SINGLE POINT THREADING 12 EASY WAYS - ZERO DEGREE COMPOUND, NO PLUNGING, NO TOOLS SET UPSIDE DOWN. Engineering hacks & tricks 2026-09-25 | SINGLE POINT THREADING 12 EASY WAYS - ZERO DEGREE COMPOUND, NO PLUNGING, NO TOOLS SET UPSIDE DOWN.
Unique automatic clutch tap wrench + tapping tips. Engineering hacks & tricks 2025-09-30 | This tap wrench is designed to remain locked during normal operation, ensuring a positive drive. The ratchet is always readily available. However, many tapping situations benefit from a ratcheting function to make the process faster and easier.Conventional one-way clutches have a major limitation — they prevent reversing the tap for chip breaking or removal. To overcome this, I developed a mechanism where the clutch engages automatically with downward handle pressure.When reversal is needed, simply reduce the applied pressure. The clutch disengages instantly, allowing the tap to move in the opposite direction while remaining locked and concentric.The result is a tap wrench that’s intuitive, efficient, and far more versatile than traditional ratchet designs.A bonus tip at the end - How to tap like a Toolmaker..
Old Toolmaker’s Fix for the Humble Flycutter Engineering hacks & tricks 2025-09-19 | Simple flycutter mods to improve tool life, reduce cutting forces, and achieve a better surface finish.This video demonstrates how to improve the performance of a budget flycutter through simple machining modifications. The process includes adding a 15° rake locator block, grinding a permanent 5° clearance on the toolbit, and preparing the cutting edge with a 45° approach angle and small radius. These changes optimise tool geometry, reduce regrinding, keeping the point on the centre, and balance cutting forces for better milling efficiency. The video also covers spindle rigidity, safety considerations, and surface finish results.Link to safety flycutter - youtube.com/watch?v=3yAGlDWpfUo
Precision fixture plate solves difficult part location problem. Engineering hacks & tricks 2025-09-09 | This part has an asymmetric shape, with no straight edges to use as reference points. The challenge is to cut a pocket, 1.5mm deep, exactly 12mm in from the perimeter.To solve this, I first created a template. That let me work out three reliable locating points around the perimeter. I then marked three holes to give a repeatable position for the part. In CAD, I overlaid the part shape, making sure the perimeter touched all three pins. That setup will make programming the pocket much easier later on. Programming the pocket used dimensions from the CAD file using the centre hole as a datum.
Custom 150mm Rule: Designed for Toolmakers, by a Toolmaker. Engineering hacks & tricks 2025-08-24 | I’ve decided to design and make what I think is the perfect rule for me.The first thing I wanted was for it to be readable whichever way I pick it up. That’s why I’ve rotated the numbers 90 degrees, so they’re always readable.I also wanted the numbers to be bigger and clearer, so I’ve gone with centimetre spacing instead of cramming in smaller marks.Half-millimetre graduations? I’ve left those out. They just make the scale busier, and I’d rather keep things simple and easy on the eye.For the graduations themselves, I’m using the old Moore & Wright wavy style. It’s a lovely, distinctive look, and it makes the marks stand out much better.On the end, I’ve added a double hook — exactly ten millimetres high and thirty wide. Both sides, and even the very end, will carry one-millimetre markings, which should be really handy for quick measurements.One face of the rule will measure from that hook, while the other will measure from the end, giving me both options in a single tool.And to finish it off, the whole thing will be 1.6 millimetres thick, which gives it the rigidity I want without feeling heavy.The graduations will be laser-etched first, and then I’ll machine the profile on a magnetic fixture to get a precise finish.
