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J Tiers
10-30-2009, 11:59 PM
I don't seem to be able to buy shell end mill arbors, not in MT2 and MT3. I can get them all day in MT4, or Cat50 and similar types.

I did hear of a guy in Texas who was supposed to have them, but when I contacted him, I was not able to get what I needed from him. I don't recall what the problem was, no stock, or he only had "complete sets", some such thing.

So, another tooling project, spurred on by a what I know is coming up as far as prototypes for work, which will involve facing biggish chunks of material. I could do it with a fly cutter, but I may have to hog off a reasonable amount of stuff.

I used to use a kludge arbor that fit in an end mill holder. That was always scary. So this one I suspect will be a bit sturdier. This is MT3, I also made an MT2 version.

The MT2 I made starting with a "blank arbor" I had, this MT3 is made from solid stock.

http://img.photobucket.com/albums/0803/jstanley/shellmillarb1.jpg

http://img.photobucket.com/albums/0803/jstanley/shellmillarb2.jpg

http://img.photobucket.com/albums/0803/jstanley/shellmillarb3.jpg

And, what it was made to fit.....

http://img.photobucket.com/albums/0803/jstanley/shellmillarb4.jpg

Paul Alciatore
10-31-2009, 02:51 AM
Neat.

I always say, first make the tools, then .....

winchman
10-31-2009, 02:52 AM
"....I may have to hog off a reasonable amount of stuff."

Well, that looks like it would work quite nicely. How much runout do you have between the taper and the stub for the cutter?

Roger

JCHannum
10-31-2009, 09:03 AM
Nice work. I have become a convert to shell mills, and have made a couple of similar R-8 holders. R-8s are available, but making them is cheaper.

I use the shell mills in lieu of flycutters to lessen wear on the spline in the milling machine spindle. They produce a better finish as well.

J Tiers
10-31-2009, 11:16 AM
How much runout do you have between the taper and the stub for the cutter?


Not much, both machined between the same centers at one go. I have not measured, simply because it hasn't been an issue. I guess that is like the datasheet note "guaranteed by design, not 100% tested".

If I had the cylindrical grinder ready, it would have been ground instead of turned/polished.

I have a selection of shell end mills in 1" and 1/2" shank, I sure do prefer a multiple tooth cutter when it is available. Some of the cutters are smaller diameter, so I don't have to use the big one if I don't need the "sweep". The fly cutter always seems to be working way too hard.

Mcgyver
10-31-2009, 11:22 AM
Nice work, what material did you use?

Ken_Shea
10-31-2009, 11:34 AM
Looks really good JT, what make/model is the little horizontal machine?

Tony Ennis
10-31-2009, 11:45 AM
Bear in mind I don't know jack about any of this stuff.

What will prevent the outside portion of the cutter from deforming under load, seeing that it unsupported, having that hollow space in the middle. I'm surprised you didn't sneak a cylindrical filler piece in there.

Mcgyver
10-31-2009, 11:54 AM
Tony, you'd stall the spindle or snap off teeth before you moved the teeth enough to be material or measurable. any movement you might thing you're detecting via measurement is imo just spindle, bearings etc reaction to the load.

lazlo
10-31-2009, 11:57 AM
Looks great Jerry!

J Tiers
10-31-2009, 12:10 PM
what material did you use?

I am pretty sure the unmarked stick I used was the leftover piece of 4140 :D . At least it was some such, and I only have 4140 in general in that size rounds. It was really wanting to work harden, and got harder than ^%$# when it did.



what make/model is the little horizontal machine?

It is a Lewis mill.

As for the cutter, and deflections, etc..... Just because a shell end mill looks a bit like the end of an older river dredge doesn't mean that you use it buried in the work.

Many are backed off a bit in diameter over their length anyway. So the main use in my case is as a large surface finisher, an alternative to a fly cutter, cuts not deeper than maybe 0.25 or so, likely. The cutter varies about 4 thou over its "length".

The MT2 versions, and the smaller cutters for this one are not so impressive-looking.


What will prevent the outside portion of the cutter from deforming under load, seeing that it unsupported, having that hollow space in the middle. I'm surprised you didn't sneak a cylindrical filler piece in there.

There is one.....

Look at pic3. The shank portion only extends that far, because the ground bore of the cutter only goes that far. You can see it in pic3, there is a ledge down in the bore of the cutter.

