Group Project: Dividing Head - Organization and Design

I did a little research on the taper endmill i had and it was unfortunately a 1/4" and not 3/16"
 
There are a lot of parts to this. If yall want me in I will cast the blanks (assuming they machine OK) and pick up some of the smaller parts. I am out of brass so I will need to buy materials for alloy. It looks like the gear shift assembly needs an owner for starters.
Robert
 
Here is the new latest and greatest BOM. I believe it is now correct with all the names on parts.
 

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@Flyinfool , could I ask you to either consolidate all of the "bought parts" into one list, or share the spreadsheet with me so that I can. I'd like to see if I can get an order together from AliExpress.
 
It probably makes sense for me to do the pair of "DH 009 Main Base End Cap". They need to match up with the trunion anyway, and would use the same stock.

If someone else was really excited to make them, I can send them some stock. :)
 
So, order of operations for the trunion, just to see if someone has an easier way to do it.

Cut an over length part on the bandsaw, with some extra for holding in the chuck, so I can do all diameters in one setup. Then face the end and turn OD with the steps. Bandsaw off holding stock, flip in the chuck and face the other end square. Or perhaps square it on the mill with the part in a vee block. Probably saves indicating it on the lathe.

On the mill, hold in the vise with the faced ends on the jaws. Mill one flat (center drawing), flip and use parallels against the flat to do the opposite side. Use the same setup to get the two flats with a radius (seen on the left/right drawings). Bore the bearing hole, drill/tap the holes. Rotate 90 degrees using parallels on the flats and cut the slot. Probably drill out, then clean up with an endmill.

Hold vertical in the vise with blocks on the flats, drill/tap the bolt circle in the ends.

Switch to rotary table, drill/mill the tapered holes. Mark lines with a 90 degree end mill. Stamp the numbers. I might need to work up a jig to line them up nicely.

Probably some deburring in there.. and a lot at the end.

Material is hot rolled, suspected 4140. I can use a forge to release stresses before machining if needed. Do we think it will be? I guess if it's not, all I'm out is a little propane and time.
 
You could save quite a bit of stock if you could turn the OD and shoulders on several at once and then bandsaw them apart.
Hot rolled doesn't have as much stress. Right?
 
Shotgun said:
@Flyinfool , could I ask you to either consolidate all of the "bought parts" into one list, or share the spreadsheet with me so that I can. I'd like to see if I can get an order together from AliExpress.
Click to expand...
 

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Shotgun said:
You could save quite a bit of stock if you could turn the OD and shoulders on several at once and then bandsaw them apart.
Hot rolled doesn't have as much stress. Right?
Click to expand...

Good point. I should be able to fit a couple of them on the lathe at a time at least. It's a PM1127, and the part is about 6" long, so perhaps 3 at a time, depending..

I have read that stress isn't as big an issue on hot formed material, but I'm unsure how much difference it makes.
 
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