Spline drive sockets & Electronic indexer

[Music] hey welcome back I got a new project to work on I got these sent to me these are these are spline drive nuts they have a very fine spline profile on the OD which almost looks like a straight knurling but it's definitely either hopped or cut knurled because you can see the lead out of the profile here normal knurling push rolling doesn't do that so I guess these are hopped these belong to a BMW airplane engine a win touch airplane engine and don't know all the details but for a restoration project they want to open up these nuts without damaging them so why scripts are out of the game of course so we're going to make a bunch of sockets for these these are three different nuts we may will make four for each size out of 42 chromo 4 which is 41 40 I think in the end the world little machine them will slot the profile on the milling machine also we need a half inch square drive internal square drive on the other end so they can drive them with a ratchet or a torque wrench first thing that we have to do is to figure out the shape of this profile we could take a very high-resolution photo with the DSLR macro lens straight on put it pull it in in the computer put in background off of a cat program and figure the profile out there or use a optical operator come come yeah shadowgraph or to make us microscope as I have a toolmakers microscope I will use that I have to see so mouth swiss-made toolmakers microscope for quite some time and I really have to say thank you to a person that gave this to me this is awesome I use it all the time and it's just a very handy addition I'm looking for a second one with larger scale of a larger XY stage but for most of the work I do this is very nice has an XY stage micrometer heads that read to one micron and up here it has a 360-degree angular dial that reads to one one one minute of angular precision yes true light from the bottom and a ring light appear with three light bulbs very heavy the ways appear are scraped and the XY stage has V groove rollerball slides so there is a wee on both sides and balls in between Rwanda super nicely made the company is still running that still make two makers mark scopes and optical inspection equipment so high price stuff there okay there's like a rough setup I'm filming through the eyepiece off the microscope I have a 30 times magnification on the microscope and are looking right at the edge of husband of one of the nuts the microscope also has a rotary stage which is the table which allows you to spin the part and I obviously already adjusted it for run out means I bumped it around until it run around true and that allowed me to count the teeth very very easily the one T tooth in the center here has a small blue mark then I just went down and counted tea from there one two three four and so on until I came back to the one with the mark and I knew that this is a 54 teeth drive not that's the first important information the overall OD over the teeth I could measure of calipers or micrometer the angle of the tooth can be measured by rotating the eyepiece of the microscope as you can see I can line up the the line with one of the sides of the tooth read the angle rotate it around and measure the other side and calculate the included angle for that of course the tooth must be aligned vertical and to get a proper reading I can also measure the height from the top of the tooth to the to the bottom and I can measure the width up here which is in this case slightly rounded over but for the sake of easiness I will grind the tool with a flat nose it won't drive on the tip anyway it will drive on the sides of the of this profile so just grind the flat here and I Roger I already measured this this is point two millimeters the included angle sixty degrees and the height of the profile is 0.6 millimeters so shaping this profile on the mill will be very fast even in quite tough still like the 4140 I'm using okay I took a piece of k10 carbide which is a very tough grade of carbide and I ground the slotting tool with the 60 degrees included angle a little bit of front brake here about four degrees sides have two degrees back rake and eye relief area in here so nothing does jam up also i ground a little bit of flat on here so i can indicate the tool in once it is in the mill ground on the d-pad grinder roughed out with a d 125 wheel and then gave it a good finish with a d40 diamond wheel both resin bout okay got the rotary table on the mill i made a test port a little menu so i can just check my fit on the shape of my of the spline drive in there have the tool here in spindle and I'm using my my - my chrome indicator - to indicate it in on the flat background previously and this is pretty much cero cero site site except in around the indicator off the part I already Center my rotary table I can crank this back to zero according to the Dro not a tool is centered to the rotary table or to axis of the Millis Center to the part here and I can just touch off on this side of the wall with my tool you saw me flooding the internal contour on this piece here this test piece and if I wasn't incompetent enough to to mess up my divisions by counting wrong this probably would have been a viable test piece but somehow I missed missed one turn on the crank of thoraseal and completely butchered up the splines in there so this one is out and I made a second test piece out of the remaining material which wasn't very much and this fits but it's too loose the flat on top of the tool here was too wide I didn't