Cutting a chamfer around a non-removable shaft?

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Skeet_Man

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Imagine a shaft protruding from a block of steel, basically non-removable. I need to cut a chamfer all the way around the base of the shaft as a locating feature. Shaft is 1" dia, 12" long, block size unimportant. Fixturing in a lathe could probably be possible but would be non-viable in this instance.

Closest tool I can think of would be an annular cutter, but it would have to be bored completely through, and the teeth at an angle to cut at an angle instead of flat. Tool could be turned by hand, as the steel should be relatively soft and the chamfer does not need to be deep or wide. Something designed like a Neway cutter would work too. It's for a one off job, and can't be hellaciously expensive.

Any ideas for something preexisting?
 
Skeet_Man said:
Imagine a shaft protruding from a block of steel, basically non-removable. I need to cut a chamfer all the way around the base of the shaft as a locating feature. Shaft is 1" dia, 12" long, block size unimportant
Click to expand...

Could you use an additive cone, instead of cutting one in? Shrinking a collar into position (or, if you use soft material, swaging
a collar onto the shaft) might accomplish the location function.
 
"Something designed like a Neway cutter would work too. " That was my first thought. Perhaps you could knock something up out of a piece of pipe with a support for a Carbide insert welded on and a seat machined on it? Even a piece of pipe bored for a nice fit and a bit of tool steel brazed on the side,(if you wanted to get fancy cut a slot to sit the tool steel in up close to the shaft), and sharpened would do the job. Hole through the top and use hand power.
 
Depending on the block size, could it be put in a 4 jaw chuck, or bolted to a face plate, with a steady rest or center for the long end and cut whatever you want on the lathe?
 
As you can see above we all love a challenge!

You say:
Skeet_Man said:
Fixturing in a lathe could probably be possible but would be non-viable in this instance.
Click to expand...

So if the lathe is out, then how about on a mill?
My mind keeps coming back to mounting the block centred on a rotary table, tilting the vertical mill head to your required angle, and then using an end-mill, boring head, fly cutter or shell mill to cut the taper, depending on the width of cut required.

With the tool centred on the rotary table centre, you would get a flat cut. Turn the rotary table to get it traveling around the shaft.
Much depends on the quality of surface needed.

Any more details you can provide (steel block size, required finish/precision, chamfer angle and cut width, etc.) could help get better answers.

Perhaps, even a router bit could be used for a "one off" project.
If you find the required chamfer angle then you don't have to rotate the head.
1597158073720.png1597158168987.png1597158328038.png
https://www.leevalley.com/en-ca/sho...outer-bits/30170-45-chamfer-bits?item=16J3062
https://www.leevalley.com/en-ca/sho...-bits/30175-groove-bits-90-angle?item=16J1362
https://www.leevalley.com/en-ca/sho...s/router-bits/30167-chamfer-bits?item=16J1203

I'd go with the largest shank option available.

-brino
 
Mount on mill use a boring head and turn the cutter to the inside of head. Maybe not if shift is 12” long.
 
I am not saying this is the best option, but I add it as another option.

Make a split ring/collar that fits the shaft, and the purpose is to have a good round reference surface. You don't have to do it if it is already smooth and round.

Then make another larger collar going over it. You can add brass setting screws for tight fit tolerance.

The second collar is attached to a handle that can mount a cutter tool like a high speed dremel tool that you can cut with a carbide bit.

May not be high precision and a bit involved with this method. But you can make with good precision if you wish I think.
 
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