Took 0.1mm passes several time while checking the diameters at both ends - I've 0.04mm of error at such short length!!! What's happening?!

Is it the collets I bought from CTC Tools in HK or is it the ER16 spindle I bought from Sherline?!

I'm too frustrated and tired to do further test. I've failed the session today. When can I get such simple job done?!

I've lost my confident at using the lathe. I need help. Who can tell me what I can do to right the alignment problem?

Anyone???

Lunch on me if you can. Please drop me a note. I'm desperate!!!

The axle project continues...

I've just gotten out of kelantan lane with more stainless steel pins. After the many trials I did, I've left with insufficient raw material to finish the job.

We are throwing a small birthday party for my little girl who is turning 8 next Thursday. The event will start at about 5. I should have some time to finish up a few more pieces. Tomorrow is a full working day for me. Won't be able to do any work.

A Mr Ho contacted me yesterday via Daddyhobby's pm. He is looking for someone to cut some holes and slots for 16 ABS boxes. I was told that they are for some circuit boards. I hesitated for a while as, you all know, I've very little shop time due to my work as a legal loan shark. But the thought of being able to try creating a simple jigs for small quantity production work is enticing. The time line of 2 to 3 weeks is a little scary. As much as I want to spend more time playing, I'm often left with a couple of hours once to at most 2 times per week.

I'll have to finish up the job I promised Dennis before starting this. Ive leant a lot from making the axles for Dennis. This, in itself, is the greatest reward.

Let's see how things turn out.


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Dennis' Axles

I was given the weekend off due to my bad lower back (thanks boss!). It is still giving me a bit of problem being rather stiff and the occasional pull but I'm determined to do some work in the shop.

Some thoughts ran through my mind about achieving a uniform diameter throughout the entire 55mm length of the axle I'm doing for Dennis' landing gear. The flex in the tool was eliminated with the purchase of the HSS insert tool for parting & grooving from AR Warner thru LMS. But I couldn't figure out how to eliminate or at least minimize flex in the stainless steel pin, especially when it gets closer to the required diameter of 4mm.

Jerry Kieffer of Sherline group suggested turning by breaking the 55mm length into shorter sections till the entire length is out of the collet. He also warned of having to have accurate collet for this to work.

I spent Saturday afternoon aligning the spindle centre line to the bed and testing out what Jerry had suggested. It turned out well for the first 2 sections but as more of the stock was sticking out of the collet, I've a small "hump" between the 2nd and 3rd sections. Don't know if it can be seen from the pic.


I tested with another piece with the same result. This seems to suggest that I've run-out in the collet. These set of ER16 collets were from CTC Tools. Likely China made as the company is based in Hong Kong and their product ship out from Shenzhen.

So now I've another set of problem to solve... Sigh... I'm using the ER16 as Sherline's MT1 collets with the drawbar doesn't allow the stock to pass through the spindle bore. maybe I should cut the grooves on all the stocks first and either turn it between centers or use the 4-jaw chuck.

I did complete 2 pieces yesterday but I miscounted the dial resulting the 1st one to be a little shorter (by about 3mm) than the required length. Screwed up the other one, my best so far, when cutting the flat, also due to miscounting of the handwheel dial. So, 2 pieces completed with defects... Sigh... I need DRO!!! Mike, when my DRO coming???


This one has a flat of 1mm deep. Supposed to be 0.45mm. What was I thinking...

One other thing I can do in the interim; switch off my phone when in the shop. Both boo-boo's where made when I was interrupted by phone calls; one was from my colleague and the other a prospective client.

That's all for this week. Before I go, I posted the pic of my next purchase, probably ordering it by end August. Shipping will take about 8 to 9 weeks (hope I hear that wrong). Don't ask me if I need it, or will be able to make full use of it. I'm just attracted to it's bright colors and my need to de-stress.

Here goes:




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Sad weekend

Got up early on Saturday to try out the Arthur R Warner HSS grooving tool I bought through LMS before my showflat duty at Seastrand. I was careful in my setup to make sure I've as little flex as possible in both the tool bit and the stainless steel pin. The circlip groove and the 3mm grooves turned out well and right at where they are supposed to be. Took a couple of pics and went on to prepare for work. I suddenly felt a pull on the lower part of my back, towards the left. Thought that it may just be the way I was standing over the lathe to tighten this and that and paid little attention to it.

The pain worsen and I was limping out of home. It's felt like spasm in the lower back. I couldn't stand straight and sit comfortably. Bear through the day and ended work at around 8pm when my colleagues asked me to.

My wife came over to pick me up to see a senseh. Spent an hour being "tortured" by the senseh. The condition didn't improve.

Now I'm lying on my bed typing this post on my iPhone. I've quite a long day tomorrow at work. Praying for miracle of instant recovery. July is another month where we are paid additional revenue for what we're bringing in. Can't afford to be down again. I could have done much more in June if not for the fever.

Ok, the 3
pics I took. Nothing much than testing of the grooving tool.


Using the Sherline thin parallel to ensure tip of tool at centre line.


First groove done. The tool was advanced by turning of handwheel to the next position. Gcode done for the ops but I want to ensure that I've flex down to minimum before going on CNC.


While cutting this 3mm wide groove, I can feel the flexing of the job as cutting came on and off though the tool was advanced consistently.

I'm planning to push the job into the collet leaving only minimum hang out.

For now, I'm banned from the shop. Quite boring lying on the bed for an active person (not in the sense of being active in sports but constantly wanting to work on something).

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Purchases from Little Machine Shop

The Arthur R Warner Co. HSS inserts have finally arrived! Ordered them from Little Machine Shop (LMS) about a week or two back.

I started searching for HSS inserts after hearing from Tang Kee and reading about it on LMS. Just that I couldn't find the exact part number given on Sherline's site for their tool holders. I emailed Arthur R Warner Co. asking if they make HSS inserts that fit. Received a reply the next day with their recommendation. Unfortunately, they don't accept payment via Paypal and I'm not comfortable providing my credit card details via phone or email. Wrote to LMS with the part number given and was told they are able to order from Arthur R Warner for me at the same price! Now I'm able to use HSS on aluminum stock with inserts!!!

Included in this shipment is the cut off & grooving tool with HSS inserts, also made by Arthur R Warner.

Some pics to round off this post:






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