HSS doesn't deflect much.... it might shatter, but won't deflect.

J Tiers
10-31-2009, 07:26 PM
Here's the whole lot

http://img.photobucket.com/albums/0803/jstanley/shellmillarb5.jpg

The MT2 (fits my vertical head). I cheated and used an MT2 blank drill arbor from Victor Machinery. Cut off the tang, drilled and tapped 3/8-16, and machined the "blank" end for the arbor form. The taper is much shinier than the one I machined all over.

http://img.photobucket.com/albums/0803/jstanley/shellmillarb6.jpg

http://img.photobucket.com/albums/0803/jstanley/shellmillarb7.jpg

Tim Clarke
10-31-2009, 09:57 PM
Your'e killing me, just what kind of mill DO you have? Looks really nice, I'd really like a photo.

Now, I have to make a arbor for my mill, with what I think is a #9 Brown and Sharpe Taper. It's one of those 'roundtuit projects...........

Regards, TC

Tim Clarke
10-31-2009, 10:02 PM
Looks like my question was answered by the time my post was up.....
Sorry, TC

J Tiers
10-31-2009, 10:46 PM
Your'e killing me, just what kind of mill DO you have? Looks really nice, I'd really like a photo.


Crummy photo of it with a mimsy little slitting saw on a big MT3 arbor. The MT2 vertical head goes on the overarm.

Actually, there is a second overarm that the V-head goes on, but I hate changing them out, so I have to do an adapter, which I have not yet done. So I run end mills in the horizontal spindle, and keep telling myself I need to make an adapter, or a second V-head that will have a full quill and downfeed. The overarm is a little light, so I want to do a better braced system for the adapter or new head, and I haven't done that yet.

http://img.photobucket.com/albums/0803/jstanley/mil_bars.jpg

dp
11-01-2009, 01:52 AM
Crummy photo of it with a mimsy little slitting saw on a big MT3 arbor. The MT2 vertical head goes on the overarm.

Actually, there is a second overarm that the V-head goes on, but I hate changing them out, so I have to do an adapter, which I have not yet done. So I run end mills in the horizontal spindle, and keep telling myself I need to make an adapter, or a second V-head that will have a full quill and downfeed. The overarm is a little light, so I want to do a better braced system for the adapter or new head, and I haven't done that yet.

http://img.photobucket.com/albums/0803/jstanley/mil_bars.jpg

Yank out the Lewis and drop in a DeWalt radial arm saw and it looks like my "poor man's surface grinder". I nearly had to do a double-take :)

Nice work, Jerry.

Glenn Wegman
11-01-2009, 08:21 AM
Trying to get a scale on that little critter Jerry. What's the table size, about 5 X 18?

.....or is that a 20hp motor and it's bigger than a K&T?

wierdscience
11-01-2009, 09:18 AM
Nice job,those arbors used to be common,but I guess like the Dodo bird they are getting scarce.

J Tiers
11-01-2009, 10:03 AM
Trying to get a scale on that little critter Jerry. What's the table size, about 5 X 18?

.....or is that a 20hp motor and it's bigger than a K&T?

When I stand on a ladder, I can just reach the table handle with a sledge to turn it. The ladder normally stands on that large patio area you see around the mill, where the tool sculptures are..

I actually got it from the guy next door to this:

http://tinyurl.com/ykbdor4

:D
.
.
.

The lead hammer at lower left is in scale.... table 4 x 18

Glenn Wegman
11-01-2009, 10:23 AM
When I stand on a ladder, I can just reach the table handle with a sledge to turn it. The ladder normally stands on that large patio area you see around the mill, where the tool sculptures are..


Do you remove the chips one at a time or do you have a dozer?

Forestgnome
11-01-2009, 10:33 AM
Yank out the Lewis and drop in a DeWalt radial arm saw and it looks like my "poor man's surface grinder". I nearly had to do a double-take :)

Nice work, Jerry.
How bout a photo of the poor man's surface grinder? I'm poor!

J Tiers
11-01-2009, 06:39 PM
Do you remove the chips one at a time or do you have a dozer?

it's done by a contractor at night;)

darryl
11-01-2009, 07:02 PM
I thought I recognized that saw blade laying there- it's a 6 ft diameter blade from a sawmill.