Re: [CAD_CAM_EDM_DRO] Twist Lock Caps and Right Angle Machining

Hi Tom

A cnc lathe would be able to cut that groove in one pass in delrin with a
properly configured single point tool.

Bob

----- Original Message -----
From: "Tom Hubin" <thubin@...>
To: <CAD_CAM_EDM_DRO@yahoogroups.com>
Sent: Sunday, September 25, 2005 2:35 PM
Subject: [CAD_CAM_EDM_DRO] Twist Lock Caps and Right Angle Machining


> Hello,
>
> I want to make twist lock endcaps for a 1.88 inch OD, 8 inch long,
> silver annodized aluminum tube. The endcaps might be brass or delrin,
> just for an attractive contrast with the tube.
>
> The kaleidoscope optics stacked inside the tube are spring loaded so the
> natural length is a about 1/8 inch longer than the tube length and the
> compressed length fits comfortably within the tube.
>
> I would like to carve a small track in the wall of a 1.9 inch diameter,
> 3/8 inch deep, pocket. The track is a little wider than a dowel pin that
> travels in the track. Dowel pin diameter is not important but in the
> range of 1/16 inch to 1/8 inch diamter would be best.
>
> A right angle drill like a dentist uses comes to mind.
>
> I have in mind 2 or more dowel pins protruding outward from the ends of
> a long tube. Drilling and press fitting would be straight forward.
>
> The endcaps would twist lock onto the tube ends like a BNC connector or
> a child-proof pill bottle. I prefer that the track not effect the
> outside appearance of the endcap so I really don't want to cut from the
> outside if I can avoid that.
>
> I am also looking at things that cut sideways like threadmills, keyway,
> and Tslot cutters. I have done threading with a threadmill but this is a
> very skinny track so not my first choice. A keyway or Tslot cutter might
> work if I can find the right one.
>
> I could also mill the track on the outside of the tube and use dowel
> pins on the inside of the endcaps. But I would still need a right angle
> drill to make the dowel pin holes from the inside of the pocket.
> Drilling through and press fitting from the outside would certainly work
> but, as above, I prefer that the pins not show.
>
> Or maybe I can jazz up the exposed pins so that they are attractive.
> Perhaps screw them in then cover with fancy cap nuts.
>
> Anyway, machining from the outside presents no challenge so I would like
> to explore methods of drilling or milling from inside a pocket.
>
> I have a Sherline 4400 manual lathe and a Sherline 5410 (metric 5400)
> CNC mill and a short 1/2 inch drill press. I have access to more
> complete shops if need be.
>
> Comments and suggestions?
>
> Tom Hubin
> thubin@...
>
>
>
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