How would you machine this part without a lathe?

  • I would spin it in the mill and hold a cutter in the vise.
  • take a block of AL drill a hole in the block for the screw (undersize). Continue the drilling for a dowel pin (shaft for your collet).
  • band saw the block from the bottom of the block to the bolt head , then saw perpendicular to the bolt head stopping point.
  • clear out the block for the head, and the sawed off piece.
  • then create 2 clamping screws to hold the sawed off part back on as a clamp.
  • Clamp the bolt in the 2 parts, mount in the collet, and use your table to remove material.
  • use a block under the cutter in your vise to hold the tool from rocking. I would shape the cutter to have a shearing cut.
Now you just remove the 2 screws, replace the screw, rinse and repeat.
Do I need to draw pics, or was that clear enough?
 
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Rotate the head on the mill 90 degrees (if you can) and you have a lathe.

Don
 
All good suggestions, but for doing a 100+ of these I would just get another lathe. That would be the simplest, quickest and easiest.

Cheers Phil
 
In a CNC hold the bolt vertically (using a pre-positioned v-block) with the bolt head on the bottom of the vise (or on a parallel). Load an end mill of appropriate size (looks like 3/8 should do it), set X,Y to center of bolt and Z to 0 at top of bolt. Cut an outside circle (profile of the circle you need) at the proper depth. Load next bolt to pre-positioned v-block and run program again.
 
rodjava said:
I have this job about twice a year to machine the end of the bolt as in the picture. Approximately 100 at a time. It was simple enough to do on my lathe. But now the lathe has been sold.

How would you machine this bolt with only a manual or cnc milling machine? I do have a 4th axis and a 5c cam collet fixture.

If at all possible the setup and run has to be simple and easy. The tolerances are very loose. 3-5 thou.

Any ideas would be appreciated.

Thanks to the membership in advance.

I don't know how to add pictures to my post. I only have this link.

https://www.amazon.com/photos/share/QSTpKzOTfLQdX6kuSuVAK7ghp5sFbacNnMNOIXkoR71

Rod in San Francisco
Click to expand...

I would think that 200 parts per year would justify getting another lathe, but if that's out of the question, all of the ideas posted will work, take your pick.
 
rodjava said:
I have this job about twice a year to machine the end of the bolt as in the picture. Approximately 100 at a time. It was simple enough to do on my lathe. But now the lathe has been sold.

How would you machine this bolt with only a manual or cnc milling machine? I do have a 4th axis and a 5c cam collet fixture.

If at all possible the setup and run has to be simple and easy. The tolerances are very loose. 3-5 thou.

Any ideas would be appreciated.

Thanks to the membership in advance.

I don't know how to add pictures to my post. I only have this link.

https://www.amazon.com/photos/share/QSTpKzOTfLQdX6kuSuVAK7ghp5sFbacNnMNOIXkoR71

Rod in San Francisco
Click to expand...


You could easily use a hollow mill (similar to a counter bore with the pilot removed) One could be made from bar stock using a short lathe tool in a slot and adjusting it until you reach size. Once set it should repeat and could even be used in a drill press.

Dick
 
I wanted to thank everybody who chimed in with suggestions.
I also wanted to apologize for not being able to respond to your post in a timely manner.

Right after posting my question to the membership, I had back surgery.

Needless to say, I was in no position to respond intelligently while I recover in the hospital, and now back at home.

I hope to get back to working on my projects in the near future to try all the wonderful ideas and suggestions from the membership.

Rod in San Francisco
 
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