Clamps Anywhere, Locks Instantly – My Best Work Support Yet! Engineering hacks & tricks 2025-08-09 | I've made all sorts of work supports, and all have their shortcomings. If I clamp them to the bed, the tee slots are not always in the ideal position. If I don't clamp them, they can move as the machine vibrates. Can I make something that clamps anywhere and also locks the adjustable height without tools?I have some height pre-set columns that attach to the bed. They have two height settings, one level with the vice base and the other set to a known set of parallels. Although they can be clamped in position on the bed, they are not always where you want them.The box style support is ideal for very quick support, but not able to be fixed to the bed. Even my end stop support bracket is precisely set level with my vice bed, but it is not height adjustable. On some precision applications, I use my precision ball screw, but it's mainly for inspection and layout because the top stays accurately parallel throughout its range. For taller setups and larger parts, I have a pair of ten-start quick-rise supports, which again not able to be clamped to the tableFinally, I have made a pair of lockable adjustable supports that can be clamped anywhere on the bed without any tools. Turning the magnet on not only fixes the support to the bed it also prevents the height ring from rotating. First, I set the height, then move them to the ideal positions and simply turn on the magnet to lock the height and the bed position.The magnetic blocks are first ground precisely square, so they can also be used as precision reference squares. I use the internal threading bar from the lathe to thread mill a 1.5mm pitch thread on the corners. The units can have multiple accessories, such as a flat top disc, support point, support ball, or a vee for round parts.At the end, there is a quick demonstration of the Ainjest threading unit for automatic depth stop when internal threading.
No Hole? No Problem – Precision Corner Rounding Made Easy! Engineering hacks & tricks 2025-08-03 | A common machining task is rounding off the end or corner of a flat bar. Traditionally, we drill a hole in the part and use that hole to align with the spindle or rotary table bore. But there are many jobs where a hole just isn’t needed — or even practical. That's where this tool comes in.This is the spindle quadrant stop. It's designed to eliminate the need for that alignment hole, while still giving us an accurate location — and it's incredibly simple. Aside from your clamps, this is the only tool you'll need. No buttons, no reference edges — all the alignment and location is handled right here. It even holds the test indicator!
Punching 10 Perfect Holes Fast with a Fly Press” Engineering hacks & tricks 2025-07-25 | One press, 10 holes, 2 semicircles — this plastic retainer never stood a chance. Watch the fly press chew through it all in one clean shot. Quick, precise, and oddly satisfying — just how we like our shop work!
“Can a Fixed Vise Jaw Pull Down? Let’s Find Out!” Engineering hacks & tricks 2025-07-22 | This video takes a closer look at whether it’s possible, or even sensible, to incorporate a pull-down feature into the fixed jaw of a vise or fixture, and whether such an idea actually works in practice. Of course, the key requirement here is that the reference position must stay exactly where we told it to stay, ideally without wandering off the moment we apply the pull-down.
Spring tensioned double milling vise stop. Engineering hacks & tricks 2025-07-19 | Using a stop on a machine prevents tools from accessing both ends of a part unless it moves out of the way. In this demonstration, one stop locates two parts, and still swings away, using a spring to accurately retain it's position.
Fixture plate - my way. Engineering hacks & tricks 2025-05-25 | 🎬 Fifty Years Without a Fixture Plate – Until Now! 🛠️After half a century of toolmaking without ever needing a fixture plate (yes, you heard that right), I’ve finally decided to join the 21st century... or at least the late 20th.Why now? Well, after years of MacGyvering setups with chunks of scrap aluminium and suspiciously convenient rectangular hollow sections, I thought, “Why not make something that actually makes sense?” So I designed a fixture plate that’s basically the Swiss Army knife of workholding – minus the corkscrew and the tiny useless scissors.💡 We’ve got magnetic chucks that practically tram themselves (sorcery), pneumatic setups clamping 51 parts at once (because why not), and a fixture plate with more precision features than a Swiss watch strapped to a CNC machine.✨ Want dual-purpose holes with steel threaded inserts and hardened bushings? You got it.✨ Want built-in sine bar capabilities? Of course.Oh, and it’s hard anodized aluminium, because even fixture plates deserve a glow-up.If you’re into clever machining hacks, efficient setups, and the occasional dry sarcasm forged in fifty years of chip-making, this one’s for you. Watch me build the fixture plate I never thought I’d need — but now can’t imagine living without.👇 Drop your questions in the comments. Or just say hi. I probably need a break from tramming things.
