Fun little job

[Brad93]

Thanks to @Milkybars getting me out of the stink on this one. Saved me buying Chinese broaches which I really didn't want to do!


This is how the assembly was sent to me.
First course of action was a wash in eco friendly degreased at 90° with the jet washer.

That left me with this:

 

[Brad93]

Got that all disassembled. Bearings had spun on shaft. The duplex gear was really worn and one of the simplex gears had two damaged teeth.

And to think the customer was complaining it was throwing the chain...

Individual parts then went into the ultrasonic for a final clean.

 

[Brad93]

Ordered new parts from local bearing stockist.

Had to pick those up and shoot down to Kent to pick up a toolholder for our 1.1mm Sandvik grooving inserts.

that proved to be a nightmare due to an accident in the Dartford tunnel.

 

[Brad93]

Gears are ⅜" pitch 15T simplex and 13T duplex. Both pilot bore.

Shaft is 17mm utilising a 6003 and 6303 bearing.

 

[Brad93]

You can barely make out the circlip grooves but you can see Phillips lovely broaching!

Gears were bored, parted and turned to correct proportions on the harrison along with the shaft which started out as 30mm EN8.

 

[Brad93]

All that is left to do in the morning is keyways in the shaft. 3/16"

 

[minimutly]

So did you make new sprockets @Brad93 ?

 

[Brad93]

So did you make new sprockets @Brad93 ?

I bought pilot bore sprockets for about £5 each from the bearing supplier.

 

[Brad93]

So did you make new sprockets @Brad93 ?

I just bored them, parted the excess stub off, then Phillip done the keyways

 

[Munkul]

nice work If only all MRO were as satisfying as that.

You'd get bored, i suppose

 

[Brad93]

nice work If only all MRO were as satisfying as that.

You'd get bored, i suppose

More bakery equipment, I really like doing it. Usually Italian so reasonably well engineered, standard metric dimensions (although I work better in inches, the lathe is metric).

Just got hung up on the broaching. So keeping my eyes peeled.

 

[Munkul]

More bakery equipment, I really like doing it. Usually Italian so reasonably well engineered, standard metric dimensions (although I work better in inches, the lathe is metric).

Just got hung up on the broaching. So keeping my eyes peeled.

I re tooled our workshop 7-8 years ago with a new marlco flypress (the old one had been abused and broke), replaced the missing broach sizes and sent the good ones for re sharpening. It was NOT cheap, and I'd hate to have to tool up for myself, it's not even satisfying kit to look at Spent about £2k on tooling alone. None of the machinists have ever complained to me about broaching since then though, so it must be holding up! The T shaped shims are the ones to go for, btw.

 

[Brad93]

I re tooled our workshop 7-8 years ago with a new marlco flypress (the old one had been abused and broke), replaced the missing broach sizes and sent the good ones for re sharpening. It was NOT cheap, and I'd hate to have to tool up for myself, it's not even satisfying kit to look at Spent about £2k on tooling alone. None of the machinists have ever complained to me about broaching since then though, so it must be holding up! The T shaped shims are the ones to go for, btw.

Who did you use for sharpening the broach. Plenty of sets on eBay but I'm petrified of buying a few hundred quid set and it being blunt

 

[Munkul]

Who did you use for sharpening the broach. Plenty of sets on eBay but I'm petrified of buying a few hundred quid set and it being blunt

WDS Components who own Marlco. Not sure if they did it in house or subbed it out, I think it was in house.
£55 a sharpen, but they wouldn't sharpen ones with dings and chips in, just replaced them at over £200 a pop.
Obviously I didn't care, it wasn't my money, in fact I've never even used a broach in my life. I just had to convince the manager to sign off on it, and he always does if I give good reasons.
It was the older machinist who, before he retired, was on my case every couple of days for a while, until I'd bought everything he wanted.
Since then, blessed peace, which comes from people having the tools they need to do their job

 

[Munkul]

I tell a lie! Just looked through my emails, I misread the purchasing system and thought it was all WDS/Marlco. The sharpening/replacing was done by JFL Broaches and we paid them directly.

I have been given this contact by Marlco themselves for servicing and sharpening.

Charles Manning, JFL Broaches

http://www.jflbroaches.co.uk/

Unit 2
Deethe Farm Industrial Estate
Cranfield Road
Woburn Sands
Milton Keynes
Buckinghamshire
MK17 8UR

Tel 01908 585103
Fax 01908 584693

I spoke to Charles a few weeks ago and he gave a guide price of £50-£75 per broach depending on how chipped or blunt it is.

 

[Brad93]

I tell a lie! Just looked through my emails, I misread the purchasing system and thought it was all WDS/Marlco. The sharpening/replacing was done by JFL Broaches and we paid them directly.

Brilliant thank you

 

[Brad93]

I've got in touch with JFL about my broaches.

I've got a ½" broach which just needs a sharpen up, a ⅜ broach with one seriously chipped tooth, and then a 14mm broach with a few small chips.

Seems they can't repair any broach. They didn't sound too positive about the 3/8 broach.

To be honest I think the 14mm broach could be laser welded with stellite quite easily but I think depends on their setup I guess.
If I can't find anyone to laser weld it I might try a buildup with stellite via powder spray.

They've quoted £70 a broach for sharpening.

 

[Brad93]

As you can see someone had a go at welding two of the broaches back together!