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HSS/Tungsten Tool Honing Machine

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Neil Wyatt17/09/2020 16:37:24
18240 forum posts
714 photos
77 articles
Posted by Circlip on 17/09/2020 11:52:56:

Hope you haven't used what looks like Aluminium for most parts Graham? At one of the ME exhibitions the "Purists downgraded the "Commutator skimming Lathe for model car motors" entered by a Youf because he hadn't used the "Correct" material in its construction. ie Aluminium instead of Cast Iron.

If yours is "Incorrect", S*d the judges, it looks fantastic.

Regards Ian.

Edit, - Next years "JS" award????

Nother edit, It would have cost a lot of money to buy the "Correct" machine to spin rivet the ball bearing operation in industry.

Edited By Circlip on 17/09/2020 11:54:32

Edited By Circlip on 17/09/2020 12:12:08

In the USA I am sure the 'purists' would laugh at our UK obsession with heavy, dirty cast iron for jobs where it's weight or vibration deadening properties are of no benefit.

Surely the best material for the job is the one that does the job best...


Graham Meek18/09/2020 12:20:44
265 forum posts
184 photos
Posted by Neil Wyatt on 17/09/2020 16:34:53:

Looks very nice Graham.


Thanks Neil,

This is the first of a pair of machines which I am working on. The second is a Rotary Hone / Lap for doing a range of bores. This design comes off the back of a novel way of adjusting a lapping tool, which I made a while back to finish the bores of my Steam Wagon. This second machine is still at the design stage, and hopefully John Slater will do some 3D views of this later in the year.

Unfortunately it will be another Aluminium construction for the main body,smiley



Circlip18/09/2020 14:57:56
1197 forum posts

I would never criticize use of Aluminium, it "Looks" as if you've used 6082?. Only improvement I would suggest is to anodize the bits to save the prospect of any oxidation, and yes, although other grades of alloy are better, 6082 DOES anodize.

Another couple of "Expurt" criticisms. The use of Plywood in the construction of the impeller on the first home constructed working model gas turbine. - Read the calcs, it DOES work. And a real gem, the use of reclaimed tinplate (print side in) on the painted cleading of a model steam loco. LBSC did have words to the judges on that one.

Regards Ian.

ChrisH19/09/2020 18:25:21
879 forum posts
29 photos

What can you say but WOW!

What a lovely bit of kit, so well designed and then so beautifully made. Following with considerable interest.

Will you be publishing plans for this (in a MEW article perhaps)?


Graham Meek20/09/2020 12:13:20
265 forum posts
184 photos

Hi Chris,

An article is already underway. The Editor of Home Shop Machinist, George Bulliss expressed an interest in this machine as soon as he saw John Slater's 3D views some months back.

I cannot say whether this will get published over here at this moment in time.



Mike Poole20/09/2020 13:14:09
2746 forum posts
64 photos

Aluminium extrusions have replaced steel and cast iron for most of the jigs in the motor car industry. Some ingenious contraptions are constructed to deliver parts for robots to pick from, lots of gravity roller conveyors are used. 17km of aluminium monorail track was installed in the body shop for interprocess conveyor. This stuff gets a very hard life making a thousand cars a day.


Graham Meek20/09/2020 16:22:59
265 forum posts
184 photos

We were using Structural Aluminium to build tooling back in the early 90's.

This ranged from Robotised assembly tools that completely assembled things like the indicator and headlamp stalks for Audi and Ford cars. Various smaller items like door switches for Toyota and Ford. As well as Micro Chip handling units. The movement of Compact discs from the moulding press through metalizing, lacquering, printing and packaging. The complete manufacture of friction window stays from raw material through pressing, to assembly and packaging. Plus the assembly of Carbon Fibre segments which would eventually become disc brakes for Aircraft. All were based on structural aluminium systems, like Bosch Rexroth, but there are others.

Many of the specialist pieces of equipment used in Radiotherapy were also built using these systems, but I cannot divulge anything about these machines.



Nigel Graham 221/09/2020 00:29:34
748 forum posts
16 photos

I don't know the material of the slideway itself, but isn't the 'Peatol' lathe bed a hollow aluminium alloy extrusion filled with a special form of concrete?

This is not really any different from the system I have read a major German manufacturer using for building massive machining-centres, though their casings are welded steel fabrication.

I worked for several years for a leading maker of very high-precision screen-printing machines used in electronics-component manufacturing. These machines had, and their successor designs still have, fabricated steel frames bearing large aluminium-alloy plates machined to complicated shapes as the bases for the moving parts.

My role was materials store-keeper, when the company made a lot of the machine parts itself. Among the stock materials I had to order, read off the drawings, was a lot of aluminium "tool-plate". I am not sure of the alloy grade but it was simply wrought plate machined or ground to precise thicknesses and flatness.

No - there is no logical reason why this tool-grinder could not be made from aluminium alloy.

Same with the commutator lathe cited by Neil Wyatt. I would envisage such a lathe, designed for a special, light task, as having its aluminium-alloy saddle fitted with linear bearings running on parallel round bars rather than dovetailed bed; extending through the end-plates of a box-pattern headstock.

As for purists, I recall at one major exhibition, overhearing one say agree with his pal that some minor detail was "wrong", on the machine I was admiring. It was a traction-engine to 3 or 4-inch scale, clearly well-built but not newly, carrying the honourable patina of a well-loved engine that had seen a rally-field or two, as intended. I wondered which were the critics' exhibits...

Michael Gilligan21/09/2020 08:30:54
16389 forum posts
715 photos
Posted by Nigel Graham 2 on 21/09/2020 00:29:34:


Among the stock materials I had to order, read off the drawings, was a lot of aluminium "tool-plate". I am not sure of the alloy grade but it was simply wrought plate machined or ground to precise thicknesses and flatness.



It’s cast, and therefore reasonably stress-free ... wonderful material.

Here’s a quick link for reference: **LINK**


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