Metalworking (rec.crafts.metalworking) Discuss various aspects of working with metal, such as machining, welding, metal joining, screwing, casting, hardening/tempering, blacksmithing/forging, spinning and hammer work, sheet metal work.

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Default Manual metal scoring project

I'm about to begin a simple project for cutting thin stock into strips.

I need to machine the following:

A) Disks that will be the diameter of slitting saws but thicker and without teeth but instead have relatively sharp edges for scoring.

B) Spacers about half the size of the above mentioned disks. (I'll grind them to the necessary thickness).

C) An "Arbor", actually a one foot rod with a long flat that the above disks, separated by the spacers, will fit on.

D) A three part table that will be comprised of two ends sitting at opposite ends and on top of the bed.(There will be an "cover" to hold the stock down to the bed).

E) Racks and gears for the bed ends and rod respectively.

The goal of this contraption is to allow me to score the metal stock so I can break off the strips. (It would be like using a rolling pin).\

I'm finishing up the exact dimensions and I'd appreciate some advice on the specific metals I should use for the parts.

Thanks.

Darren Harris
Staten Island, New York.
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Default Manual metal scoring project

wrote in message
...
I'm about to begin a simple project for cutting thin stock into
strips.

I need to machine the following:

A) Disks that will be the diameter of slitting saws but thicker and
without teeth but instead have relatively sharp edges for scoring.

B) Spacers about half the size of the above mentioned disks. (I'll
grind them to the necessary thickness).

C) An "Arbor", actually a one foot rod with a long flat that the
above disks, separated by the spacers, will fit on.

D) A three part table that will be comprised of two ends sitting at
opposite ends and on top of the bed.(There will be an "cover" to
hold the stock down to the bed).

E) Racks and gears for the bed ends and rod respectively.

The goal of this contraption is to allow me to score the metal stock
so I can break off the strips. (It would be like using a rolling
pin).\

I'm finishing up the exact dimensions and I'd appreciate some advice
on the specific metals I should use for the parts.

Thanks.

Darren Harris
Staten Island, New York.


Here's the mechanism. You supply the cutting wheels:
http://www.amazon.com/Rolling-Mill-J.../dp/B000RB5CXC



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Default Manual metal scoring project

wrote in message
...

I'm about to begin a simple project for cutting thin stock into strips.

I need to machine the following:

A) Disks that will be the diameter of slitting saws but thicker and without
teeth but instead have relatively sharp edges for scoring.

B) Spacers about half the size of the above mentioned disks. (I'll grind
them to the necessary thickness).

C) An "Arbor", actually a one foot rod with a long flat that the above
disks, separated by the spacers, will fit on.

D) A three part table that will be comprised of two ends sitting at opposite
ends and on top of the bed.(There will be an "cover" to hold the stock down
to the bed).

E) Racks and gears for the bed ends and rod respectively.

The goal of this contraption is to allow me to score the metal stock so I
can break off the strips. (It would be like using a rolling pin).\

I'm finishing up the exact dimensions and I'd appreciate some advice on the
specific metals I should use for the parts.

Thanks.

Darren Harris
Staten Island, New York.
================================================== ======================================

If you want to make everything from scratch, ok, but I think that the
cutting wheels are going to be the heart of your process so I would go
shopping for pipe cutters and find one with a cutting wheel the right size
for your mechanism, then buy replacement wheels. That way someone else has
already optimized the material and shape for you. Scoring and breaking is
going to leave you with rough edges and probably slightly bent parts, so I
think you should cut all the way through if possible.

-----
Regards,
Carl Ijames


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Default Manual metal scoring project

On Friday, May 27, 2016 at 5:59:32 PM UTC-4, wrote:
I'm about to begin a simple project for cutting thin stock into strips.


Thanks.

Darren Harris
Staten Island, New York.


It is always helpful if you explain what you are trying to accomplish. You say thin stock, but how about what the stock is and how thick is it. If it is 1/16 to 1/8 aluminum, I would use a table saw. If copper I might still use a table saw, but with some thin plywood under the stock.

And how many strips do you want or need?

I am not sure how well it would work on wide stock to many thin strips. The disks are going to try to make the sheet wider. Not much of a problem for 4 or 5 strips, but 20 might be a problem if the strips need to be straight..

You might consider scoring on both sides of the stock, but only half as deep.. You might also consider having the spacing of the scoring disk twice is wide as you want. You would then run the stock thru once, and then flip the material over and score so you have it scored to the width you want. It would take less effort than trying to do all the scoring with one pass.