check it I just eyeballed it when I ground and it was point four millimeters double the width so this has way too much side-to-side play in here and we will wobble surround so that's also not good chin should bind off the tool and I prepared a new a new test piece this time out of a tool because o to tool steel because why not the final pieces will be steel too so why not use the proper material and this is a very good fit the problem when you take apart old equipment is of course that's not in its precision words its mount that will be not in pristine conditions it will be mangled up it'll dirty somebody with y scripts or large pliers will have gone at it and they will have to force these nuts on there with a hammer probably so these will the final not not to test piece will be hardened and tempered the material is 4140 or as it's called here 40:42 chromoly 242 chromophore sorry and I just ordered a stick of the materials so I have proper material not some unobtainium out of my script in and that's what you get when you order steel from a proper dealer not only the steel but also the the security that the steel will you order is the steel you get which is very important when you do parts that involve a lot of steps machining and heat treat and in the end it doesn't get hard or it explodes or to catch fire or something like that you don't want that you want to be on a safe side when you make complicated or expensive parts so in this case it's it's definitely the same decision to buy material that I know that is what it is it's 172 25 plus cootie this is the material number the ISO material number plus cootie means commercial heat treat this is already he treated to something like surly certainly Rock will see more for toughness time for Herman and here is the old the old designation that's not really used anymore 42 chromophore and did I mention 25 millimeter by one meter probably yeah 25 by thousand millimeters and these are the people I'm dealing with this is Abrams premium steel well I finished the first eight of these nuts or drivers and I went for a relatively loose fit because most of these nuts will be quite damaged so probably these have to be forced on with a hammer when taking apart an engine so I went for a relatively loose fit but still with the high number of teeth and engagement there's still terribly over constrained so should work out same for this style of nut very good fit I what I also did I milled the half inch drive on the other side with a three millimeter carbide end mill in I left the corners with with the radius I don't have a 1/2 inch ratchet or driver so I had to order a half inch extension to see if if this works out still waiting for that if the corner radius is too large I will have to broach the corners out shouldn't take very long all this protein and all this indexing cranking the rotary table gets quite odd over time so over the holidays I took a stepper motor made an adapter that that goes on to my rotary table it just replaces the indexing disc and the sector arms and the index pin without any modifications to rubbery table you just undo this one screw here and then you can pull the whole assembly up and put the hand crank or the indexing disc back on if you want stepper motor of course needs to be driven by a stepper driver and the stepper driver needs to be driven by some logic and this is what I came up with this is a 48 volt 5 amp power supply this is a Meanwell clone this is a leach shine clone stepper driver also 5 amps there's an Arduino microcontroller board that's very easy to program and very easy to interface I hope I put it all on a piece of married board and used wire wrapped wire to do all the connections I also had a display in my collection of parts rubber encoder and a few buttons this is Paulo supply here but also this is used to broke program it to modify the program but then in general this allows you to do divisions it's like an indexing plate an adjustable electronic indexing plate with this rotary encoder down here you set your number of divisions from starting from zero all the way up to locked right now I need 50 then you just hit the button and it counts up I can also go in the reverse direction but the rotary table has obviously a warm graph and the warm drive has backlash when you do manual machining what you would do with backlash you would crank in the other direction over your desired position by a few degrees just by cranking further and then going back to your final position that's what I'm doing with my controller when I go in the opposite direction to those little movement that you see at the end that's take out the backlash I decide this only for dividing burg not for milli not for rotary milling not for stuff like that only for dividing in this case for slotting but also for for cutting gears or splines or whatever it's just to take away the indexing plate the counting of the holes the possible errors by missing a hole stuff like that so this will make life a whole lot easier also it has a dog mode where I can just very finely adjust the position of the rotary table this is for indexing parts lining parts in this mode it doesn't have backlash compensation I can still undo the screw and disengage deform that can freewheel the rotary table by itself this is for rapid dialing in run out of a part then just re-engage the worm lock it and we're good to go I will release the schematics and yard we know code for this but and I'm also designing a proper PCB so you do not have to do this so all of this can go in enough in a