Pattnmaker
Stainless
- Joined
- Nov 2, 2007
- Location
- Hamilton, Ontario
I have a job coming up we have been forging for years but the customer has made a major change to the end that we Forge. Typically we are making 10 or 20 of these every few months however the volume has gone down over the last few years and due to upcoming process changes in a few years they may or may need them after their process changes.
I made some samples of the new design a year ago. I forge (flatten) the end of a 12ft long bar of 4340. When we're done forging the bar Hardness could be as high as low 50s rc. but will likely be mid 40s especially if I normalize the end. When finished the end of the bar gets hardened to low 50s. I then have to cut out a spear shape from the flattened end and chamfer both sides. Spear shape tolerances are pretty loose, for the samples we made a template zip wheeled and ground to shape with an angle grinder. I had considered making a really quick and dirty shearing die to shear them hot which I have done before but it's an expensive option for a job with an uncertain future.
It occurred to me this morning machining the ends might be a good option. On my mill the table moves in and out in y but the head is on a gantry for x so sticking out the front of the machine the bar would only be moving in and out. Even so a lot of x moves make me nervous. What would your approach be to machine the spear shape out of 1/4 4340 on the end of a long 1" bar? Slow full width cut with one endmill. Slow full width roughing cut with rougher then finish cut. Or just go at it with an adaptive and live with all the in and out of the 12ft bar. Rough out the 3/32 chamfer or just cut in one go?
Workholding easiest would be to clamp on the round but it leaves the spear unsupported. If I clamp on the spear the clamp would be in the way and require a longer tool.
I made some samples of the new design a year ago. I forge (flatten) the end of a 12ft long bar of 4340. When we're done forging the bar Hardness could be as high as low 50s rc. but will likely be mid 40s especially if I normalize the end. When finished the end of the bar gets hardened to low 50s. I then have to cut out a spear shape from the flattened end and chamfer both sides. Spear shape tolerances are pretty loose, for the samples we made a template zip wheeled and ground to shape with an angle grinder. I had considered making a really quick and dirty shearing die to shear them hot which I have done before but it's an expensive option for a job with an uncertain future.
It occurred to me this morning machining the ends might be a good option. On my mill the table moves in and out in y but the head is on a gantry for x so sticking out the front of the machine the bar would only be moving in and out. Even so a lot of x moves make me nervous. What would your approach be to machine the spear shape out of 1/4 4340 on the end of a long 1" bar? Slow full width cut with one endmill. Slow full width roughing cut with rougher then finish cut. Or just go at it with an adaptive and live with all the in and out of the 12ft bar. Rough out the 3/32 chamfer or just cut in one go?
Workholding easiest would be to clamp on the round but it leaves the spear unsupported. If I clamp on the spear the clamp would be in the way and require a longer tool.