Mastering ER50 Collet Blocks on the Lathe – Versatile Workholding Explained Engineering hacks & tricks 2025-05-08 | In this video, I will demonstrate the collet block assembly on a center lathe. We will start by holding the collet block in a four-jaw chuck using simple magnetic aluminum jaw pads. The ER50 socket taper will be initially indicated true.For the first example, a 32mm ER50 collet will hold a quick-change tool holder that clamps a 6mm keyless chuck. In use, this setup may require the part to be indicated true initially for maximum accuracy. Later in the video, I will demonstrate the repeatability of this type of setup. The second demonstration is similar but for larger diameter parts. A 16mm keyless chuck with a 3 Morse taper will be held using a 40mm diameter Morse taper socket in an ER50 collet. The tool-less quick release feature of keyless chucks can be utilized for batch production. An option for parts up to 3/4" diameter is to use a keyed drill chuck. In this example, the chuck has a 25mm straight shank held by a 25mm ER50 collet. Although not a keyless drill chuck, the small chuck key may be preferable to use instead of a larger lathe chuck key for multiple parts.Moving on from drill chucks, the video will demonstrate the ability of the collet chuck to hold 40mm diameter long parts using a lapped bronze bush for additional support. Still using the 40mm bore ER50 collet, an ER40 adapter can be used for diameters up to 32mm. Although an ER50 collet could still be used, the smaller collet wrench will be easier to use for multiple parts.If a 5C collet system is required, the same 40mm bore ER50 collet can hold a 5C adapter. The first demonstration shows an 80mm 5C three-jaw chuck, enhancing the ability to hold parts in the bore.An unusual method for externally threading small rods is shown in the next demonstration. It still uses the 40mm ER50 collet holding a 3 Morse taper adapter. This socket then holds a spring return quick release tap or die holder. The demonstration shows a 4mm diameter rod held in a keyless chuck mounted in the tailstock and a quick release M4 die. Holding the rod in a keyless chuck can assist with multiple parts. This setup can be completely reversed if required.An alternative to holding the block in a four-jaw chuck is to use a circular switchable magnet held in a three-jaw chuck. One advantage is that individual parts can easily be dialed in by simply tapping the unit and indicating the part. In the first demonstration using the magnet, a 5C adapter is held in a 40mm ER50 collet. A coin is held in a custom counterbored adapter using a fixed depth stop collar, all held in a 30mm diameter 5C collet. The following demonstration also used the 5C system but with a square collet. It shows that subsequent operations can be performed on other machines by sliding the whole unit off, releasing the magnet, and leaving the part set.The whole concept of the system used on a center lathe is to indicate the part when loaded, not always relying on the tolerance stacking of multiple holders. Once set, the repeatability can be checked. There is a demonstration towards the end showing the repeatability of a 16mm keyless chuck.The final few minutes of the video briefly show how the sine function can be used in a milling vise and reiterate the concept and manufacture.
The Ultimate Collet Block? ER + 5C in One – Game-Changing Precision Tool! Engineering hacks & tricks 2025-04-14 | You've never seen a collet block like this before. 🔧💥Introducing my custom-designed hybrid collet block that holds both ER and 5C collets – built for speed, precision, and effortless setups. This innovative design is packed with unique features that eliminate setup headaches and boost your workflow.✔ Dual compatibility: ER + 5C✔ Precision-engineered for rock-solid alignment✔ Smart features that save time on every job✔ Built by a toolmaker, for machinistsWhether you're in a prototyping shop, a production environment, or just love great tooling – this block changes the game.👀 Watch the full video to see it in action, and find out why this is not your average collet block.Link to basic information video for setting odd angles using the sine function. youtu.be/W0A_dmgLPNc?si=q0db9r_Qq1XRtIE4
Simple Part Mods That Make Machining WAY Easier! Engineering hacks & tricks 2025-04-04 | Most machinists are familiar with using rods and flatted balls to accurately position a part face against the vise's fixed jaw. While these tools can be somewhat cumbersome, a few modifications can make them significantly more user-friendly.
