Making a shell mill !!!

Making a shellmill/facing mill using plate steel and APKT 1604 inserts. This was an interesting learning curve and could be much better but im relatively happy with it
Twitter: Fr...
#bridgeport #boxford #diy #machining #hobby #metalworking #learning #machine

[@patrickd9551]

2.5mm alone is impressive enough for a "simple" home machinist type of setup and you want to go to the full 15mm? DANG! Subscribing and clicking to find that next video :D

[@Argosh]

Good work, only thing that bothered me was the voice of my uncle yelling at me "if you cover a bad weld you just have a bigger bad weld". 😁

[@canonsonico3752]

Nice thing you just made!

[@lawmate]

Awesome work! If you ever make another, if you space the inserts at unequal angles between each pocket, it helps reduce resonant chatter when it's cutting.

[@allangles4020]

Thanks .... note taken 👍

[@TheZombieSaints]

Makes sense, nice tip 👍

[@TradeWorksLLC]

More welding rod 😤 … 4lbs wasn’t nearly enough I need more welding rod! Me: If 1 rod is good then 2 is better. Since better is twice that of good then 4 would be best being twice as good as better …. But if 4 was best and 8 is better still than there can only be one conclusion: we multiply best by better still and Throw ALL 32 sticks at the thing like a champ! Then and only then will i call it good … 🔂 😙

[@homemadetools]

Great work. We shared this video on our homemade tools forum this week 😎

[@c4t4l4n4]

I commend you for your tenacity in tapping the threads for the inserts. You must have found the inner most Zen for that stretch of work, lol. 👌😊

[@allangles4020]

.........when somebody even mentions a tap & die set I start shaking 🤣 😂 😭

[@n.b.p.davenport7066]

It brought back a lot of memories

[@adamdiaz8442]

You’ve made something there that your grandkids could use u should be proud excellent work mate 👍🏽

[@muratbasarir6046]

Really good job brother.greetings from Turkiye

[@Steviegtr52]

Great build you have done. 5star job. Steve.

[@danshavit4510]

I just can't comprehend how such precise work is accomplished. Blows my mind. Fantastic work mate 👏 👍 👌 Thanks for sharing

[@kimber1958]

VERY NICE JOB, GREAT TOOL.

[@francisfruscalzo]

It's a really nice job to made this tool.

[@craigtate5930]

Spectacular build

[@hans-peterkahland794]

Excellent job!

[@davidlakatosh9456]

A ton of work but really worth it, very nice!

[@SGS_Engineering]

Cracking work! Thanks for sharing👍

[@allangles4020]

Cheers

[@terryjennings2356]

That turned out amazing

[@metalgeria]

That was fantastic

[@jongerber3476]

Nice job.

[@greggminkoff6733]

You're right you did spend a lot of time doing it but you're not done yet. You need to remake the locking nut located on the bottom larger and counterbore a pocket for it so the bottom is completely smooth. Then you need to black oxide your tooling to prevent surface rust. Then you're done.

[@allangles4020]

Apsloutly agree about the black oxide ......however the nut on the bottom is a little trickier to unravel ...due to the cutter being made out of multiple plates and the nature of the cutting forces the nut on the bottom more or less helps to presses the plate together aswell as centralise things (even though welded) long story short space was becoming an issue and it was a balance between room and thickness.......

[@mantisgaming]

Great video! I'm surprised at how few subscribers you have

[@grahamdavies22]

One more now, I’m in! 😄👍

[@kenwood8665]

Great video

[@DanKoning777]

I'm not a machinist and admittedly, I know very little regarding this industry-I'm merely fascinated by this type of work. There is one thing I don't understand though; where are all the machinist who do understand what they're seeing? Seems this channel would have 267k subscribers not 2.67k-well done.

[@wordwyrd]

probably lack of exposure? I'm a toolmaker/moldmaker, and this was the first I heard of the channel.

[@NikColyerMachineWorks]

Great job, but after all of that lovely work you make the R-8 shaft out of rebar which is purposely made soft so it can bend. That kind of shafting needs to be out of 4140 or 1045 so it is ridged under that kind of pressure.

