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Posted by DC on April 24, 2008, 10:32 am
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I have a project where I need to cut a 0.188" radius fillet for about
16" in aluminum. Unfortunately, the cut is at the bottom of a 4.5"
deep channel. I haven't been able to find a cheap (<$20) ball/radius
mill that is long enough to do the job.
However I can get a .75x6" HSS two flute for about $7. Could I get
away with just grinding a radius on the end of the flutes? I don't
have a grinding jig so I'd have to do it by hand. I'm thinking that
it might be wise to grind it such that only one flute is cutting.
That way they don't have to be the same. Obviously, this is a hack
--- I realize that. That said, my tolerance is loose and my budget is
low.
Thanks for any advice,
-DC
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Posted by Tom Gardner on April 24, 2008, 11:12 am
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>I have a project where I need to cut a 0.188" radius fillet for about
> 16" in aluminum. Unfortunately, the cut is at the bottom of a 4.5"
> deep channel. I haven't been able to find a cheap (<$20) ball/radius
> mill that is long enough to do the job.
>
> However I can get a .75x6" HSS two flute for about $7. Could I get
> away with just grinding a radius on the end of the flutes? I don't
> have a grinding jig so I'd have to do it by hand. I'm thinking that
> it might be wise to grind it such that only one flute is cutting.
> That way they don't have to be the same. Obviously, this is a hack
> --- I realize that. That said, my tolerance is loose and my budget is
> low.
>
> Thanks for any advice,
> -DC
You might silver-solder an extension on a short ball-end mill. I've done such
many times with mills and drills. I use a length of angle iron with a section
cut away to access the joint in the tool/extension. Just clamp the parts in the
angle after grinding the ends to be joined to a point. Then grind away the
surplus.
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Posted by Mechanical Magic on April 24, 2008, 11:48 am
Please log in for more thread options DC
If you have the room for a 3/4" end mill, then you have room for a
3/4" extension holding a 3/8" diameter ball end mill.
Or am I missing something?
DJ
> I have a project where I need to cut a 0.188" radius fillet for about
> 16" in aluminum. Unfortunately, the cut is at the bottom of a 4.5"
> deep channel. I haven't been able to find a cheap (<$20) ball/radius
> mill that is long enough to do the job.
>
> However I can get a .75x6" HSS two flute for about $7. Could I get
> away with just grinding a radius on the end of the flutes? I don't
> have a grinding jig so I'd have to do it by hand. I'm thinking that
> it might be wise to grind it such that only one flute is cutting.
> That way they don't have to be the same. Obviously, this is a hack
> --- I realize that. That said, my tolerance is loose and my budget is
> low.
>
> Thanks for any advice,
> -DC
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Posted by ff on April 24, 2008, 12:00 pm
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>I have a project where I need to cut a 0.188" radius fillet for about
> 16" in aluminum. Unfortunately, the cut is at the bottom of a 4.5"
> deep channel. I haven't been able to find a cheap (<$20) ball/radius
> mill that is long enough to do the job.
>
> However I can get a .75x6" HSS two flute for about $7. Could I get
> away with just grinding a radius on the end of the flutes? I don't
> have a grinding jig so I'd have to do it by hand. I'm thinking that
> it might be wise to grind it such that only one flute is cutting.
> That way they don't have to be the same. Obviously, this is a hack
> --- I realize that. That said, my tolerance is loose and my budget is
> low.
>
> Thanks for any advice,
> -DC
Rough the radius with the grinder and finish it with a stone. A radius
gage would help for comparison or a paper template.
Fred
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Posted by Karl Townsend on April 24, 2008, 12:10 pm
Please log in for more thread options Could I get
> away with just grinding a radius on the end of the flutes? I don't
> have a grinding jig so I'd have to do it by hand. I'm thinking that
> it might be wise to grind it such that only one flute is cutting.
> That way they don't have to be the same. Obviously, this is a hack
> --- I realize that. That said, my tolerance is loose and my budget is
> low.
Sure, I've done just that. Use a radius gauge, go slow, be sure you have
relief. You won't take much off for .188 radius.
Karl
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> 16" in aluminum. Unfortunately, the cut is at the bottom of a 4.5"
> deep channel. I haven't been able to find a cheap (<$20) ball/radius
> mill that is long enough to do the job.
>
> However I can get a .75x6" HSS two flute for about $7. Could I get
> away with just grinding a radius on the end of the flutes? I don't
> have a grinding jig so I'd have to do it by hand. I'm thinking that
> it might be wise to grind it such that only one flute is cutting.
> That way they don't have to be the same. Obviously, this is a hack
> --- I realize that. That said, my tolerance is loose and my budget is
> low.
>
> Thanks for any advice,
> -DC