Square Hole

[eLuSiVeMiTe]

Anyways, this has been good experience for me

Even though I’ve not fully achieved what I set out today, I’ve learned a lot

But most of all it’s been very much fun. I’ve been out in the play pen and got my hands dirty.

When you spend all week pen pushing, it’s what sundays are made for

That's what it's all about.

Took me 3 attempts to make that. And a fair bit of stock. Learnt a lot doing it though.

 

[gaz1]

a query here and no im not there myself yet

you center drilled it

I presume you then predrilled it from the internal drill hole

did you then drill to the exact size of the square hole lets say 6mm for a 6mm square hole

which would then be a round hole

then use a smaller milling drill bit to then work into the corners ?

 

[Parm]

That's what it's all about.

Took me 3 attempts to make that. And a fair bit of stock. Learnt a lot doing it though.
View attachment 203188

I remember that, bit more complicated than what I’m trying to achieve

 

[eLuSiVeMiTe]

I remember that, bit more complicated than what I’m trying to achieve

Not complicated.
Just an absolute @#$& to set up in the chuck for the offset.
Second attempt was good. Then I snapped a tap in the end.
Wife heard me cursing from inside.

What's the key actually for mate

 

[Parm]

a query here and no im not there myself yet

you center drilled it

I presume you then predrilled it from the internal drill hole

did you then drill to the exact size of the square hole lets say 6mm for a 6mm square hole

which would then be a round hole

then use a smaller milling drill bit to then work into the corners ?

What I did was mark it all out. Drill the corners with 3mm drill

Then bored it out on the lathe with an 11.2 mm drill

Then had an argument that i can’t make a blind hole

So while angry I drilled it with a milling cutter in the milling machine.

It would have worked, but the red mist had descended

 

[Parm]

Not complicated.
Just an absolute @#$& to set up in the chuck for the offset.
Second attempt was good. Then I snapped a tap in the end.
Wife heard me cursing from inside.

What's the key actually for mate

It’s a massively over engineered solution key for the milling machine give I got from the Vark a while back

 

[Parm]

Must say I’m not an angry person, but today my buttons were pushed

 

[8ob]

Am I the only one here that would of heated up a collar to cherry red and beat a square bar into it to form that socket .

May take a few minutes to wrestle the square out of the hole but it would be quick .

Bob

 

[awemawson]

If you've not made mistakes you've not made ANYTHING. Mistakes are all learning experiences, and help to fill up the 'bits bin' as a source of material for the future.

 

[eLuSiVeMiTe]

Am I the only one here that would of heated up a collar to cherry red and beat a square bar into it to form that socket .

May take a few minutes to wrestle the square out of the hole but it would be quick .

Bob

I'd probably have drilled a hole at 11.5mm before using your method to broach lol.

Or I'd have milled and turned a bit of tool steel to make a broach to drive in.

 

[earthman]

I’m not a competent engineer, and this is the second time I’ve used my milling machine

This is part of the problem I feel.

Seriously though, what do you expect? Most machines etc take time for one to master.

 

[jsf55]

Check the stock cupboard for one of these
https://www.ebay.co.uk/itm/Pentel-J...251563&hash=item419a94b9b2:g:UUYAAOSwd0BVwjWa

 

[zx9]

Anyways, this has been good experience for me

Even though I’ve not fully achieved what I set out today, I’ve learned a lot

But most of all it’s been very much fun. I’ve been out in the play pen and got my hands dirty.

When you spend all week pen pushing, it’s what sundays are made for

I had a bit of a learning day today too, it involved a milling slide on the lathe, shall we just say that it took me all day to reduce a small block of steel down to 1" x 1" x 1/2" definitely not worth posting pictures of that one. But did I have a good day? Yes.

 

[slim_boy_fat]

I now now that I need to get some marking blue

Try a broad marker, I find ot works for my needs - certainly cheaper than the marking fluid which I did consider getting a while back.

 

[Screwdriver]

Am I the only one here that would of heated up a collar to cherry red and beat a square bar into it to form that socket .

May take a few minutes to wrestle the square out of the hole but it would be quick .

Bob

Not the only one no, I’ve done that with offcuts from an Allen wrench to make relatively shallow hex head fixings. I would hesitate to suggest that would be “easy” to do to make a one inch deep socket. Maybe a combination of drilling a hole and forging a socket might work but you’d really have to be very accurate driving it in. Better off using a Flypress but then things start getting so involved the other options start looking more attractive.

 

[slim_boy_fat]

Just an absolute @#$& to set up in the chuck for the offset.

Have a look at @doubleboost's video on how to get stock where you want/need it in the 4-jaw. Makes it SO much easier!

 

[rikrobson]

would it be easier to drill relief holes at the corners and then drill and mill the square? so 2mm holes as the relief and then a 1/2" hole in the centre and work smaller mills say 4mm then 2mm to remove the rest and into the corners

 

[Screwdriver]

would it be easier to drill relief holes at the corners and then drill and mill the square? so 2mm holes as the relief and then a 1/2" hole in the centre and work smaller mills say 4mm then 2mm to remove the rest and into the corners

View attachment 203217

I think that's what's happening. The problem with having that clearance in the corner is that it leaves a weak spot exactly where all of the pressure is being applied. The sharp internal corners will deform over time leaving a sloppy fit. Much better (imho) to have the relief holes inside the square and have a slight radius on the drive bit which shouldn't have sharp edges anyway. Just my 2p, I'm sure it will be fine...

 

[Parm]

would it be easier to drill relief holes at the corners and then drill and mill the square? so 2mm holes as the relief and then a 1/2" hole in the centre and work smaller mills say 4mm then 2mm to remove the rest and into the corners

View attachment 203217

Good drawing and that’s exactly what I tried to do, but you can see from my picture that it didn’t quite go to plan

I know what the issues were, first thing I need to buy a smaller diameter cutter. Next I need to learn how to seton cutter to marks and then use the markings on the hand wheels to move job around

it’s wasn’t a total loss as I’ve learnt some stuff

Edit: I spent ages marking it all out with my height gauge, square and surface plate. Then it started to go wrong as the marks slowly started disappearing as the job got hot. Then there wasn’t enough light and I was holding a torch to see what’s going on

I’d say they were mostly my issues, but now I’ve experienced them I know what I need to do next time

 

[eLuSiVeMiTe]

Good drawing and that’s exactly what I tried to do, but you can see from my picture that it didn’t quite go to plan

I know what the issues were, first thing I need to buy a smaller diameter cutter. Next I need to learn how to seton cutter to marks and then use the markings on the hand wheels to move job around

it’s wasn’t a total loss as I’ve learnt some stuff

If your graduations are metric and you have a 4mm cutter you would need to move it 7.5mm to go side to side in an 11.5mm square.
Dro is something I really want on the mill. Would make life a lot easier