How would you cut this?

[motormech1]

If necessity is the mother of invention, laziness must surely be the father.

Man, I’m totally making that my sig! Lol

Using one piece. I would drill a hole with the diameter accross corners, this will locate the part except for the rotation. Tap a hole in the end and use a dog point set screw to locate the flat and clamp the part. Like clamping a round boring bar that has a flat in a lathe tool holder..

Great idea

 

[motormech1]

The square cutout is obviously the best idea here.

I would say it depends.

 

[Parlo]

The square cutout is obviously the best idea here. but if I NEEDED that hex, I would cut the bottom face to depth, then use a sine-bar to just tilt the work over and cut 1 of the angles (then again for the other side). Its a little tedious, but easy enough IMO.

Would you need to cut a flat bottom for this job? Just cut a vee and the hex part will locate on the angled sides.

 

[ErichKeane]

Would you need to cut a flat bottom for this job? Just cut a vee and the hex part will locate on the angled sides.

You couldn't do that with a 90 degree endmill I think, so you'd end up having to have some amount of relief at the bottom. Depending on the size of the mill used for the sides, you'd need a clearance op anyway

 

[Parlo]

I would use a cutter similar to this with the part horizontal in the vice.