Making A Hole Punch Kinda Thing - Tormach 1100MX Project

I needed to make a giant hole punch to cut some decals or stickers to size. I designed two mating blocks in Fusion 360 and cut them out with my Tormach 1100MX. I thought my Tormach failed me because the first set of blocks did not line up, I finally figured out that the issue was a design flaw. I made a new set and they work great. I now have a heat treated 4140 sticker cutter or decal cutter.
Designing any type of mating parts like a mold, you need to make sure you have a consistent point of origin that all measurements are coming from. Ideally a center point or something away from the outside edge. Especially in my case since my edges were only saw cut and not accurate enough to measure multiple points from for mating parts.
CNC or any machining is not just about machine accuracy, the design has a lot to do with how your overall part is going to turn out.
In the end, this punch is going to work to allow me to correct these stickers that were not cut very well when I purchased them.
BladesIIB Stickers are available on my website:
www.BladesIIB.com
or www.Blades2B.com
Thanks for watching!
Bud Beets
BladesIIB Knives

[@johncrisman576]

Beautiful! Great video! As a non machinist I appreciate your approach. The problem, the plan, the execution and machining issues with solutions, the finished product. I’m sure you will see your channel grow!

[@BladesIIB]

John Crisman - Really appreciate your comment. My goal was to try and provide just that, the full process and help others learn or replicate projects or parts of them or just enjoy what goes into it. Makes my videos a little longer but it is good to hear they are adding value, thanks!

[@jameslaird8399]

Bought a Sticker, the least I could do, I'll add it to the side of My 1100MX. Your installation videos saved me so much grief and made the assembly of my 1100MX here in the UK a whole lot easier! Thanks!

[@BladesIIB]

James Laird - Yes, I saw the order thank you. Will get it sent out Monday. Glad the videos helped with your setup!

[@ToBeeOrNotToBeHoney]

I'd consider using only 2 pins (diagonal) since that should be sufficient to locate the punch, and that would reduce the friction you need to fight against. Cool project, now you can make it fit a press (like a reloading press) and boom sticker cut in a fraction of the time/effort!

[@BladesIIB]

To Bee Or Not To Be - I will try just two pins. Good idea thanks. And yea a little arbor of some kind would be the Bees Knees for sure. 😀

[@kimber1958]

NICE

[@BladesIIB]

Kimberzelik - Thanks!

[@ericsandberg3167]

A great tutorial video....makes one have a greater appreciation for the folks that design and make dies/molds. On the top piece, would it have made more sense to chain drill the big slug of material out first, then finish up with a few contour passes....??

[@BladesIIB]

Eric Sandberg - Thanks for the comment and the question. I agree drilling would have been a good way to remove a bulk of the material from the center. With my vise mounted on the pallet, I am limited on drill length so for this one part I went with machining. Making more of them, I would likely mount the vise to the table lower and drill. Would likely save a lot of time if doing any quantity.

[@ElevatedEdge]

On your first design You could have pre drilled a small hole in the corners leaving “Mickey mouse ears” to give you clearance in the corners then profile it.

[@BladesIIB]

The finance rookie - agree, drilling would have been a good way to clear the corners, and even clear the middle some to avoid the full ½" wide cut. Thanks for the comment.

[@MrLongpants]

Hey man, I enjoy your KZbin feed. If you don’t mind answering a question, I have ordered the same lathe that you have from Precision Matthews. I only have single phase at my home where the lathe will be located, I would like to have the 3 phase motor option rather than the single phase option. How has the VFD worked out for you? I don’t believe the 3 hp, 3 ph motor they offer is designed for a VFD, have you had over heating issues? Is there any advise you have for me ? Thanks very much for taking the time to help me. Bruce

[@BladesIIB]

Bruce Davis - Congrats on the new lathe and thanks for the feedback on the channel, glad you are enjoying it. The VFD on my lathe has worked great. I have not had any motor trouble at all. True, the motor is not VFD rated, I don’t run it more than 20% over or under speed because of this. I still use the gears and honestly run it the majority of the time at 60hz, just make small adjustments between gears when needed. I am sure you have already watched my video specifically about wiring the VFD for the lathe. If you go to my website and use the contact form to send a message, I am happy to email the diagrams and info from that video to help you with your VFD build. The lathe is a nice one, you are going to love it. www.BladesIIB.com

[@wmcrash]

How much for some of the original flawed and now collectible stickers?

[@BladesIIB]

Cosmin - I was going to put the uncut ones out on the table for free at The Blade Show in Atlanta. If you buy some off my website, I will make sure you get equal number of each. 😀

[@Todestelzer]

33:19 wait a minute, no chamfer action? 😅

[@BladesIIB]

@Todestrlzer - thanks for the question. Correct, no chamfer on that section since I wanted the sharp edge to cut the stickers like scissors. At the time stamp you mention I did have a design issue that I had to fix before this worked but it does work in the end.

[@Todestelzer]

@@BladesIIB was a interesting project. I was thinking while watching that a drag knife could cut a whole sheetn of stickers. Thanks for the vid 👍

[@BladesIIB]

@@Todestelzer Yes if they had cut them right the first time I am sure their system would be fast. Thought it would be fun to try and come up with a way to fix them after they were cut. Good learning but not very efficient.

[@shaneclendennen1929]

Here is my two cents. I've been machining for 30+ years, but you didn't account for vise pressure and when you released the vise it sprained back. And the chattering in to fast on rpm

[@BladesIIB]

Shane Clendennen - Appreciate the comment and the feedback. Both great points. I thought with the material left on the edges it would account for the vise pressure, but no doubt there would be a better way to make sure it was not a factor. And chatter is never ideal, if making more of these I would work on tuning the speeds and feeds to hopefully eliminate the chatter.

[@dannirr]

Testing the fit while squeezing the top part in the vice is not a good idea. Take it out to fit

[@BladesIIB]

dannirr - Yes, I agree there too, was thinking the material on the sides was holding it enough. Also, I should have designed the part with more clearance on the long side and less on the short side, vs. just taking extra all the way around. I think I really only needed the extra on the long side. The difference in prototyping one part, vs. making hundreds I guess. Great comments though, keep them coming.

[@dannirr]

No need to spiral that last 1/4 inch end mill in - there's no material there - go directly to depth

[@BladesIIB]

dannirr - No argument there, that is still my weakest link in the process is modifying tool paths in Fusion. Have not invested the time so for this project, it was faster to wait that 2 minutes than spend 20 figuring out how to make it do what I want. I am getting there, I have cleaned up a few tool paths on other project. Definitely a place I need to invest some time and energy. Thanks for the comment.

[@dannirr]

@@BladesIIB Yeah, I get that - nice video, nice project. well done

[@BladesIIB]

@@dannirr Thanks!