Lot's of ideas but one huge problem:
No idea of the OP's machinery or skills. Without those it's like putting a note in a bottle and casting it into the sea.
Certainly what comes to mind is an indexer or collet block and a 2-axis CNC mill. For this even a Spindex would work.
But again, without further information from the OP we are just guessing.
Thank you every one for all of your suggestions.
I need to make approx. 50 per month.
The part goes into the main drive for a Drone.
The material is Chromium Molybdenum Ally Steel RC 38 but gets Heat treated to RC 58
When I seen it first, I thought this should be easy but it is far from easy.
I though about getting a grinding wheel made with the actual profile of the Ball end Hex Head and doing is on a grinder using an indexer but that would be ridiculously slow. I have a Tsugami MO8SY Dual spindle with Y axis and Live Tooling that has been running the same job for almost four years 10 hours a day and it looks like I am going to have to try program it and run it on this machine. I know it can be done on this machine but it is still going to be a pain in the butt.
I believe that the heads are forged on the Hex Keys.
I don't claim to be a master machinist but I have been in the business almost thirty years and have shipped 7.3 million parts to my customers. These include Boeing, AirBus, Lockheed, Raytheon and many more. Our Quality rating is currently 99.98% and has not fallen below that number for several years.
I would like to think I know what I am doing but I have my days. This is not an easy part to make as a production part.
Thank you everyone and I will let you know how it worked out and hopefully post a few pictures.
I knew I had seen it being done on PB Swiss hex keys, wouldn't you know it was an episode of How It's Made. Around 1:20 they show it. Like you said, a few seconds.They aren't forged in quantity production, they're polygonal turned... It's a matter of a few seconds work. Probably not going to make sense for those lower quantities though.
Not long ago there was a PM thread using a whacker rotating tool bit and a timed lathe for making such items..I think it was that Russin guy who made the thread.
-I was the point man in the ball driver project for Eklind Tool in the mid 90's. The process in the video that creates the ball itself is similar, nothing else is. The spindle speed for both the cutter AND the workpiece have to be timed to have the correct relationship that produces a "flat" or it will produce something similar to a screw extractor, I have a few examples in a toolbox somewhere. The remaining profile of the ball and neck can be easily programmed in the two axis movements in the equipment the OP already has IMO.I knew I had seen it being done on PB Swiss hex keys, wouldn't you know it was an episode of How It's Made. Around 1:20 they show it. Like you said, a few seconds.
As the polygonal turning is happening (Bondus video ) is the cutter moving towards and away from the spindle to maintain hex shape?They aren't forged in quantity production, they're polygonal turned... It's a matter of a few seconds work. Probably not going to make sense for those lower quantities though.
As the polygonal turning is happening (Bondus video ) is the cutter moving towards and away from the spindle to maintain hex shape?
Pardon my ignorance, I’m an old manual Man.