Upd: Sherline mill, can get to a Bridgeport.Upd2: Rotary table and regular mill?
I would like to create an array of 6 mm dia round posts, 6 mm tall, on a 1 x 1" square array, Aluminum 6061 or better yet, 7075. The diameter of posts needs to be to within 0.001" tolerance, as they would slide-fit onto a reciprocal array of 6 mm holes. Is there a specialty endmill with blades facing inwards, to create the posts in one cut, and 'fill in' the unmilled surfce with a regular mill? Googling did not produce a result. Or is CNC the only method to achieve this?
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Upd: Sherline mill, can get to a Bridgeport.Upd2: Rotary table and regular mill?
Hi I don’t know of any tool that would do that, I may be wrong, but not to 0.001”
Read my blog for help and advice for beginners on CNC routers
http://the-cnc.blogspot.co.uk/p/home.html?m=1
There is no tool that I know of that would do what you want.
I think I would drill/ream holes and press in pins unless there is some reason this can't be done. Do the top & bottom pieces together that way the holes would be aligned with no error. Trying to align the pins with the holes would be very difficult without a CNC machine, not impossible, but difficult.
Jim Dawson
Sandy, Oregon, USA
Mill between the posts, and then use a boring head to make the posts round. I have used a boring head with a standard brazed carbide boring bar to do single outside diameters. Don't know why it wouldn't work for multiple. Just need a tool that will fit between the other posts. When using a standard carbide boring bar to do an OD, you run the spindle backward.
109jb is spot on. Rough out with an end mill, finish with the boring bar.
Why would you bother with a boring head, the average cnc mill can hold .0005,or better so just milling with an endmill would be more than enough, he asked for a tolerance of .001 which is easy to achieve, the photo I posted, the pins where only
.080" x .500" long, and they milled to better than .001 tolerance
Mactec54
From Post #1:
From Post #2:Is there a specialty endmill with blades facing inwards, to create the posts in one cut, and 'fill in' the unmilled surfce with a regular mill? Googling did not produce a result. Or is CNC the only method to achieve this?
No mention of the sherline or bridgeport being CNCUpd: Sherline mill, can get to a Bridgeport.Upd2: Rotary table and regular mill?
Many thanks, 109jb , a boring head is exactly what I need.
Sorry, folks, that I haven't mentioned that my machine (Sherline) is manual. No CNC.
I have, indeed, considered pins at first, but posts would have holes drilled and tapped in them. I.e. the posts serve to align and to hold the mating part that would have matching slide-fit holes. Pins would get pulled out otherwise.
Last edited by runcyclexcski; 12-30-2017 at 07:35 AM. Reason: more precision/accuracy
Mactec54