We need to machine several large rollers. These vary around 12-16 inches in diameter, 12 to 24 inches long and look something like the attached. They only need like a 1 inch side wall thickness. Buying solid material ends up being very expensive and also very very heavy to work with. Would it be possible to take flame cut or laser cut rings that are bigger on the OD and smaller on the ID and have them cut to match the radii of the complete part? They would would get welded together from inside and then you would end up with a part basically big on the OD and small on the ID that you could machine to the right size. It would be a lot of roughing over corners. Does this make sense and has anyone heard of it?
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How To Machine Large Roller?
- Thread starter munruh
- Start date
- Replies 8
- Views 1,248
stephen thomas
Diamond
- Joined
- Jun 3, 2001
Is that going to save any time or even significant material cost?
"Rollers": Will the finished welded product be suitable (strong, durable, fatigue resistant, uniform surface hardness) enough for the intended application?
smt
"Rollers": Will the finished welded product be suitable (strong, durable, fatigue resistant, uniform surface hardness) enough for the intended application?
smt
JRIowa
Diamond
- Joined
- May 27, 2003
- Location
- Marshalltown, Iowa, USA
What is several? 2 or 20?
After weld, then machine through the flame cut, you'll have almost as much time and money in them as if you would have made from solid. I would look at casting. We get 1 off sand mold made with 3D printing now. Parts bigger than yours.
JR
After weld, then machine through the flame cut, you'll have almost as much time and money in them as if you would have made from solid. I would look at casting. We get 1 off sand mold made with 3D printing now. Parts bigger than yours.
JR
Limy Sami
Diamond
- Joined
- Jan 7, 2007
- Location
- Norfolk, UK
IMO short of finding some hollow bar (unlikely) or a forging (unless there's something close you know is made, - fergeddit) that's a kick bollock and bite heavy machining job from solid.
Welded rings etc etc is fraught with more man traps than you can shake a stick at - and a SOB to machine in to the bargain.
Put the job in a metal moving (as opposed to fancy doo dads) lathe, shove the DOC and feed up as high as your bottle will stand, grit your teeth and make serious chips.
Have fun
Welded rings etc etc is fraught with more man traps than you can shake a stick at - and a SOB to machine in to the bargain.
Put the job in a metal moving (as opposed to fancy doo dads) lathe, shove the DOC and feed up as high as your bottle will stand, grit your teeth and make serious chips.
Have fun
Onepass
Hot Rolled
- Joined
- Jun 2, 2014
- Location
- Kansas City
IMO short of finding some hollow bar (unlikely) or a forging (unless there's something close you know is made, - fergeddit) that's a kick bollock and bite heavy machining job from solid.
Welded rings etc etc is fraught with more man traps than you can shake a stick at - and a SOB to machine in to the bargain.
Put the job in a metal moving (as opposed to fancy doo dads) lathe, shove the DOC and feed up as high as your bottle will stand, grit your teeth and make serious chips.
Have fun
Yea fer that! You need a heavy 10 SB
Open Die Forgings - Seamless Rolled Rings - Metal Forging | Scot Forge
Does one off and low volume work, rather in-expensivly.
Does one off and low volume work, rather in-expensivly.
HuFlungDung
Diamond
- Joined
- Jan 19, 2005
- Location
- Canada
Assume this is a simple 44W grade of material, consider the prep time to make the joint(s) prior to welding, fixture the pieces and the welding and cooling time. And, it costs money to have heavy sections cut out anymore (oxyacetylene). I'd assume that if 1" wall is important, then you don't want to just lay a stringer bead on the joint in hopes of holding things together. Welding rough cut parts can be very wasteful, as you have to place a considerable amount of metal in the overburden just to make sure you've got enough on for the piece to clean up properly.
Hope you have a cnc lathe that can swing this, it's a great job to rough on a cnc, whereas it would be a PITA on a manual.
Hope you have a cnc lathe that can swing this, it's a great job to rough on a cnc, whereas it would be a PITA on a manual.
Limy Sami
Diamond
- Joined
- Jan 7, 2007
- Location
- Norfolk, UK
Good call Doug
be interesting to know the price difference to work out the economics of the two methods. .....then there's the lead time.I'll check these people out.
