How should I make this?

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Subject Author Date
How should I make this? Ian 03-29-2008
Posted by mark@ems-fife.co.uk on March 29, 2008, 5:47 pm
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> I need to make several 'Top Hats' out of stainless steel, below is a sort =
of
> cross section in my first attempt at ascii art.
>
> The part is about 45 diameter and 45 long and will have a wall thickness o=
f
> 1.5mm thick. The flange (brim) is 3mm thick and 48 diameter.
>
> As 50mm barstock will not pass through the headstock of a 5" Boxford I hav=
e
> though about buying cut blanks, gripping the OD in the 3 jaw and fully
> machining the bore. Then machining the OD by holding the part on some sort=

> of mandrel. (The inner and outer concentricity need to be within 0.2mm or
> so)
>
> My dilemma is trying to decide how to hold the part on the mandrel (which =
I
> don't want to take out of the chuck until I've made all of the parts.
>
> I have thought of making an expanding mandrel which is somehow activated
> through the headstock spindle but it seems overcomplicated
>
> Thanks in advance for any suggestions
>
> Ian Phillips
>
> llllllll
> llllllll
> lllllllllllllllllllllllllllllllllllllllllllllllll
> =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 llll
> =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 llll
> =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 llll
> =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 llll
> =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 =A0 llll
> lllllllllllllllllllllllllllllllllllllllllllllllll
> llllllll
> llllllll

As you`re limited by the spindle bore it would be better to get cut
blanks about 47mm long.
Grip in the chuck and rough bore the hole.
Do them all to that stage.
Grip in the bore with your three jaw and turn and finish the OD all
over.
Bore a set of soft jaws and grip on the OD and finish bore and face
off flange.
Mark.

Posted by _ on March 29, 2008, 5:50 pm
Please log in for more thread options
 On Sat, 29 Mar 2008 21:29:10 -0000, Ian wrote:

> I need to make several 'Top Hats' out of stainless steel, below is a sort of
> cross section in my first attempt at ascii art.
>
> The part is about 45 diameter and 45 long and will have a wall thickness of
> 1.5mm thick. The flange (brim) is 3mm thick and 48 diameter.
>
> As 50mm barstock will not pass through the headstock of a 5" Boxford I have
> though about buying cut blanks, gripping the OD in the 3 jaw and fully
> machining the bore. Then machining the OD by holding the part on some sort
> of mandrel. (The inner and outer concentricity need to be within 0.2mm or
> so)
>
> My dilemma is trying to decide how to hold the part on the mandrel (which I
> don't want to take out of the chuck until I've made all of the parts.
>
> I have thought of making an expanding mandrel which is somehow activated
> through the headstock spindle but it seems overcomplicated
>
>
> Thanks in advance for any suggestions
>
> Ian Phillips
>
>
>
>
> llllllll
> llllllll
> lllllllllllllllllllllllllllllllllllllllllllllllll
> llll
> llll
> llll
> llll
> llll
> lllllllllllllllllllllllllllllllllllllllllllllllll
> llllllll
> llllllll

Can you make soft jaws?

Do the hole and that side of the flange.

Flip it over and grip from the inside with the soft jaws; do the outside.

Posted by Dragon on March 29, 2008, 6:18 pm
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>> llllllll
>> llllllll
>> lllllllllllllllllllllllllllllllllllllllllllllllll
>> llll
>> llll
>> llll
>> llll
>> llll
>> lllllllllllllllllllllllllllllllllllllllllllllllll
>> llllllll
>> llllllll
>
> Can you make soft jaws?
>
> Do the hole and that side of the flange.
>
> Flip it over and grip from the inside with the soft jaws; do the outside.

Several folks have suggested something like that.
As the actual item is not as robust as the sketch would suggest, is there a
danger that it will distort when held by the bore?

Henry



Posted by Ian Phillips on March 29, 2008, 6:36 pm
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>
>>> llllllll
>>> llllllll
>>> lllllllllllllllllllllllllllllllllllllllllllllllll
>>> llll
>>> llll
>>> llll
>>> llll
>>> llll
>>> lllllllllllllllllllllllllllllllllllllllllllllllll
>>> llllllll
>>> llllllll
>>
>> Can you make soft jaws?
>>
>> Do the hole and that side of the flange.
>>
>> Flip it over and grip from the inside with the soft jaws; do the outside.
>
> Several folks have suggested something like that.
> As the actual item is not as robust as the sketch would suggest, is there
> a danger that it will distort when held by the bore?
>
> Henry
>

I suppose that is why I wanted to grip it with something that expands
equally all round. I have considered Loctite'ing it to a mandrel then
heating it after machining to loosen the bond.

Ian



Posted by Ian Phillips on March 29, 2008, 6:33 pm
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> On Sat, 29 Mar 2008 21:29:10 -0000, Ian wrote:
>
>> I need to make several 'Top Hats' out of stainless steel, below is a sort
>> of
>> cross section in my first attempt at ascii art.
>>
>> The part is about 45 diameter and 45 long and will have a wall thickness
>> of
>> 1.5mm thick. The flange (brim) is 3mm thick and 48 diameter.
>>
>> As 50mm barstock will not pass through the headstock of a 5" Boxford I
>> have
>> though about buying cut blanks, gripping the OD in the 3 jaw and fully
>> machining the bore. Then machining the OD by holding the part on some
>> sort
>> of mandrel. (The inner and outer concentricity need to be within 0.2mm or
>> so)
>>
>> My dilemma is trying to decide how to hold the part on the mandrel (which
>> I
>> don't want to take out of the chuck until I've made all of the parts.
>>
>> I have thought of making an expanding mandrel which is somehow activated
>> through the headstock spindle but it seems overcomplicated
>>
>>
>> Thanks in advance for any suggestions
>>
>> Ian Phillips
>>
>>
>>
>>
>> llllllll
>> llllllll
>> lllllllllllllllllllllllllllllllllllllllllllllllll
>> llll
>> llll
>> llll
>> llll
>> llll
>> lllllllllllllllllllllllllllllllllllllllllllllllll
>> llllllll
>> llllllll
>
> Can you make soft jaws?
>
> Do the hole and that side of the flange.
>
> Flip it over and grip from the inside with the soft jaws; do the outside.



Soft jaws sounds a good idea but I don't have any.

Ian



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