[@skyopinions3857]

Hello from France (Normandy), very nice video on the manufacture of a surfacing plate. very often used to surface an engine cylinder head or engine moc block. and with so many machining inserts you should have a very nice surface provided you have the right feed rate per revolution. 😊 ps/ on the other hand what a shame that you didn't activate automatic translation on the video.☺

[@anjoschwarz5800]

Das hat mein vollen Respekt,Ausdrehköpfe für s Bohrwerk auch schon mit Härten gemacht,aber einen kompletten Fräskopf Woh! Cool Anjo56

[@grahammctygue724]

Happy Christmas best of the holidays for you an your,s

[@UnyahPe1601]

I know, MERRY CHRISTMAS & Happy Holidays and HAPPY N/YEAR 2023 to You and All. No Problem and All the BEST for this coming New Year...🤗👍💖✌️🙏✝️

[@TrPrecisionMachining]

Hello from spain...good video

[@DolezalPetr]

15mm depth of cut sounds awesome, I want to see that

[@kentuckytrapper780]

Excellent job. New subscriber.

[@edsmachine93]

Very nice job. Thanks for sharing. I just subscribed to your channel. Take care, Ed

[@Shnick]

I’m wondering if a harder steel than rebar would have been a better selection for the shaft. That part alone will be suffering a huge amount of deflection, even under light use.

[@allangles4020]

Agreed ...but unfortunately it was the only bit of steel I had that was big-enough...just some old sections of dywidag bar my dad dragged back from work ....which is abit more consistent than rebar ...but it is high tensile steel with carbon content upto 0.80% which chould be hardend.....although that may warp things out of Shape...

[@LuizCarlos-cj3nu]

excelente trabalho 👏👏👏👍

[@watahyahknow]

nicely made , mightve gone about making it in a little different order , basicly first smooth the mating surfaces where the parts lay on top of eachother with a good center hole through and through . bolt through all the parts to clamp them together together to weld them in one go then use the center hole and a temporary way of mounting to chuck the part in and machine the circumference of everything with the hole mostly in the center use the outer surface to chuck it in and clock it out so its centered along the circumference and mostly level against the face and bore out the center hole for the tool holder machine the toolholder mount it in the hole mount the toolholder in the chuck (maibe make a precision receiver for that type of taper to put in the chuck or adapt it to the taper in the lathe i bet that comes in handy in the future ) then machine the 3 surfaces to size so its perfectly square to the toolholder and do the chairdance between the divider on the mill and lathe to cut the pockets and finish the underside guess im going to look around for a source of that superthick rebar as i bet thats a lot cheaper than buying round stock in that diameter , should be ok steel

[@Seanfrtd]

And I thought my welds were pretty Talk about a work of art

[@parnuzutech]

good job 👍, greeting's from Indonesia 🇲🇨🙏

[@BalandaevVladislav]

Хорошая работа!

[@shiro-r4m]

That's quite impressive, I've got some boxes of inserts with no cutters for them unfortunately they are a funny shape I can't readily mill a pocket for. Maybe one day when I get CNC capabilities

[@nos9784]

I always wondered how hard it is to do electric discharge milling at home. There are a few videos on youtube about that. You should be able to sink just about any shape into a perfect fit hole that way... perfect for odd inserts, in theory. As far as i understand that theory.

[@shiro-r4m]

Worth considering if I have a need for it, currently I’m happy using my other more regular face mills

[@Tristoo]

amazing video, instant subscribe

[@azarellediaz4892]

It looks great and I’m wondering, are the drawings for this available to us? How can you tell if all the insets are cutting on the same plane? How did you determine the angle to cut the pockets to in order to achieve the optimal relief cutting angle when the inserts were installed? I just watched this for the second time and realized I didn’t post my other questions, why not just weld the shaft in place? It looks to me that a lot of work could be saved by making the R8 shaft a press fit and then welded from the bottom. It would eliminate the four screws, the two bars they hold and the cap and screw under the shell mill itself plus you could machine the weld flush giving it a better appearance. All this while assuring less possibilities for an unbalanced shell mill.

[@javiercalvo8031]

Exelente Herramienta

[@manfredtrosch4793]

Tolle Leistung einen Messerkopf / Planfräser selbst herzustellen. Nur rechnet man den Zeitaufwand und das Material müsste das Werkzeug fast vergoldet sein, Ein Fräser dieser Größe kostet ca. 500,00€. Ich rechne dass man einen Tag für die komplette Herstellung benötigt. Bei 8 Stunden und einem Maschinensatz je nachdem was für eine Maschine im Einsatz ist CNC oder konventionell von ca. 150 / Std. konventionell, sind das 1200,00 €. Ob sich das lohnt? Ach ja was ich noch anzufügen hätte, es gibt ein Spruch: "Ich bin der Dreher eilig, was ich nicht dreh das schmiergel und feil ich..." . Trotzdem eine klasse Leistung.

