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Hemingway Kits Knurling Tool

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  • Mr Bowcat
    • Dec 2016
    • 4613
    • Bob
    • London

    #1

    Hemingway Kits Knurling Tool

    Morning all,

    So I've had my mill for a few months now, the lathe I've had around 4 years. Since I've had the mill I've been busy learning how to use it and decided it was time to actually build something useful. Hemingway supply kits to model engineers, including engines and locomotives, but also sell a number of tooling projects. I already have a purchased knurling tool, but it's not very good, and this clamping style that I'm building should work a lot better.

    For anyone who doesn't know knurling is the imprinted pattern often found on tool handles, like this:



    On to the kit, the box art:



    The instructions:



    The sprues: ?



    I spent some time on the instructions, this is the first time I've used proper engineering drawings and it took some time to decipher them, particularly as they are in Imperial and I work in Metric.

    The first step is the main body, which are the side plates and a spacer block. All parts were machined to dimension, and a number of holes drilled, and in some cases tapped. Two further holes were drilled and reamed to precise dimension which will later take the arm pivots. The rear corners were also knocked off, this will be the operator side so lessens the chance of injury.




    The final step to this part is the tool block, this is simply an extension to allow the tool to be mounted to the tool post.




    And that little lot took around 6 hours! What I have learned from machining is that most of the time is spent fixturing and measuring, and a small amount actually drilling or cutting.

    I am very pleased with the progress however, everything fit perfectly, and is square and true and all the holes lined up perfectly, so I'm doing something right.

    Next up are the arms which are far more complex pieces with a number of features to be machined.


    Si vis pacem, para bellum.
  • Steven000
    • Aug 2018
    • 2830
    • Steven
    • Belgium

    #2
    Thanks for sharing the project, I really love these kind of projects and machining and all that, I'm more of a woodworker myself, but if I had the budget and know-how I would get metal machines as well. Have fun, cheers

    Comment

    • Mr Bowcat
      • Dec 2016
      • 4613
      • Bob
      • London

      #3
      Thanks Steven,

      Know how has just been picked up from books, forums and You Tube (and plenty of practice), but if I could go back 30 years I think an apprenticeship and career in engineering would have been fun.

      The machines aren't cheap, mine are bench top "hobby" models, but still a bit spendy. Saying that, I actually bought the mill in April because it had 25% off (around £500 saving) but at the time didn't actually have space for it. it wasn't until around July that I had cleared space in my workshop (which involved having a concrete slab poured and building a new, much larger shed for all the stuff that was in the workshop) that I could use it. ?
      Si vis pacem, para bellum.

      Comment

      • Jim R
        SMF Supporters
        • Apr 2018
        • 15774
        • Jim
        • Shropshire

        #4
        Very interesting. Looks as if you've certainly got the hang of this engineering. I look forward to future projects.

        Comment

        • Mr Bowcat
          • Dec 2016
          • 4613
          • Bob
          • London

          #5
          Cheers Jim.

          It's early days but I'm learning all the time, and as Adam Savage says, chasing zero's.
          Si vis pacem, para bellum.

          Comment

          • Ian M
            Administrator
            • Dec 2008
            • 18271
            • Ian
            • Falster, Denmark

            #6
            Cool. Not a touch envious. I would love a lathe and a mill.
            Maybe one day a Proxxon thing will land my way.
            Group builds

            Bismarck

            Comment

            • Mr Bowcat
              • Dec 2016
              • 4613
              • Bob
              • London

              #7
              Cheers Ian.

              Si vis pacem, para bellum.

              Comment

              • Ernie
                SMF Supporters
                • Apr 2018
                • 144
                • Ernie
                • New Hampshire

                #8
                Very cool project! I have been a machinist for basically my whole working life.

                Comment

                • Mr Bowcat
                  • Dec 2016
                  • 4613
                  • Bob
                  • London

                  #9
                  Thanks Ernie.

