Compact rotary broach - Part 3

[Music] hey welcome back to a shop this is part 2 on comfort rotary broach I'm building off a Hemingway kit and right now I'm encounter boring the mounting holes that hold the body to the shank and I have to read rind I took a 6 millimeter drill the standard twist drill and I ground a step on the end and Irish sharpened the cutting edges with my die grinder with small colorful but have a pilot with counter bore with 6 millimeter major diameter and 3.5 millimeter minor diameter I don't have such a counter bore I don't even think such such a thing exists normally they have six point five millimeter all the diameter and smaller pilot but there is no space for a bigger counter bore Bangor so I had to regrind drill bit another way to do it would have been to use a six millimeter end mill and plunge down but I would have to indicate each hole by itself and I think that's faster and I'm holding the part ship in a three chart Chuck and that's sliding freely on the table so it can align with the pile up on the counter board a little bit of cutting oil there we go okay works a treat and while I'm freehanding at the milling machine a quick safety tip whatever you do on the milling machine if you hold a part freehand and also this wild lumber drill press never never never never props or pinners in the tea flops when you hold the part like the propping of finger in a tea flop whether on part does not ask that but if you have a wife's or something like that and you try to hold it and you prop your finger then you get a catch why fooling around and here your finger off flush to the table how to get a nice guillotine action between the table and your park so don't ever do that never prop your fingers in the P float is and as I can see this one over here is already done it's finished and this one still needs some work well I have done I aligned it the two parts are left here with flat line and you can align them side to side following this key we machined in and you need to align them so if you have a broach in there that the end of the broach runs through and I set that just on a lathe with an indicator and it will show you that in a second and after we have set that to Center we will take out once true at Loctite screwed in and to the other screw to so it's locked permanently there are there is no need to adjust this later and long if you make all the approaches to the same length that's not a problem the first burger I made this is a four millimeter hacks almost four millimeter I just rushed this out of a piece of high speed steel to get a first test running and it works quite well and after I have set the split line correct and locked it in place I can machine the outer diameter of the brooch down so the alignment surface here when ish and look at it gets a nice and neat package I will also engrave into them the length of the punch deck has to be used with so it has to make a punch for a brooch for the sky in five years from now and I don't have to drawing around I just have the measurement readily a will on the tool so that's also another thing to do and of course we'll make a bunch of these brooches I want a complete set of hex brooches from from two to six millimeters across the flats I clamp the rotary broach in the colored Chuck and I left enough space here between the rear face of the shank and the collet so I can take a hex wrench and tighten the crews that hold the shank the tool together and the whole reef for the sole exercises to align the the tool itself on the shank when I when I spin the chap you you see all sorts of run out be at the tool itself is angled by one degree it it has this weird motion this weird run out and avid tool with a comb in a diameter clamped and to its end in the body or in the spindle of the broach and I have my indicator tip at the precision where the normally me rotary broach would be ending the face of a real research would be at this position as you can see this is roughly the face of tool is roughly in line with the tip of the dial test indicator and when we spin the spindle we get a run out up here on the indicator and we want that run out to be as small as possible and I will do that with a hammer and but by looting by tightening by semi tightening the screws so I can bump the body of tool around and now I need to deburr the crush hole here that's typical crater work and scraper three-sided scraper which is in this case there were no needle file that I harmed on the end is not an eel it and then I ground it like a straight okay I get a very useful tip a few days ago the luer lock how to donate needles that is used for solder dispensing and also for medical syringes they fit without any modifications on the tip of a Loctite bottle also on the big lock tight bottles see this one go down without the modification and that's a very useful thing if you have because the original nozzle of the bottle is not very precise to speak to speak friendly and I guess I got a whole assortment of these luer lock hypodermic needles those are without a short tip I also have shortened one these are medical needles these will go through flesh without without problem and you have to be careful with those hurts like hurts like crazy if you get puncture with those and also you don't want to get locked tight thread Locker under your skin so let's take out will the first screw I do not remove both screws get some thread Locker on there and drop them back in place that's just so nobody does accidentally change the setting of the offset setting up this tool so it doesn't hurt to lock strike them down so they are fixed in position and this is just the lock type 270 high-strength thread Locker not the six four eight bushing glue that holds everything until the end of days flushing the middle out with some isopropyl alcohol and some compressed air okay I have taken apart both of the rotary brochures cleaned them out from all from eventual ships that got in there during the machining process of the other shape and also getting rid of any grit from the from sanding it and polishing it so I took them apart and I rinsed everything with isopropyl alcohol then I used some some grease on the open bearing the axial bearing looped it up with a reasonable amount of grease and put them together back together and the process of REE reassembling them i shared off one of the pins of this face banner is one of the adjustable tribes with the pins that you can set to the desired distance and this was a as one with 1.5 moving a pins and those pins are not hard shirred trade-offs so I made I made a proper face spanner with which two-minute 1.5 millimeter hardened dowel pins and this is more than adequate probably