[@ryanthede4689]

This is a cool build. The only thing you should probably learn to avoid doing is climb milling. That and improper fixturing is why your endmill pulled your workpiece out of the vise. Best case scenario you end up with a mess up cutting tool or workpiece. Worst case scenario you end up with a chunk of steel embedded somewhere in your body

[@wordwyrd]

absolutely not. if the setup is rigid, you will get better results climb milling almost every time.. even with roughers.

[@ryanthede4689]

@wordwyrd does it leave a better surface finish? Yes. However, you should almost never climb mill on a manual. If that machine has any backlash, you risk damaging the machine or chucking your part out of the vise

[@ryanthede4689]

@wordwyrd I also want to add that when I was in school I literally had a chunk of carbide embedded into my arm because the idiot on the machine behind me decided it was ok to climb mill

[@wordwyrd]

@@ryanthede4689 it's definitely going to require you adjust your gibs and use correct speed and not overfeed.. generally on a manual machine I will use conventional milling until the last 2 passes, and do a semi-finish pass (no more than .040) and whatever my finish pass is climbing. By then I will have the speed dialed in pretty well even if it's by ear. That said, trade school is definitely not going to be a place to try this kind of finessing. Half the kids there are running mills at half the speed they should (or double etc.), overfeeding by scary amounts, etc. Honestly, I was perfectly happy when my instructor limited everyone to HSS only back in the day. I guess what I am saying is try it out for lighter cuts, just make sure your work is secure and you adjust the gibs (try to lock the axis you aren't cutting in too of course). I've had success with that on everything from a 1/4HP desktop to a big knee mill that was a chinese bridgeport knockoff, and the only time I ever had the slightest issue was when I didn't have the gibs close.

[@arnearne12345]

how much weld should i use sir? use all of it SIR? ALL OF IT I SAID!!!

[@MadebyEG]

Hi, thanks for video.What kind of steel did you use?

[@matiasbarraza9256]

Amazing Job!!!!!

[@willieatkins123]

All that work, for that simple part 😂.

[@joewest1972]

Great video and work! Any plans by chance 😬

[@allangles4020]

Unfortunately no everything I make is designed in my head 🤯.... but I'm happy to share any dimensions, tips and techniques for you to make your own....

[@TorteTS]

Great. When you change the chuck you oil the thread or centring? You have experience with seizing?

[@allangles4020]

On the lathe I allways oil everything I can to try and minimise ware and keep things smooth.....but tbh I use excessive amounts of (iso68) oil on all my machines.......that lathe is about 20 years older than me but still in amazing condition...

[@Karacan3655]

health to your hands❤

[@billmacfarlane4083]

Excellent work, you earned a sub from me!

[@eduardogarcia3049]

Is it just the video or does it look like the taper is not seated and it’s bottoming on the anti rotation hold down?

[@allangles4020]

Yh I achwelly thort this aswell but when you get the light behind it you can see a thin line .... just a very cloce tolerance 😁

[@byron3176]

What's he using for lubricant, used motor oil?

[@desalegnsimon6671]

Nice project. Do you think the insert holder tips need to be hardened(quench and anealed) or is this the industry standard?

[@beatrute2677]

Mad Lads: Heavy Metal Edition

[@innominatum9906]

Nice video and great project! =) I was wondering... is it because you couldnt get your hands on big enough material that you decided to weld that much? Probably would have been faster to turn down some larger stock hehe

[@allangles4020]

Yh👍the thickest steel I had at the time was only 15mm. I opted for this design because I thort it whould be the most rigid and reduce chatter/vibration. also the amount of weld I used was achwelly essential to the design of the pocket for the insert .🛠🗜 I suppose in the long run there was manny ways to make this 🤔

[@innominatum9906]

@@allangles4020 The end justifies the means, as they say! =) You got a very good tool out of it, so you def succeeded. I'm a machinist/CNC programmer in my daily job - and youre right: 5 guys given the same job will make it 5 different ways. Merry christmas

[@allangles4020]

Merry Christmas to you aswell 🎄

[@willi-fg2dh]

nice build . . . you make it shinier and shinier then you hit it with a bundle of those little ugly sticks . . . now you have to make it shiny again.

