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Fixing the Fixture Plate and Machining Roller Type 3

10/8/2015

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After the failure in removing the roller from the fixture, I wrote to the Thai gentleman again seeking his advice.  While waiting for his reply, I decided to drill through each recess with a smaller diameter size drill.  This way, I can tap the rollers out after they've been machined.  It will be tedious doing it this way as I'll have to re-indicate the fixture for every batch.
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Milled the steps and drill through to tap out the rollers after machining.
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Started milling and broke my 1mm carbide endmill... I've no more in the box and have to get one after the long weekend...
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The tip of the stylus is 1.90mm. My trusty Proxxon parallel used as the plate for accurate Z height touch off.
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With the measurements, I redo the blank in 3D.
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Thank God that Mike opens on Saturday, despite being eve of our National Day! Rushed down in the afternoon to purchase 2 x 1mm carbide endmills. The Garryson endmills are a few dollars cheaper than those Mitsubishi endmills. I bought a 2mm from Horme and paid slightly more than $20 for it. Garryson's was only $16+ inclusive of GST.
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Didn't quite cut through but easy enough to push the unwanted portion out.
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The back before deburring.
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After more deburring.
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Test fit. Very tight but now I'm able to remove it by lightly tapping from the drill hole.
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Had some time to spare and so made myself a stylus to help as a touch probe.
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To get the flat land within the 2 chamfers, I first touch off the flat portion, lift Z off by 0.1mm, and proceed to touch off the X axis at the rim and hub ends.
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Type 3 based on the new blank in 3D.
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After zero'ing in several times in Z and in the middle of the 5mm bearing hole, I nervously click on Cycle Start.
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After the unwanted portion pushed out with a screw driver.
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Front
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The back looks cleaner...
It was nerve racking watching the mill went round doing its job.  I was so afraid of breaking another endmill.  I was told that with endmill so tiny and my max. spindle speed at 2800 rpm, I should go no more than 56mm/min feedrate and at DOC of 0.2mm per pass.  It will be painfully slow...  For this roller, I went at 100mm/min instead.  It turns out well except having to spend quite some time deburring the tiny spokes.  With my "old flower eyes" (long sightedness, started when I crossed 40...), it was painfully difficult.

Next up, upgrading the Sherline to 10,000 rpm pulley.
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