Versatile & Adjustable Vise Stop with Bonus Features! Engineering hacks & tricks 2025-03-30 | After 20 years, it's time to upgrade my datum-retaining end stop.I want to preserve its original features while incorporating a few enhancements to improve its functionality. The body must maintain a ground-flat datum plane, precisely aligned with the Y and Z axes. Similarly, the moving arm must be ground flat, with the sliding rod hole accurately bored square to the face. The sturdy sixteen-millimetre diameter ground stop rod, with its ground-flat ends, will remain, though with minor modifications.Since I always locate on the midpoint of the datum face, the arm must allow both forward/backward and up/down adjustments without altering the X position at the stop rod’s end. As before, the stop arm assembly will move freely without requiring clamps to lock or release it.The new body was made to the same height as the vise base and can now also support longer pieces. I'm sure that the body will be used for other applications as it is similar to a precision ground angle plate.
Hidden Feature! ER Collet Lathe Backstop Doubles as a Polishing Tool! Engineering hacks & tricks 2025-03-21 | This Backstop Does More Than You Think! Long Bar Support & Polishing Mop Holder in One!
Game-Changing Inside Clamping Hack with a Kurt Vise! Engineering hacks & tricks 2025-03-19 | Engineering OverviewThe primary challenge was securely clamping a 500mm bore using a Kurt-style vise. These vises are not designed to provide safe clamping when in an open position, necessitating an alternative approach. Once a viable solution was identified, additional design opportunities emerged with minimal modifications. These were incorporated into the system, leading to its first functional iteration.Clamping MechanismThe internal clamping was achieved by implementing a new fixed jaw at the handle end. This design converted the forward-pushing motion of the moving jaw into a pulling action. The pulling force caused the drilled jaws to separate while the moving jaw remained engaged via the spherical button.To enhance versatility, a second drilled jaw was introduced. This addition enabled the vise to clamp both circular and parallel components using rods and non-marring discs, preserving workpiece integrity.Design ConsiderationsFrom the outset, it was clear that clamping round workpieces required three pins. To maintain symmetry, the hole pattern was designed with even-numbered holes on one jaw and odd-numbered holes on the other. However, an oversight resulted in the hole patterns being reversed.Ideally, the even-numbered holes—positioned symmetrically on either side of the jaw center—should serve as datums on the fixed jaws. The third clamping pin, located centrally on the moving jaw, should align accordingly. The correct configuration would have the fixed jaw with even holes and the moving jaw with odd holes, ensuring proper alignment and consistent clamping performance.
Quick change keyed arbor. Engineering hacks & tricks 2025-03-18 | Easy change arbor for tools with a bore & key.
Expanding lathe backstop & bar support with ER collet adjustment. Engineering hacks & tricks 2025-03-09 | The backstop body expands, and the 6 balls lock it securely in place by gripping the spindle bore. The backstop rod can then be adjusted with the Er collet nut. When fully inserted, the rod can reach the front of the chuck jaws. It has a tapped hole in the end to accommodate various ends to suit specific applications. This can also be used as a long bar support.
Automatic reversing tapping head. Engineering hacks & tricks 2025-03-08 | A quick video to show how an old school tapping head can still be useful in today's production environment.
3 way offset lathe chamfer tool. Engineering hacks & tricks 2025-03-03 | This offset tool allows you to chamfer the outer diameter (O/D), inner diameter (I/D), back face, and grooves without removing the existing tool. By simply adding or removing the chamfer tool while keeping the primary tool in place, you eliminate the need for repeated tool changes, improving efficiency and workflow.
Machining a 70 degree acute angle vee. Engineering hacks & tricks 2025-03-01 | Machining acute angles less than 90 degrees can present problems as most cutters and grinding wheels have square corners.This is my method. I leave the block oversize - finish the vee & then finish grind the oversize block to the pin.
Testing the 45 degree fixture on production parts. Engineering hacks & tricks 2025-02-23 | A Job came up where a handed pair of parts were required with matching 45 degree bevels. This is a good test for the fixture to see how well it repeats.This video contains some previous footage showing the manufacture and early testing.
