Square hole help

plothoundsman · Aug 27, 2014

I am quoting a hot job ( 30 days ) for a new costumer, seems like I very well may get the job as well . The problem I have is the square hole . I have attached a photo of the part , 22MM hole C11 tolerance I think , 6.299 long , any suggestions or help on this square hole would be greatly appreciated . Like I said parts to be delivered by the end of Sept, at least 16pcs, they will buy 32 or 48 at a time , should be a long going order since the Co. has a long term contract. I can do all the machine work other than the hole. Located in Black Mountain NC.

Thanks Guys ,
Regards Eddie

Anti-matter · Aug 27, 2014

Use a broach.
A quick search turns up this: http://www.amazon.com/Metric-Sized-Square-Individual-Broaches/dp/B0067BVY1K

It wont be cheap.

Jeremy · Aug 27, 2014

Yep. Drill a hole, then run a square broach through it.

reedeprintice · Aug 27, 2014

We have a broaching machine and may have that size also .

michiganbuck · Aug 27, 2014

May want to box it in to broach a thin wall part. That may mean to hold sizes closer than print to fit box.
Not for hole size but for better life of the broach.
Broaching is almost the lowest cost manufacturing next to drilling, shaping and planning..
But it takes a very solid set-up.
May be best to start at top of size limit so broach can have more re-sharpenings.

I see they now have drilling of square holes but special machines and special spindles are required.

reedeprintice · Aug 27, 2014

if it had a pilot then it would be this quick

Jorgo · Aug 27, 2014

Looks like a wire edm job perhaps.
Jordy

plothoundsman · Aug 27, 2014

Thanks Anti-Matter for the link on the broach , I got a lot of machines ( mostly pretty busy ) don't have a broach machine tho , most of my broaching is done on a Vertical mill or lathe , since the only press I have is a little hand pumper. Hey Reedeprentice , how about dropping me a PM , lets quote this part ? You could call me as well if you like . Was hopping to find someone close , but what the Heck , that's what UPS is for !

plothoundsman · Aug 27, 2014

Also I got a wire EDM , went south for the winter tho , crapped out on me , just been so dang busy I aint had time to get er fixed !

plothoundsman · Aug 27, 2014

Left out my phone # Daaaaa, 828-776-0534 , might answer ? Pretty laud this AM , running a big Campbell OD grinder , might not hear it ring ?

reedeprintice · Aug 27, 2014

Thanks for your time . Jess

plothoundsman · Aug 28, 2014

HELP !!! Not looking so good on the broach side of things , part is so long 6.3 inches , seems like it is gonna take a special broach , $5000 tooling and broach charge ( not in the budget ) good lord have mercy ! Back to the drawing board , anybody got a wire EDM that might be able to cut this square hole out ? I hate the thought of grinding my own tool and stroking this stinking hole out with one of my mills , I could do it but don't want too. Any help out there guys ?
PS My engineer is just to banged up on work, to even think about getting our wire EDM up at this time . And I honestly don't have the experience or knowledge to run the EDM if it was in service. Waiting down here in the beautiful Mtns of NC. Ed

Gobo · Aug 28, 2014

Have you looked into rotary broaching? Pretty cool.

plothoundsman · Aug 28, 2014

Heard about it , but not really got to witness it yet , I guess I might have to check into it . They say it's wild and crazy , oh my younger days !

bigjon61 · Aug 28, 2014

You should be able to slug this part out all together on the WEDM. I assume by the picture that its all straight walls? Clamp a bar the width of the table with some start holes for your square hole, indicate it in and load the program, go home for the night. If you have the table space, you could do all of these in your sleep.

John Welden · Aug 28, 2014

reedeprintice said:
if it had a pilot then it would be this quick

Amazing 50 guys haven't gone crazy about telling you to NEVER WEAR GLOVES AROUND A MACHINE!!! THAT BROACH WILL SUCK YOU IN AND KILL YOU!! :rolleyes5:

Mud · Aug 28, 2014

That's a pretty long LOC for a broach, unless the broach is 6 feet long or you use 3 progressive broaches. And way too long for a rotary broach. A WEDM would be easiest. A keyseater might do it but it's pretty small dia. to start.

sfriedberg · Aug 28, 2014

Agree this is not a job for a rotary broach. BTW, you can synchronize a rotary broach with a part to get (for example) a square hole aligned with the part sides, but having to arrange that, especially within nice parallelism tolerances, is a second reason (beyond hole depth) to avoid rotary broaching this example.

reedeprintice · Aug 28, 2014

John Welden said:
Amazing 50 guys haven't gone crazy about telling you to NEVER WEAR GLOVES AROUND A MACHINE!!! THAT BROACH WILL SUCK YOU IN AND KILL YOU!!

There rubber skin tight gloves , they will not suck you in . Leather or nylon will suck you in . Been doing it like this every day 240 days a year for 3 years now .

reedeprintice · Aug 28, 2014

Bob at Pioneer has the cutter , pay him to pull it .

Square hole help

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