slightly over killed this will last me a lifetime if I ever need a one point five millimeter face banner with 14 millimeter pin distance again so what we need now are tools or brooches and I've one here that's the one we use and the last video for the test run eight millimeter high speed steel and I ground a four millimeter roughly four millimeter hacks on to it using the single up cutter grinder and I want to make a complete set of these brochures from three millimeters up to six millimeters I just took a look at the two point two millimeter approach and this looks awfully small but I will give it a try to two millimeter and two point five but for now we will start with three four five and six millimeters some high-quality eight millimeter high speed steel this is a cobalt ten ten percent cobalt great high speed steel anthesis as the real deal we will cut off length of 28 millimeters with the cut off wheel on the surface grinder because that's the fastest way to cut I speak steel and I know it's even faster than with the angle grinder for some reason the the the cutoff from use for the surface grinder cut way more aggressive and high speed steel than an angle grinder wheel so let's go over to grinder and cut off some pieces [Music] okay I already ground two of the axe puncture this is a six millimeter hex and this is a five millimeter hex so next we'll grind a four millimeter and the three millimeter one first I need to dress the grinding wheel and now we set the depth or length of the hex section that we're going to write by adjusting the infeed like this and I want about this length now roughing out the you and that's four millimeter plus a little bit and that I would even prefer a bit more oversize because I think when your machine hold with the rotary broach it tends to get smaller slightly smaller than the punch because of elasticity in the material itself but for now this is good enough I have to to get some experience with the rotary broach first because that before I can do more tooling for them I ground Brosius from two millimeters up to six millimeters for beginning I only need one set because I'm out of eight know your high speed steel stock I first need to order a new one as the two rotary broach is finished and also have the key that I possibly never need again okay we're over the milling machine and I have a piece of angle iron hot rod and the end wife and three no meter thickness and I pre-drilled with a five millimeter drill and now we're going to broke up five minutes into some cutting oil help that's for sure then we get it in contact and now we have a chance to align the orientation of our hex just by spinning it and the orientation want and bringing it into contact with the work piece and give some pressure on the quill let me turn on the machine I have it set to 1000 RP a-- there we go it takes its time you will feel that it takes a little bit of pressure on the quill but FB the angle after rotary broach itself is only one degree the chip it takes on each corner for each revolution is quite small at sea I have a 500 hex key here and let us Oh blue this is a very nice fit I will do the second one and then I'm going to bring the camera in bring it in contact give it some rpm I think the pre-drilled hole could almost be a little bit smaller there are still some some round section from drill bit left that can be seen but apart from that doesn't look too shabby also I'm of course lacking experience with such a tool completely I this pretty much the first time I'm using something like this I don't think that the tool is something for super high precision applications but to get a hex into drive something with with an allen key that's that's the right thing to go or if you want the square hole for a carriage bolt that's your tool to go and here you can see the backside of the test piece we don't get a whole lot of third so that's real honest rule with a blind hole you get of course the chips collected at the bottom again not all of the lathe and that's the six millimeter hex punch and one of the roller birches and pre-drilled six millimeters so let's try this get some cutting oil on there get it in contact and get from rpm and I push the dark into the column helps you clamp your workpiece properly do this bend over one of the ends of the chart so the hex started to form but then the first needed to push the chip down into the hole get too big and workpiece get pushed down into the collet and that's not good for a workpiece or your collar okay see if we can engage in the in the existing hex again okay there we go got it back engaged okay six room in hexxus vo definitely takes a lot of axial force that's not something I would do on this lace all day long but hex came out spectacular you can see that the chips piled up on the bottom of the hole completely and I think to go deeper I would have to remove the chips or drill bit and then come back with the rotary broach but man that's that's a good result as that's a proper hex and it even fits my my distinct you know English whistle it's quite nice pleasant doesn't walk much surface finish on the sidewalls is quite impressive for such a almost brutal - cause it's pushing away - material so I'm very happy with the result 5mm in hexam steel formulate a hex and steel both on the lathe e5 moving the hex on the milling machine and feel all not a problem at all so okay I took the rotary Burgess and I engraved my initials the year of make and Elm l 0 28 millimeters that's the length of of the punches of the order brooches so about having the documentation to this tool at hand I always know or the person who gets the second one of these always knows that the punch has to be 28 millimeters long and 2 tip so that's helpful I blackened them this time using Colt blue after engraving i i dapped on some cold bluing waited on pill it's reactin I got a black color and then I remove the excess with some fine scotch brite and it worked out quite well I like it seems to be very durable of course because the the cold blue finish gives the oxide layer or something and this should be a resistant against oil and solvents so I hope you enjoyed this project this will be a rather handy tool and you I'm pretty sure that you will see it in the future in another upcoming project I have a second Hemmingway kit that I'm going to build so thank you all for watching and the next time [Music] you [Music]

Channel: Stefan Gotteswinter

Views: 46,889

Rating: 4.980835 out of 5

Keywords: heminway kit, hemingway, rotarybroach, rotary broach, pendelräumen, pendelräum, vierkantbohrer, drehbank, 9x20, 250x550, homeshop machinist

Id: Dy4mifBycd8

Length: 27min 3sec (1623 seconds)

Published: Tue Mar 14 2017