Originally Posted by jorgepease  .....Actually there will be a sphere on the other end of the shank as well......The only way I see it would work would be to cut one half the sphere with one (leading)edge of the tool and then have the program do a finish pass in the other direction using the other edge of the tool....As far as the chatter, I figured that might be an issue. |
We make a part that is similar but bigger. With a 1/2" ball and 1/8" stem you may have serious problems with chatter. Also for the ball on the other end you will need a second chucking. I have done a sketch showing the sequence I would use. The tools are Iscar brand with a .008" nose radius, you need a left and right hand because it is not possible to use a single tool for the full sphere. The first three steps in the sequence are from bar stock. To minimize chatter the first ball is finished before the stem is turned.
Doing these in Delrin will be a real challenge because it is so flexible; brass would be my choice but aluminum is probably okay. What accuracy are you aiming for? Because the spheres have to be done using two tools and a second chucking for the second ball it might be tricky getting better than +/-0.0005".