ROTARY TABLE TIPS AND TRICKS COMPILATION. Engineering hacks & tricks 2025-02-18 | This is my first compilation video where similar topics are all grouped together. I concentrate on shortcuts & efficiencies that are useful in both hobbies & business.Unfortunately, the video production is poor but hopefully, it conveys the techniques and gets slightly better as the video progresses.Whenever possible ( but not always ), I try to use a continuous shot at normal speed to give a fair reflection of the processes. If nothing is happening, some sequences are shortened, and some repeated events are speeded up.If you find any of these useful please consider a small voluntary donation to the Guide Dogs.The details are on my community tab or use this PayPal link, No need to log in -paypal.com/GB/fundraiser/charity/12621?tx=2TB62072MN618893A&st=Completed&amt=1.00&cc=GBP&cm=12621%2C0%2C&item_number=&item_name=The%20Guide%20Dogs%20for%20the%20Blind%20Association&token=Iq8L_GtkjjEYrl_3geBmgFVL1BNyS_6ohX9UTnanJBUSHYu-KXbPhpedbNwsaZDQRuHahU2JLTuHYSdLyXrklEn0JIa
A couple of overdue simple workshop upgrades + vee block tip. Engineering hacks & tricks 2025-02-15 | My vise has a leadscrew concentricity problem, which led to jaw backlash. A thrust bearing did not totally cure it as it was then either too tight or too loose. Adding a Belleville washer to preload the bearing cured the problem.My CNC mill has a coolant delay due to the coolant flowing back to the sump between tool changes. Adding a check valve prevents this, saving a tool initially cutting dry.Have you ever wondered what the largest radius a vee block can hold without the vee corners digging in? There is a quick tip at the end of the video.
Stepped vise jaws? Minimizing part lift. Engineering hacks & tricks 2025-02-06 | The video demonstrates why stepped vise jaws should be flush or below the vise body.
Vise spring extension pads. Engineering hacks & tricks 2025-02-04 | A quick project to get my vise springs in order. Using just a few springs with a range of pads is a quick solution to holding parallels against the vise jaws.
A double sine square. Engineering hacks & tricks 2025-01-29 | A sine square is very useful for holding tall narrow parts by providing extra side support. Also handy for angles over 45 degrees by primarily locating on the side face instead of the base.
Quick release die. Engineering hacks & tricks 2025-01-26 | Continuing with the quick release tooling system. This is a short demonstration of the quick release system adapted to suit a die.
Asymmetric vee blocks?- Excellent for squaring up parts. Engineering hacks & tricks 2025-01-23 | Asymmetric vee blocks can hold rectangular parts safely and squarely when vee blocks can't. By locating on the 4 previously machined faces, the ends can easily be machined accurately and repeatably square.
Toolmakers sine ladder. Engineering hacks & tricks 2025-01-21 | This low profile of this design allows far more room underneath parts held in a machine vise. The ability to choose from multiple roller distances allows for different positions along the vise jaw increasing the gripping area.
R8 ultra short form quick release tapping head in action on mill & lathe Engineering hacks & tricks 2025-01-16 | My challenge was to make a tapping head as short as possible for smaller machines. I decided to fit all the working parts inside the arbor that is inside the spindle. This first prototype is an R8 taper with an adapter to suit a 32mm bore lathe tooolholder. Using the quick release system also allows for other machining operations by locking the spring loaded collet holder.This design allows tapping on the lathe carriage and also on mills with a worm drive quill. A MT3 model is almost finished for use in a lathe tailstock or mills with a morse taper spindle.
Hexagon collet block modifications for improved accuracy. Engineering hacks & tricks 2025-01-08 | When loaded, my hexagonal collet block rests on the threaded end of the collet. I was surprised to see how far it was off-square & decided to rectify this. Grinding the nut flat and adding a ground spacer, the collet block now rests on these two ground spacers and sits perfectly square.Once this issue was resolved I made a ball end vise end stop that located the centre of the collet block exactly 150mm from the stop outside end, including the edgefinder.
Quick release lathe tools introduction - short video. Engineering hacks & tricks 2025-01-07 | A quick look at some of the tools that can be used with the quick-release system on a centre lathe.Modified R8 toolholder held in a custom sleeve to suit a 32mm bore lathe toolholder.
