Cutting Internal Keyways in Manganese Bronze Gears on the Vertical Slotter - Manual Machining

foreign [Music] welcome to topper machine I'm Josh topper and today's job we are going to cut some keyways in these manganese bronze um worm gears and we're going to do it all in the Mori vertical Slaughter now I already cut the first one and it came out well now I got to get the second one done so let's get this done this is a test job for a new customer to see how I perform on it so hopefully we get the repeat work after this I'll show you guys these are the chips off of the first one because manganese bronze is such a tough material I have to do it in two cuts it this cut a little heavy there but I do it with a narrow cutter first this guy and then I finish it off with the the full size three quarter and the first one finished out uh 752 and I have 750 plus four thousands for for tolerance so came out really well so let's go ahead and get this thing set up and get to work foreign [Music] [Music] [Music] [Music] [Music] thank you [Music] thank you [Music] so my tolerance on the center isn't um isn't real critical on this um I gotta actually quite a bit on open for tolerance there so we're within a about one and a half maybe two thou that's perfect for this we'll get the cutter set up and start cutting [Music] so this calls for a three-quarter inch keyway and because of the nature of the material because it's so hard I gotta start with a smaller cutter take the center out and then I go in with the with the three quarter inch cutter and finisher off and it works extremely well and these are just Morrison key seat Cutters that I bolt in here and that said they work incredibly well all right now I need to reset my height because I had to raise it up to get it out of my way to use the indicator [Music] and we'll make sure we clear everything before starting so I'll run it to the bottom of the stroke and then just make sure I come out the bottom and I could take it up just a little [Music] perfect [Applause] [Music] so we're all set up here and I'm trying out something new the last one I cut I used oil and it made a mess it was kind of dirty and filthy but it worked and this manganese bronze is some really tough stuff to cut and I've talked to a friend of mine about it and he suggested a coolant misting system so I ordered this cool mist um little portable magnetic unit from KBC tools and it's just got an air hose and a suction hose and I put it in a jug of coolant here and you just turn it on and there it's starting to suck up the coolant so I can run that and we'll see how that does I'm really excited to try this out because if this works I've got other jobs that with this machine that that'll be absolutely perfect for so let's get this thing cutting and make some chips [Music] oh [Music] foreign thank you [Music] [Music] [Applause] and I'm just going to get in there with my caliper and just see where I'm at three 3010 and I have to go to 3163 so another 153 to go and I've got quite a bit of Tolerance on these plus 10 minus five so we'll keep on cutting [Music] foreign all right we'll go ahead and measure it one more time just see where we're at I think I got about 20 to go so you know measure 48 times cut once about uh 18 to go so we're close we'll go ahead and start her back up and take that last 18. and then I always when I'm on my last pass I let it stroke a while just to make sure that we're getting a good cut that'll help smooth it out if there's any deflection in the cutter usually you'll take out whatever's wrong [Music] [Applause] okay [Music] go ahead and measure this one more time see where we are at 165 perfect that's within tolerance so we'll go ahead and switch out our cutter to our wider one and open that up before I switch out here I've been taking the bore gauge and running it down and checking the cut just to make sure it's all good so I need to move the table out of the way or thus the cutter and then I can run the mortgage down in there and I'm not shifting it off center so I'm still good on my alignment all around so we'll go ahead and see where we are [Music] top to bottom within five tenths perfect and the way I do that is I put the the measuring end on this side and the solid rod on this end and stick it tight in a corner so I'm I know I'm coming off of a consistent location so now we'll go ahead and change out that cutter [Music] [Applause] so again run it down by hand to get our make sure we're clear of everything it looks like I can bring it in quite a ways here from the start of our cut that looks good all right let's start cutting [Music] and this time I'm engaging the power feed because I can get a consistent 4 000 and having the center taken out of it it cuts much better once she starts making contacts they'll start cutting foreign [Music] [Music] thank you [Music] [Music] foreign [Music] [Music] yeah and I think that was the bottom and we're there that key way is cut so now we can spin it 180 degrees and cut the opposite one okay before I spin it around I got my gauge blocks I want to check my width just to be sure this is a 650 thousandths and this one's 102 making 752. and I already checked that with the mic and look at that nice snug fit that is about perfect and my tolerance was plus four thousand so 754 so we're within tolerance we're perfect so I'll switch out my cutter we'll spin it 180 degrees and we'll cut the other side [Music] [Music] okay we're all set up right where I want to be and let's uh start cutting [Music] and you can see I got my coolant messed in a little different location we're going to see how this works and we're cutting you know what I don't like where that's spraying I don't like the sound it's making it's a little different than what I had before we're gonna go ahead and just move our coolant sprayer [Music] so I think where it was spraying before it was a little better spot that does look a lot better [Music] here all right that looks good I will go back to cutting well that sounds much better like it's actually getting cutting fluid foreign [Music] thank you [Music] this looks like a good spot to stop and take a measurement [Music] I got interrupted by a phone call and then the customer stopped by so now's actually a good time to take a measurement and see where I am [Music] 365. I need to go to 443 so we'll take the last bit oh [Music] all right we'll take another quick measurement we're in the last about 20 thou and about 15 to go [Music] [Music] [Music] perfect we're with intolerance actually very close right to the tolerance so we'll go ahead and switch out our cutter and then widen it out so as I change this out I want to let you guys know that because of the tolerance of this part and it's pretty wide open the problem that really became apparent to the customer was the they were broaching this push broaching and this stuff does not Broach well so the tolerances that I'm hitting with this machine are significantly higher than than a push brooch ever will and they're really beat cutter out of there because this thing tight I didn't want my Cutters moving let's go ahead and put our three-quarter inch in there and we'll set up and open this thing up to size foreign [Music] thank you all right I'm going to move the cutter out of the way and take some final measurements for the quality control report and uh then get this thing out of here and get her boxed up and sent back to the customer again we use our gauge blocks check Checker fit nice fit 752 feels consistent most of the way through a little tight here at the top but I don't think I could get a 753 in there so perfect we'll get this out of here and get it deburred [Music] there it is all out of the machine beautiful keyways and look at this these beautiful chips I mean these things are just it's like gold absolutely beautiful and the cool mist coolant Mister that from KBC tools absolutely loved it it worked perfectly for this application actually it the cut came out much better than it did with oil so I'm very happy with that I think I'll be using this moving forward on other jobs as well so very happy with the Mori vertical shaper here just been a great machine well I hope you enjoyed the video and the the little job that I had here this like I said these are the first ones for this new customer and uh looking forward to their feedback and hopefully I get some return work out of them this is this is a actually a a fun job a different material than I've worked with before and it cut much better than I expected especially with the coolant Mister so with that we'll end here until next time get out in your shop and get it done right the first time [Music] thank you

Channel: Topper Machine LLC

Views: 29,002

Keywords: manual machinist, machine shop, topper machine, metal planer, metal shaper, DIY, homemade, monarch lathe, Bridgeport milling machine, lathe work, boring mill, HBM, drill press, metal lathe, milling machine, welding, press brake, Vertical Slotter, keyway cutting, broaching keyways, keyseater, keyseat cutting, job shop, amazing tools, abom79, cutting edge engineering, diresta, mr beast

Id: Tx7BQ9AUq6E

Length: 27min 28sec (1648 seconds)

Published: Sat May 27 2023