Appreciate peoples ideas

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Appreciate peoples ideas

This topic has 9 replies, 4 voices, and was last updated 14 August 2018 at 11:06 by Gordon W.

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13 August 2018 at 18:41 #367144
Absolute Beginner
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@absolutebeginner
Hi All,

I just thought I might ask some of you clever chaps your thoughts as to how to produce a slightly "rounded/hollowed" surface to a flat piece of aluminium bar.

So I have a piece of aluminium tube 2 inches in diameter and I want to mount a pice of flat aluminium bar onto its circumference/surface. The mating surface is only 10mm wide, I would like to make the bar joining edge 10mm reflect that of the diameter of the bar 2 inches. I was thinking of using a ball end milling cutter to try and mirror the circumference of the tube but to get the correct dimensions I guess I would need a cutter to be 2 inches …..not easy.

Any thoughts as to how I might be able to achieve this consistently ?

Many thanks in anticipation of your suggestions,

Gary
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13 August 2018 at 18:41 #26138
Absolute Beginner
Participant
@absolutebeginner
Help with ideas to produce a curve/hollow shaping a flat piece of material
13 August 2018 at 18:48 #367150
JasonB
Moderator
@jasonb
Here are two methods for starters
13 August 2018 at 18:58 #367151
Absolute Beginner
Participant
@absolutebeginner
Jason, thanks so much for your reply what cutter is that in the mill. How have you achieved such a large diameter?

Gary
13 August 2018 at 19:07 #367157
Absolute Beginner
Participant
@absolutebeginner
Jason

I think I have answered my own question above. A boring head.

Now why didn't I think of that………..Many many thanks

Gary
13 August 2018 at 20:16 #367174
Neil Wyatt
Moderator
@neilwyatt
You need this month's reader's tip from MEW.

If you can lean your mill's column slightly and use a large radius end mill, by experimenting with the angle you can get a good approximation to the correct curve.

Neil
13 August 2018 at 20:21 #367176
JasonB
Moderator
@jasonb
That gives an eliptical recess not a constant radius and would need a cutter of approx 50mm dia
14 August 2018 at 09:49 #367261
Neil Wyatt
Moderator
@neilwyatt
Posted by JasonB on 13/08/2018 20:21:10:

That gives an eliptical recess not a constant radius and would need a cutter of approx 50mm dia

I did say 'good approximation' – whether that's good enough will depend on the purpose of the item.

Neil
14 August 2018 at 10:02 #367267
Neil Wyatt
Moderator
@neilwyatt
Here we go, I've sketched it out in TurboCAD. 50mm cylinder, 10mm wide work and 13mm diameter cutter.

At an angle of 13 degrees the maximum error is about 0.05mm or a four thou with the edges touching.

Is that a close enough approximation? By using 12.7 degrees you can get it down to +/- 0.015mm.

<edit> get the degrees right…

Edited By Neil Wyatt on 14/08/2018 10:09:11
14 August 2018 at 11:06 #367280
Gordon W
Participant
@gordonw
I've just done something similar- a 35mm rad on a piece of brass 25×12 x 40 long. I soldered the brass to another piece and clamped it in the toolpost with packing to the correct hight. Cut in two passes with a flycutter.
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