Quick release short form tooling demonstration Part 1- R8 mill. Engineering hacks & tricks 2025-01-06 | In this video, I show 30 tool changes to produce a part with tapped holes from M3 to M12. All the tools are within 30mm of each other, minimizing knee movement. These short-form tools and the compact holder are ideal for smaller machines.The system is also suited for the centre lathe, either in the tailstock, toolholder or in the chuck. I will set up a part to show turning - boring - drilling - tapping and maybe a bit of screwcutting.I hope to finish making a sprung loaded holder for tapping on the lathe, drill & mill. If time permits I may also show the system on CNC machines without a tool changer.
Tool-less quick release short form milling tooling. Engineering hacks & tricks 2025-01-01 | Adapt any tool with a quick release adapter. Change your milling tools without using the drawbar, just lift the clamping collar to release. Click another tool into the holder and away you go. Particularly useful where reduced height is available.
Carriage drilling with an ER40 collet, my way. Engineering hacks & tricks 2024-11-30 | To eliminate the toolpost and compound rotating under load, this collet assembly is held on the centerline of the lathe.
Tilting a chamfer tool for facing + chamfering oustide diameters & small bores. Engineering hacks & tricks 2024-11-28 | When using a tool for facing parts plus I/D and O/D chamfers, sometimes the bore is too small for the chamfer tool, and it rubs due to a lack of front clearance. Tilting the tool forward gives more clearance at the front, and the tool can then be used for all three operations.
5c Z axis datum stop ring for consistent length parts. Engineering hacks & tricks 2024-11-17 | Adding a stop ring below a 5C bush head gives a constant repeatable Z-axis datum regardless of the part diameter.
Simple machinable 5c collet bush. Engineering hacks & tricks 2024-11-16 | Machinable 5C collets can be expensive. This method uses simple tooling to make machineable 5C collet bushes at a fraction of the price. Integral backstops can be easily added by tapping the small end.To keep a reliable and repeatable Z axis reference, a simple stop ring can be added between the underside of the bush head and the spindle nose face.This will repeat regardless of any fluctuations in part diameter.
Single ball mirror burnishing of small areas. Engineering hacks & tricks 2024-09-05 | This single ball tool can be programmed to burnish small areas.
Offset ball burnishing test. Engineering hacks & tricks 2024-09-04 | Will the 0.05mm offset of the two omnidirectional balls have sufficient overlap to make a difference?Mirror burnishing of small individual areas is now uploaded.youtu.be/RJFdL0TEhoA
Drilling 6 holes. Kevins speed challenge. Engineering hacks & tricks 2024-08-14 | I suggested on Abom79's recent video on machining a bolt hole circle that a Prototrak SM1500 could program, set datums, load & then drill 6 equispaced holes on a PCD in under 10 minutes. Kevin from Mechanical Advantage issued a challenge for me to upload a video showing that it could be done. Could a retired Toolmaker resist the challenge, let's see how I managed at the end. I also countersunk both sides for good measure.@MechanicalAdvantage17 hours ago @machinists-shortcuts Ok. Now do a whole video that you present on YouTube and let’s see how fast you do it.
Is this design the tightest clamping slitting saw arbor? Engineering hacks & tricks 2024-08-12 | This unique design clamps the saw nut from the top of the arbor body instead of inside, allowing a much larger clamping screw to be used. The huge torque that can be applied through the12mm A/F socket in the M14 high tensile cap screw, directly relates to the clamping force applied to the saw. No problem with rounded off hex sockets when the saw tightens itself. Precise location and rigidity is achieved through two separate diameters that locate in almost the full length of the arbor body.