housing in a box and be safe to use right now we have 240 volts back here not very well protected so anyone out watch out it also has a mode for retina I have to set the modes with a jumper link this is division and this is angular increment your set an angle here like seven point two five degree it goes and then it indexes seven point two five degree every time you push the button and if you want to go seven you just change it to seven like this and it moves seven on if you want to see really doubt on all about it press the button it has some rounding errors obviously this is 5000 so 50 degree then you go from there yeah that's all these three options angular increment index plate mode and jock also I wanted a better way to lock them the spindle of my mule against rotation so I defined a part in cap and 3d print as a prototype this is what I came up with it has three point contact up here on this large diameter the quill it has a flexor slot here and is true pressing against it to to clamp it and it has a smaller diameter also with three point contacts down here with a screw pressing in from the outside again with a with a flexed wrist lock so it can it can actually plan and I find it that way so it can be 3d printed in one go without supports in here this relief is just to keep the material function quite low and also decrease the print I'm still at 50% infill with three parameter shells three top and bottom layers took about eight hours to print but it printed without me just ran along so that's quite nice and the way this works this comes over over the quill up here just like this and we look for a right key we lock it up here just by tightening the screw it's locked we can still kind of spin the spindle it has a lot of drag now this is ideal to align the tool run an indicator along it and finally adjust its orientation then we tighten down the same screw down here which then locks the spin against rotation quite a handy piece if it works out all the time I will replicate this part in a more durable material but for prototyping this 3d print is really nice and this is about as good as you want to dial it in this is a 2 micron indicator okay obviously a actual customer part is the best way to beta test your hardware you decide that makes sure that you had to take care and bug fixing before using it this is a 50 tooth spline growth nut and obviously get it got a bird ecent fit goes in very nice but has very little it has basically no noticeable rotational plane this is very nice this felt great one done sorry to go the the electronics in plank works great I'm I'm very happy that works that well okay got all the the driving sockets done shaping the last four with the electronic index so was really a joy Brooks very fast very reliable you do not have to keep keep tracks off your turns on the hand crank and it's just it's just more reliable and more safe so that worked out well and they fit very good fit really nice done with indexing all parts time to take up the stepper motor as this is still obviously a prototype I'm not going to leave this set up removing the motor is simply ass opening this one screw here open it pull it off as you can see this this mounting block is slit all the way through 45-degree like this then just cut the slitting saw this way and in there you can see the coupling the couples to the stepper motor to the rotary table we have two flats on here these are already there and the coupling in there is just a piece of round stock with a slots through it and this slips over those two flats it has some backlash but it doesn't matter because I'm going always the same direction even if I step back one increment that's why I have the back left backlash compensation and as I said before the setup is not suitable for milling the stepper motor is not powerful enough the there is way too much friction loss and the warm drive to get any reasonable torque at a flow rotary table for Milli I would have to use a more powerful stepper motor or use a belt gear the motor down in speed wheel a belt drive but as I intend to use this only for indexing probably with the table locked once it's in position I'm fine I could add automatically an automatic lock or a brake to the rotary table code wise that's not a problem that's just a few lines of code that undo the brake for moving the stepper and resetting the brake once the motor has stopped but I do not want to to have anything hanging off the rotary table so I will probably just use the manual locks and there we go back to normal manual operation I will harden them and strode them in the tumbler just to give them a good finish all over slightly break the chamfered the address after chamfers and they're done hardening has to wait a little bit because it's it's really cold outside and I'm not too keen on oil hardening in the shop I have done that before and it's not the best idea yes I will do separate video and description and whatnot on the electronic index sir and I will release the code and schematic and whatnot and if I get around to do a piece by layout I will release that too it's all open source so hope you enjoy it making these drivers these these spline drive nuts or spline drive sockets thank you all for watching and see you next time [Music]

Channel: Stefan Gotteswinter

Views: 43,792

Rating: 4.9853063 out of 5

Keywords: spline drive, stoßen, hobeln, shaping, slotting, shaper, slotter, arduino, electronic indexer, opimum mb4, rf45, 3d printer, ender 2

Id: k5vJJ7veYa8

Length: 30min 2sec (1802 seconds)

Published: Sun Dec 30 2018