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Tool Talk Discussion Forum

any machinists out there?

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flying belgian

02-05-2008 10:40:07




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I need to move a 1/4 inch hole over 1/4 inch and enlarge to 1/2 inch hole. It is 1/4 inch thick stainless and I need to do it to 39 holes. Should I weld existing holes shut and redrill or do it with end mill? What kind of end mill is best in stainless? how many holes could I expect to mill with life of mill?




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Fred Martin

02-07-2008 11:25:26




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 Re: any machinists out there? in reply to flying belgian, 02-05-2008 10:40:07  
I can mention another way of doing this job...and probably cheaper too. By using a flat bottom twist drill and a hardened drill bushing centered over where you want the new hole. You would probably also learn how to sharpen a flat bottom drill in the process. The flat bottom keeps the drill from wandering off as easily...or bearing on the drill bushing and creating heat. Anyway, this is a cheaper way that I thought I'd mention. ohfred

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DouginMI

02-06-2008 05:15:37




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 Re: any machinists out there? in reply to flying belgian, 02-05-2008 10:40:07  
Hougen still makes that set. I have one and its worth the money RotaCut Small Diameter Cutter Kits 11075 is what I have>Link
Doug



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Gun guru

02-05-2008 15:18:37




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 Re: any machinists out there? in reply to flying belgian, 02-05-2008 10:40:07  
On a Bridgeport mill... Indicate in the first piece and move over the .250" then use a 1/2" milling cutter and plunge cut at about 250rpms. Slowly plunge cut. Then set up the next piece and do the same. If it were me I would have all the pieces done in an hour. The best cutter is HSS which stands for High speed steel, or heat treated tool steel.



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JD9295

02-05-2008 14:41:10




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 Re: any machinists out there? in reply to flying belgian, 02-05-2008 10:40:07  
like andy said a water jet would probably be your best bet. we have a company that does our water jetting for us, wish we could talk the keeper of the checks into buying us one



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Andy Moncman

02-05-2008 14:20:14




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 Re: any machinists out there? in reply to flying belgian, 02-05-2008 10:40:07  
Try to find a shop with a water jet, they are relatively inexpensive as far as machine time and can open up the holes with out reguard to the existing hole centers. The machine time is usually based on the finish and accuracy you require.



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Kentb of SWMO

02-05-2008 14:09:53




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 Re: any machinists out there? in reply to flying belgian, 02-05-2008 10:40:07  
Is this in 39 individual piece or in one piece. If one piece, I think it would be cheaper to replace the metal and do the holes. If 39 individual pieces and the holes are all in the same place, I would build a locating fixture and use a center cut cardide end mill. You will most likely need five or six if not more.

Kent



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wyod

02-05-2008 12:19:23




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 Re: any machinists out there? in reply to flying belgian, 02-05-2008 10:40:07  
I agree with not welding... depending on the alloy, the steel could end up harder than woodpecker lips! You don't mention in your post if you have a mill available or if you can secure the workpiece to the table... if you can, you'll get the best results with a solid carbide, 4 flute, center cutting end-mill. Keep rpm's low (start off around 500-600 and experiment from there), use power feed, and keep tooling and material cool... preferably with cool-mist or similar set-up. (you could accomplish the same thing with a hand-held spray bottle of coolant) If kept cool and not abused, the carbide end-mill should do the whole job! HTH, D

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Bob - MI

02-05-2008 11:37:13




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 Re: any machinists out there? in reply to flying belgian, 02-05-2008 10:40:07  
Are you doing this on a CNC mill? You could circle interpolate this using a smaller cutter such as .375"

Both other suggestions are good ones. I would avoid welding.

What alloy stainless?



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Gerald J.

02-05-2008 11:08:22




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 Re: any machinists out there? in reply to flying belgian, 02-05-2008 10:40:07  
Welding will probably make a hard spot in an already obnoxious material.

If you can us a milling machine and hold the work solid, a two flute endmill (be sure it cuts to the center most do, but not all) will not be pulled off by the existing hole. Probably want a carbide endmill for life. But it will cost enough you can use ordinary endmills and swap them out when dull. A good cutting oil will help, but stainless is obnoxious to machine.

Most drill presses won't be stable enough to keep the hole round without the pilot of the tapered drill bit.


If all the holes need to move the same direction, think about moving the outside of the piece instead.

Gerald J.

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shawnspeed3

02-05-2008 11:04:58




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 Re: any machinists out there? in reply to flying belgian, 02-05-2008 10:40:07  
I would reccomend a Roto Broach from Hougen Mfg., They used to make a small set from 1/4"thru 3/4 that would work for what you are trying to do,maybe do a google search for "aviation hole saws" they may have a bigger pilot than the roto broach. I would not weld them closed first. Think about contacting a steel fabricator with a punch press????? Good luck Shawn



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