[@brandontscheschlog]

Very cool! What is the thick black substance you use for threading cutting?

[@allangles4020]

Well used engine oil 🤣

[@pitmanncb4368]

nice

[@eduardogarcia3049]

Nice! What machine are you running and controller?

[@allangles4020]

Boxford mk3 made on (10/11/79) a bridgepoet made by adcock and shipley with a 2hp motor ...and a wm18 mill that I converted to cnc and a 2hp motor with 5k spindle speed ...... all running chinease 380v single to 3phase converters

[@passenger6735]

That turned out Ok. Well done. My next tool would be a tap extension for that work on the mill and a tailstock chuck for power tapping on the lathe.😵‍💫

[@ryanclarke2161]

Where does rebar that big even come from?

[@allangles4020]

This looks like rebar but is achwelly dywidag bar (dividag bar)...essentially its a massive bolt that has a verry corse thread down its length..thease are used as tie bars to hold shuttering together as well as various other concrete structures .....

[@abdullahuk3252]

انت بارع جدا في عملك

[@MJPilote]

The inserts on commercial cutters are on small incline for the depth so that when it advances every insert is cutting some. You get that buzzing sound as it cuts, on this you get tap tap tap as the first insert cuts then the second one has no material until the end of the advance as the previous leaves the material. Then the next one again has a full cut and so on. But still nice build, I’m too lazy to make tools and buy them.

[@allangles4020]

Around Christmas 🎄 I'll be making another video going over a few bits ...that taping sound as the cutter hits the material is achwelly the top of the machine I believe its the splines that's drives the spindle as the noise can be reduced by holding the draw bar .........this will be fixed

[@wordwyrd]

you should think about at least starting the taps with the quill. if you don't like power tapping, at least put it in high gear and manually start a fre threads, ir use a spring loaded tap follower?

[@n.b.p.davenport7066]

Can you harden rebar?

[@allangles4020]

Not as far as I'm aware think you need atleast 0.5% carbon to harden it and rebar is at most 0.3% rebar is kinda abit of a mix of steels ...But on the other hand some scorces say it can be hardend however I think that is referring to specific grades of rebar I haven't myself tried to harden the rebar I have on hand but it can be cace harden unfortunately I don't have the facilities to do so ....

[@jameslee4946]

For a fly cutter, it is over design. But you got the talent.........

[@outsider7658]

VERY NICE PIECE! I would like to make one, for my self, is it possible to have a drawing from You? I would be very thankful, if so. This would be a crown juvel, in my "toolbox". Just now, I am making a major repair, to my milling machine. Just bought it and, it was mede to "sales condition", it lacked a locking screw for table feed, vertically. So, short: I tried it back home, and fed it down on automatic feed, till I thought, it would stop. Not so, it went straight to total stop, in the end of the feeding screw, and was stuck. This cost me 1500 euro`s+ some hundreds, for two gears! And a lot of work time. So, I am in the lack of a tool like this. If You are able to helt me, I would be very thankful. From a Finn in Diaspora.

[@allangles4020]

I'm more than happy to help ..I have no drawings or plans I can send you as everything I make is designed in my head.... but I'm happy to pour over all the key details and sizes inordder for you to make your own............

[@andrzejporeda7281]

Bardzo świetna jest zrobiona ta robota ale pytanie do czego to nabyć i służyć pozdrawiam twórcę tego filmiku 👍👍

[@anjoschwarz5800]

Form- oder Kraftschlüssig? As 💰🥱

[@Tristoo]

bro 😂 why did you lay that much weld on there?? that thing so overpowered it could probably withstand a direct nuke hit. hell the filler rod and the gas alone probably cost you more than all the rest of the materials combined

[@allangles4020]

🤣

[@ChixWoman]

Great work. Like the format of your video as well. Just enough talking. Glad you measure in mm and not 🍌🍌. Cheers from South Africa.

[@allangles4020]

🤣

[@JustOneFeather]

There was no sense to weld that much. Just one 5-7 mm bead on circle was be enough, moreover, on 230Amps there wasn't need to add rosd at all.

