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What size radius (if any) can you put up with in the corners of the hex?
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I need between 10-30 of these parts turned from solid brass round stock. Dimension are in mm. The centered through hole is 2.025mm to slip-fit on a 2mm motor shaft. The hex-shaped cutout is 5mm from flat to flat, and is 8mm deep. If interested contact me at dwells77 at yahoo.com. CNC preferred for consistency
What size radius (if any) can you put up with in the corners of the hex?
Last edited by abcmojave; 09-28-2011 at 04:24 PM. Reason: stupid wording
Thanks for the quick reply. The radius has to be as small as possible. I could probably get away with maybe .25mm (.0098"). However, looking at the orginals, it looks like the manufacturer center drilled a 5mm hole maybe 9 or 10mm deep, and then used a 5mm hex rotary broach to form the 8mm deep hex cutout.
Is it possible for you to do that?
Donnell
Originally Posted by abcmojave
I do not have access to a rotary broach. I sure would like an excuse to get one though. Don't think 30 parts will do it.....
If you don't mind me asking, how were you going to cut the hex opening? I know that the turning and drilling would be by conventional means, but forming the hex opening intrigues me. If I had a lathe, I try them myself, but...
Donnell
PM sent
Depending on the size (this one is fairly small) you can make a steel hex or use a sharpened Allen wrench on a hydraulic press to make hex broaches.....not as nice as a rotary broach though.
thanks
Michael T.
"If you don't stand for something, chances are, you'll fall for anything!"
Broaching, through and blind is a pretty common operation. Examples of through broaching are pulleys, sprockets, and gears that fit on a shaft and are held in alignment with a key. The best example of blind broaching is almost any socket head cap screw. Look down inside the hex of almost any socket head cap screw and see the metal that looks like chips stuck in the bottom of a hole.
Last edited by txcncman; 09-30-2011 at 11:08 AM.
http://www.kirkcon.com/
Small diameter end mill cnc operation after drilling to 5 mm. Pretty standard program. End up with radius in corners though... and pretty slow.
If you still have the need for the parts please pm or e-mail me. I have several lathes. With such a small hes in brass we will broach in the spindle before parting off.
Thanks
HP
Success is the ability to go from one failure to another with no loss of enthusiasm-Sir Winston Churchill
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