                  I may be bending your ear for advice.
                  Si vis pacem, para bellum.

                  Comment

                  • Mr Bowcat
                    • Dec 2016
                    • 4613
                    • Bob
                    • London

                    #10
                    Morning all.

                    I've been out in the workshop the last few evenings working on the arms. The first steps were just to machine to dimension and drop a couple of holes in each arm, one for the pivot to the main body, and the other for the knurling wheels.

                    While everything was still square I decided to tackle a feature that I wasn't looking forward to, a shallow scallop in each arm.




                    This would be easy to do on the milling machine with either a rotary table or boring head, unfortunately I have neither. I had a good think about it and decided the only way I could do this was on the lathe with a boring bar, the issue being how to fixture the parts. I think I came up with an elegant solution.



                    I milled some 10mm plate and used the existing holes in the arms to attach them to the plate. I also added a centre drill hole in the middle to allow the part to be dialled in precisely.

                    Centre drills form a 60 degree cone for the purpose of adding a live- or dead- centre for support. For my purposes by adding an extension between my live centre and the work piece in the chuck I could dial in on the extension to get everything centred. Better still, I managed to get it to within 0.005mm (5/1000 of a millimetre), or about 2 ten thousandths of an inch.




                    A quick scratch pass with the boring bar showed I was dead nuts on, now all I have to do is remove the material.
                    Si vis pacem, para bellum.

                    Comment

                    • Ian M
                      Administrator
                      • Dec 2008
                      • 18271
                      • Ian
                      • Falster, Denmark

                      #11
                      So do you say "Aaaannnnnd Yahtzee!" when you part bits off. IYKYK
                      Group builds

                      Bismarck

                      Comment


                      • Mr Bowcat
                        Mr Bowcat commented
                        Editing a comment
                        No, I think Quinn has that copyrighted.

                        Seriously though, parting off is my least favourite activity, on a small lathe it's a fine balance between feeding in fast enough, but not so fast that you jam the parting blade and stall the machine.
                    • Steven000
                      • Aug 2018
                      • 2830
                      • Steven
                      • Belgium

                      #12
                      Looking at those dimensions and angles, that's quite a big challenge to set up ?‍? Hope it turned out well

                      Comment

                      • Jim R
                        SMF Supporters
                        • Apr 2018
                        • 15774
                        • Jim
                        • Shropshire

                        #13
                        A very clever solution. Hope it works. You're learning all the time.
                        ​​​

                        Comment

                        • Mr Bowcat
                          • Dec 2016
                          • 4613
                          • Bob
                          • London

                          #14
                          Cheers gents.

                          Well the boring went quite well, surface finish could be better but should clean up with some emery. To be honest it's not too critical, there will be some brass parts riding in the scallops but they won't be high friction.




                          With that done and the edges tidied up with a small file the parts were taken to final dimension and a slot milled through each one. This was a little tricky as the slots are angled out at 10 degrees each end.




                          Last couple of operations for the arms are the slots for the knurling wheels, but before that the radii need adding to each end of the arms. Again, this would be an easy job with a rotary table, but I don't have one. I could just grind in the radii with a belt sander, the actual curves are not too critical, but I wanted to try and do better. With this in mind I turned to an old school technique and made some filing buttons.

                          Essentially these are turned from steel to the required diameter and a hole drilled through the middle the same size as the holes in the part. These are then bolted through on either side of the part and act as a guide for filing the curve. The clever bit is that they are made from O1 tool steel which is heat treatable, so after heating to around 800C they are quenched in oil and come out glass hard, meaning the file will skate over them.




                          I will remove most of the material on the mill first, then just file down to the buttons, hopefully leaving a perfect curve.
                          Si vis pacem, para bellum.

                          Comment

                          • Steven000
                            • Aug 2018
                            • 2830
                            • Steven
                            • Belgium

                            #15
                            That looks the part ? nice work and good thinking with the heat treatable parts, cheers

                            Comment

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