[@allangles4020]

Yh I guess there was manny ways to make this🤔 .I thort this way whould produce the most sturdy cutter and whould reduce chatter and vibration the most..... but more importantly all the excess weld was achwelly essential to the pocket design for the insert 🗜

[@fourk6096]

Очень сложная конструкция можно быто сделать все на много проще

[@christiandasse2005]

Failitacoin pour ta pièce 😅 bravo

[@lumotroph]

Great video! More talking please. Subscirbed

[@mikemraz8569]

Nothing looks worse than a deep scratch in a high polish 😩

[@allangles4020]

🤫😂😂

[@romanrekunov2268]

Шедеврально

[@Molb0rg]

Disco cnc, lol

[@forrestaddy9644]

Why do you take such tiny cuts? You have ample grip on the work. Is your lathe limited in power? It seems in cood condition and your tooling is modern and sturdy. I suggest you practice taking capacity cuts on surplus material, increasing depth of cut and feed rate until you hear the motor labor and actually begin to stall. Efficient stock removal has several benefits. Your work goes quicker, you save on tooling inserrts, you make chips instead of birds nests making clean-up simpler, and your finished improve.

[@mooreevair]

Id love to hear his answer, but I'd say one thing I've learned is if you have the time , then taking your time to make something lends better results.

[@allangles4020]

The lathe is a Boxford and Boxford lathes especially the mk3 wer perfect for teaching students on and wer adopted by manny schools. but due to new regulation most of them wer never used ....so the lathe is In amazing condition and from a school in Glasgow (hence the color coded chuck) ...but the lathes that wer fitted into schools only had a 0.75hp motor where's the home hobbie ons had a 1hp motor ....when turning down I take a 0.5mm pass or 1mm off the diameter ....as for the mill I'm still getting use to carbide but recently found out I can cut through 10mm steel in a single pass !

[@forrestaddy9644]

@@mooreevair I can't agree. A comfortable pace while working efficiently is one thing but endlessly sneaking up to desired part size and geometry stultifies skill development. I've had many apprentices in my clutches over the years and the most successful of these were self competitive to a degree. They pushed to define limits and then backed off to the "sweet spot" where productivity, safety, risk, job satisfaction, etc comfortably co-existed.

[@markshort9098]

Fixing the shank to the face mill is ridiculously over complicated and messy, a set screw in from the bottom right through the threads would hold it from unscrewing no problem and it would have been way neater, easier and quicker than that mess

[@allangles4020]

I thort you ment somthing else at the start but the idea of it being the way it was is so that I can use the same r8 spindle for diffrent size cutters and tools that I plan to make 🔧

[@romakapar7937]

Ок

[@АртурАлферов-ь7б]

Кагда коту делать нечего он яйца лижет эти фрезы продаются заводские!

[@Nnnnnnnnnkj]

Разве виноваты мы что родились в России.....

[@Mehanikus]

842

[@gencxu6422]

制作技术一般般

[@ИринаШаршова-ы1ч]

Жю

[@MG-nz6bx]

can no one else in these comments hear that it's only cutting with one or two inserts? i mean nice try and all, buuuttttt....... meh

[@allangles4020]

I believe that whould be due to the width of the material........the machine is also very noisey on deep cuts due to rattly spindle splins........ this will be fixed

[@Sydney268]

Yeah mate, your top quality Chinese one cuts with at least 3 inserts doesn't it, haha - knob

[@clayschwartz3538]

could have bought a face mill for $200 waste of time

[@quick5387]

part of the fun is making the tools yourself

[@don_karleone53]

21:50 как называется это прибор, для определения геометрии или плоскостей ???

[@therealme613]

What is that old motor oil your using for cutting?

[@allangles4020]

Indeed it is

[@Sydney268]

@@allangles4020 yeah that's what I thought too, you wanna burn that shit and keep warm - not make yourself look like a chimney sweep!

[@don_karleone53]

Все понял и как бы оценил,👍🏻☝🏻 но не могу понять зачем столько лишних манипуляций?🤷🏻‍♂️☝🏻

[@jp-ll7ps]

아무리 잘해도 안전이 우선이다 장갑을 좀 끼고 일을하거라 보기가 많이 불편하구나 니는 손이 10개냐 거반하게 하지말고 나는 장갑을 끼면 일을 하니못하니 하는말은 거반스러운 행동이다 장갑살 돈이 없냐 좀 보내줘랴

[@mrjibrhanjamalkhan2144]

Nice