anyone got any idea on tooling to carry this out

This topic has 27 replies, 11 voices, and was last updated 23 March 2026 at 17:54 by kilmolymock.

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22 March 2026 at 10:53 #841874
kilmolymock
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@kilmolymock
looking for tooling / punch /jig to form these indents in low carbon bright
Advert

22 March 2026 at 11:52 #841878
Robert Atkinson 2
Participant
@robertatkinson2
Looks like it’s just 3 round punches on a PCD slightly larger tha the shft diameter. It would be fairly simple to make up a guide to slip over the shaft with 3 guide holes. The outside of the guide holes would have to be relived outside the shaft PCD to allow the metal to be displaced.

If not worried about exact postioning just use a flat ended round punch freehand.

Robert.
22 March 2026 at 11:53 #841880
Dave Halford
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@davehalford22513
If they are all of equal depth I would expect a large ish hand flypress at least £200 worth.

You could replicate one at a time with silver steel and what ever size hammer that works but the washer may cock over.
22 March 2026 at 12:14 #841882
kilmolymock
Participant
@kilmolymock
Yeh I would be looking for repeating over and over the same depth each time, keeping the washers parallel and square

,I was thinking about boring or drilling a sleeve out and coming in from the side with 3 pieces of silver steel to form the indents as the top and bottom of the core needs to stick out about 1.5mm above the washers each end

that pic shows one knurled both ends and the washers just pessed on
22 March 2026 at 12:31 #841888
Robert Atkinson 2
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@robertatkinson2
Ahh. an idea of the size and that it was double ended would have helped….
22 March 2026 at 13:13 #841892
kilmolymock
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@kilmolymock
Sorry about that ,was getting earache at the time about cooking a chicken! 8mm shaft, soft bright steel ,32mm long ,washers 1-2mm thichness held at 1.5 mm either end of shaft, washers only need stopped on the outer faces
22 March 2026 at 14:50 #841901
Robert Butler
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@robertbutler92161
A reduntant drill chuck ??

Robert Butler
22 March 2026 at 15:13 #841912
old mart
Participant
@oldmart
The indents are for retaining the washers only, I presume. Another way would be a vee groove turned in the end of the shaft near the outer edge which could be swaged outwards by a turned press tool with a vee shaped ring of a slightly bigger rad. Used quite often for retaining parts on shafts for aircraft use or parts in holes.

A larger size punch with three blind holes with three pins set into them standing out from the surface would be easy to make.
22 March 2026 at 15:49 #841914
Dave Halford
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@davehalford22513
On 22 March 2026 at 12:14 kilmolymock Said:

Yeh I would be looking for repeating over and over the same depth each time, keeping the washers parallel and square

,I was thinking about boring or drilling a sleeve out and coming in from the side with 3 pieces of silver steel to form the indents as the top and bottom of the core needs to stick out about 1.5mm above the washers each end

that pic shows one knurled both ends and the washers just pessed on

So production, you need a proper fixture to remove any measuring, if you model engineer this it will cost too much time.
22 March 2026 at 17:25 #841925
kilmolymock
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@kilmolymock
Yes, that is what I am after
22 March 2026 at 17:43 #841930
kilmolymock
Participant
@kilmolymock
I do groove both ends as it is but was looking at getting away from that as I only have manual machines, after a day standing at a lathe grooving both ends of these I end up drawing ducks on the wall and throwing bread to them
22 March 2026 at 18:18 #841938
bernard towers
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@bernardtowers37738
A whole (8hrs) day how many are you making?
22 March 2026 at 18:43 #841945
Peter Cook 6
Participant
@petercook6
If I understand correctly, the washers don’t need constraining inwards, i.e. are free to float just can’t come off.

Would a hollow tube, loose fit on the shaft, with three punches mounted in the bottom and three guides, a sliding fit on the shaft work?

Drop a shaft in, hammer/press the top end – remove slip on two washers and put it in upside down and repeat the press action.

The guides inside the tube are needed to provide space for the indents to come out.
22 March 2026 at 19:18 #841953
kilmolymock
Participant
@kilmolymock
Yes, the washers can float inwards at the time of “punching” Iwas thinking along these lines
22 March 2026 at 19:23 #841954
kilmolymock
Participant
@kilmolymock
As many as i can in one working day , but then I never said I worked 8 hrs a day , I am lucky enough that I can choose what, when and for how long I do my doings for
22 March 2026 at 20:23 #841961
Dave Halford
Participant
@davehalford22513
If you don’t need the shoulders for the washers you don’t necessarily need the lathe. You can use a bandsaw or donkey saw with a simple length fixture unless the ends need to be very square.

But you need to be very accurate with punching the three detents to keep the length so this or a larger one is required
22 March 2026 at 20:32 #841964
kilmolymock
Participant
@kilmolymock
Shoulders required and ends require machining, I have presses, lathes ,miliing machines, it was only the means of creating the 3 retaining dimples , i will try making up the tooling in that little sketch
22 March 2026 at 23:11 #841971
Dave Halford
Participant
@davehalford22513
On 22 March 2026 at 20:32 kilmolymock Said:

Shoulders required and ends require machining, I have presses, lathes ,miliing machines, it was only the means of creating the 3 retaining dimples , i will try making up the tooling in that little sketch

Yes, the washers can float inwards at the time of “punching” Iwas thinking along these lines

????
22 March 2026 at 23:23 #841973
kilmolymock
Participant
@kilmolymock
23 March 2026 at 06:15 #841974
cedric 1
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@cedric
On 22 March 2026 at 23:23 kilmolymock Said:

I can’t see how that is going to work. The indents will be in the wrong plane from your original picture. And the displaced metal would make it impossible to pull the part out of the tool afterwards.

It looks to me like your 3 round punches need their axes parallel to the axis of the job.
23 March 2026 at 06:27 #841980
kilmolymock
Participant
@kilmolymock
it is only sketch and an idea, not a good one right enough

but yeh u are right ,brain fog set in ,probably end up with a 2 or 3

part fixture
23 March 2026 at 11:41 #842015
Howard Lewis
Participant
@howardlewis46836
Why not mill a square on the end of the spool and drill/file/punch a square in the washer, so that it is an interference fit?
23 March 2026 at 15:08 #842044
Peter Cook 6
Participant
@petercook6
I envisaged something like this

Red is the spindle, Green three guides, Blue the three punches, Grey the support tube – without the cut out at the bottom. The guides may be a bit thin, but he design gives room for the extruded metal to expand and still come out of the tool.
23 March 2026 at 15:22 #842049
duncan webster 1
Participant
@duncanwebster1
You sometimes see things that look a bit like Belleville washers but with radial slits not coming right to the od. You can press then on one way, but they won’t reverse off. No idea what they are called or where you would get them
23 March 2026 at 16:39 #842060
bernard towers
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@bernardtowers37738
Spire Nuts
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