The original 2 piece simple concept tool for mirror finishes on flat surfaces. Engineering hacks & tricks 2024-08-08 | A quick demonstration to show how my free spinning burnishing tool first shown in December 2023 can also produce mirror finishes as well as patterns. This unique small robust tool has just two simple manufactured parts, 2 standard balls & a shoulder screw. Larger models can easily incorporate far more balls for incresed feedrates.The balls are rolled by the steel profiled race when they are gripped between the race and the face of the part. They loosely move the brass retainer at half the spindle speed. The balls are not pushed round by the tool, they travel by naturally rolling at half the spindle speedTo see how this tool was made - youtu.be/PZ7XHXsY_no?si=uZC4k7BWdzrh1Xg0Spring loaded single ball flat burnishing - youtu.be/X_St-JSrBQw?si=Q2jFBxnwCb7VeUKPBurnishing complex shapes on the lathe with an omnidirectional ball - youtu.be/Avgv5uD49rk?si=_y905E99lNo9EXSBPattern burnishing on a lathe - youtu.be/srBk8jEbaOE?si=m_9xv5NQw7Ion2Y-
5C collets & bushes for accurately drilling shaft ends. Engineering hacks & tricks 2024-08-02 | Using 5C collets to hand drill & tap accurate holes in the end of long shafts.By making a couple of easy parts to clamp 5C collets to shafts allows the use of simple bushes to centrally guide drills, taps & reamers parallel to the shaft axis.
Safety flycutter. Simple design. Surprising surface finish compared to a button insert face mill. Engineering hacks & tricks 2024-07-13 | I've never been comfortable with the tool protruding from a flycutter body, it becomes invisible when spinning fast. If you do use flycutters try to use the appropriate size to minimise or eliminate any tool protrusion from the body. This 2lb tool has a cutting radius of 45mm and is designed to use the 100 degree corners not often used on CNMG shape inserts. The 75 degree leading edge gives a smooth engagement with the part, minimising impact and the inserts are virtually free. With the tool slightly protruding past the body the maximum depth of cut is 11mm.Starting from scratch the design ignored the traditional tilted tool which is simply not required unless square HSS toolbits are used. This is because insert tools have the cutting point protruding from the tool body, naturally having its own clearance. This simplifies the design considerably and is easily scaleable.The traditional downsides of flycutters are:Safety from protruding tools.Tip impact on the workpiece and spindle.Balance and rigidity.Painfully slow & uneconomic.Taking care with the design to minimise the inherent shortcomings with flycutting I compared it with a relatively inexpensive button tool to see the results. As expected, the button tool far outperformed the flycutter for metal removal rates and the finish was surprisingly far brighter.Watch a button insert really earning its money double tandem cutting while also chamfering on the inside of the inserts here. youtu.be/mHJMuitzENc?si=tATPNKcbHtyvcb6U
Dedicated edgefinder tooling + backlash tips. Engineering hacks & tricks 2024-06-23 | ISO 40 & R8 dedicated toolholders for antimagnetic edgefinders.Unique edgefinding tips for those without a DRO or DTI eliminating backlash issues even when finding the centre of a round bar. These techniques can find the centre of a bar end in only 3 axis moves or 2 axis moves & even just one axis move!! in under a couple of minutes without protracted calculations!!
Unique double tool for accelerated production of chamfered spacers. Engineering hacks & tricks 2024-06-09 | This double sliding box tool allows the mass production of chamfered spacers or washers on a manual centre lathe. The rod can extend far from the chuck as it is guided by a hardened steel bush at the cutting zone. This allows multiple spacers to be made without constantly stopping the machine, opening the chuck then advancing the rod and finally closing the chuck.The X axis is set permanently on the centreline of the machine spindle. All the diameter moves are accurately made by the internal cam for both tools. The tool is advanced on the Z axis by the required part thickness plus the parting tool width ( this tool = 2mm ). The diameter of the part can also be machined by the parting tool as the carriage is advanced. The tool has a detent setting on the handle to control the cutting diameter or the midpoint for advancing the carriage.The sliding mechanism is accurately guided by preloaded precision balls, this eliminates any possibility of chatter.
Unique double clutch speed chuck key gets a test run. Engineering hacks & tricks 2024-05-27 | Had a few hundred rollers to machine using my home made gang tools. It was a good time to see how the double clutch key worked and whether it would reduce the common elbow strain. It proved surprisingly comfortable throughout the run, allowing the ideal handle positions for both opening and closing the chuck.
CNC Form shaping any radius without custom tools. Engineering hacks & tricks 2024-05-14 | If a custom radius is required, this method quickly cuts accurate forms without special tooling. It is especially useful on long parts.
