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Making Tool holders for my Shaper

Used the shaper to make parts for Toolholders for itself..

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Joseph Noci 101/09/2017 15:42:40
542 forum posts
832 photos

Me again...

I used my Nice New ALBA NC shaper to make new jaws for its vice, and promptly decided that the next thing to make is a darn Chip guard! Wow, can that shaper toss chips about! As the only space I have left for it is in the Woodwork shop, chips don't go down well in there!

So, here are some pics of the guards - quickly fitted and removed by means of 4 thumbscrews, and 4 ex-hard-disc drive magnets siliconed to the guards:

chip guard1.jpg

chip guard2.jpg

chip guard3.jpg

Two right side thumbscrews

chip guard thumbscrews.jpg

Two left underside magnets

chip guard magnets under.jpg

chip guard front end open.jpg

Then I started making some toolholders for cutters made from 10mmx16mmx80mm HSS.

First doing the flat bars in the shaper:

smoking chips1.jpg

smoking chips2.jpg

One bar is 12mm thick, the upper bar in the pic below, the other is 16mm thick. The 12mm bar made horrid chips - all squashed and scrunched, torn out of the bar, while the lower bar chips curled off nicely. Both mild steel, with black scale, flame cut to sort of size - supplier could not tell me what grade/type of steel these were!

strange chips1.jpg

strange chips2.jpg

strange chips3.jpg

The lousy chips come from the upper bar in the pic below...Surface finish is strange! Same feed speed, DOC, ram speed and cutter as the lower bar. Upper bar cut first.

both bars finish.jpg

holder bar odd finish.jpg

Cutter as ground as used - a HSS cutter 10mmx25mmx150mm

25x10 cutter end view.jpg

25x10 cutter oblview.jpg

25x10 cutter top view.jpg

The open slot end of the tool holder - fitted with steel insert to be welded..

slotted end weldup.jpg

Castle tool holder clamped to bar, ready for welding

holder weld prep.jpg

TIG Tacked...

tig tacked.jpg

All welded and cleaned up, ready to use.

Welding dome with TIG, at 200amps to get real deep penetration, and to put the weld where I wanted - not so easy with MIG..

all assembled.jpg

all assembled2.jpg

richardandtracy01/09/2017 16:01:06
avatar
938 forum posts
10 photos

I suspect the upper bar was structural steel. Had the same finish on a bit of S275 (430 N/mm^2 ultimate, 275 N/mm^2 yield, weldable fine grain steel) from a channel section. Not nice finish. Retains grease well, if it's any consolation.

Looks pretty good otherwise.

Must use my Boxford more.

Regards,

Richard

Andrew Tinsley01/09/2017 16:06:58
919 forum posts

Blimey! The shaper looks brand new! I didn't think shapers were made any more, so it must be a really high grade restoration! CNC too, the mind boggles!

Seriously I suggest that you submit the rebuild (?) as an article in MEW, very little good shaper information about. It would make a change from "One man and his Lathe"

Andrew.

Neil Wyatt01/09/2017 16:47:08
avatar
Moderator
16562 forum posts
687 photos
75 articles

> Seriously I suggest that you submit the rebuild (?) as an article in MEW,

It would be most welcome. I have mentioned this thread in the next issue.

Neil

IanT01/09/2017 18:01:02
1315 forum posts
135 photos

Damn Joseph, now I'm going to have to upgrade from the cardboard box I've been using too!

Regards,

IanT

Clive Foster01/09/2017 22:04:33
1839 forum posts
59 photos

Another vote for wanting to see a write up on the restoration job and details of how the numerical control was done.

Vested interest in my case as a similar NC exercise for mine is on the "have a good look at it list" for, provisionally, 2020 - 21. Shop Gremlins permitting of course. Fairly sure Josephs work on the NC side will be better than what I'd do if starting from scratch. Special attention to gear cutting in y case as I'd like to do a full set of extra gears for my P&W B once the service, spruce up and re-paint planned for 2019 - 20 is done. Not that I need the gears but might as well do the job right.

Clive.

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