Dan





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Default Manual metal scoring project

wrote in message
...
On Friday, May 27, 2016 at 5:59:32 PM UTC-4,
wrote:
I'm about to begin a simple project for cutting thin stock into
strips.


Thanks.

Darren Harris
Staten Island, New York.


It is always helpful if you explain what you are trying to accomplish.
You say thin stock, but how about what the stock is and how thick is
it. If it is 1/16 to 1/8 aluminum, I would use a table saw. If copper
I might still use a table saw, but with some thin plywood under the
stock.

And how many strips do you want or need?

I am not sure how well it would work on wide stock to many thin
strips. The disks are going to try to make the sheet wider. Not much
of a problem for 4 or 5 strips, but 20 might be a problem if the
strips need to be straight.

You might consider scoring on both sides of the stock, but only half
as deep.. You might also consider having the spacing of the scoring
disk twice is wide as you want. You would then run the stock thru
once, and then flip the material over and score so you have it scored
to the width you want. It would take less effort than trying to do
all the scoring with one pass.

Dan
=============================

https://en.wikipedia.org/wiki/Slitting_mill



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Default Manual metal scoring project


wrote in message
...
I'm about to begin a simple project for cutting thin stock into strips.

I need to machine the following:

A) Disks that will be the diameter of slitting saws but thicker and
without teeth but instead have relatively sharp edges for scoring.

B) Spacers about half the size of the above mentioned disks. (I'll grind
them to the necessary thickness).

C) An "Arbor", actually a one foot rod with a long flat that the above
disks, separated by the spacers, will fit on.

D) A three part table that will be comprised of two ends sitting at
opposite ends and on top of the bed.(There will be an "cover" to hold the
stock down to the bed).

E) Racks and gears for the bed ends and rod respectively.

The goal of this contraption is to allow me to score the metal stock so I
can break off the strips. (It would be like using a rolling pin).\

I'm finishing up the exact dimensions and I'd appreciate some advice on
the specific metals I should use for the parts.

Thanks.

Darren Harris
Staten Island, New York.


Are you still trying to cut phosphor bronze contact springs?

It is hard to tell, but from your description, it sounds like you want to
impress score lines rather than cut them.
If this is the case, then you will run afoul of what I like to call the
"conservation of volume."
When you impress a line into metal, the metal is displaced to the sides.
Your center strip will run true but the strips on either side will be wonky
as they move outward because of this displacement.

Paul K. Dickman


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Default Manual metal scoring project

How thick is your stock? It should be noted that a Pexto sheer,
either store bought or home made (think paper cutter with hinged on
one end blade) may be "good enough" and considerably faster for
production.


I've already tried other ways of doing this including looking into ideas given to me on this forum, and it has now come down to me designing a little jig in order to accurately and more efficiently cut these strips. So I decided to start this project.

Here's the mechanism. You supply the cutting wheels:
http://www.amazon.com/Rolling-Mill-J.../dp/B000RB5CXC


I'm not familiar with a jeweler's grade rolling mill and don't know if it is adequate of would fit standard stock sizes.

If you want to make everything from scratch, ok, but I think that the
cutting wheels are going to be the heart of your process so I would go
shopping for pipe cutters and find one with a cutting wheel the right size
for your mechanism, then buy replacement wheels. That way someone else has
already optimized the material and shape for you. Scoring and breaking is
going to leave you with rough edges and probably slightly bent parts, so I
think you should cut all the way through if possible.


Thanks. I'll look into cutting wheels for pipe cutters to see if I can fit these into my design. I don't know if cutting all the way through is plausible, but slightly bent or even rough edges is not a problem. The dimensions only have to be close. (And I can file the edges if needed).

It is always helpful if you explain what you are trying to accomplish. You say thin stock, but how about what the stock is and how thick is it. If it is 1/16 to 1/8 aluminum, I would use a table saw. If copper I might still use a table saw, but with some thin plywood under the stock.

And how many strips do you want or need?

I am not sure how well it would work on wide stock to many thin strips. The disks are going to try to make the sheet wider. Not much of a problem for 4 or 5 strips, but 20 might be a problem if the strips need to be straight.

You might consider scoring on both sides of the stock, but only half as deep.. You might also consider having the spacing of the scoring disk twice is wide as you want. You would then run the stock thru once, and then flip the material over and score so you have it scored to the width you want. It would take less effort than trying to do all the scoring with one pass..


My attempts have been in line with scoring because scoring produces the minimum amount of waste. The stock is as thick as .042" thick and made of soft metal/alloys like copper/bronze. Of course the strips have to be straight and accurate to the eye. Attempting to score on both sides would present accuracy problems. (These strips are less than 1/8" wide).
Yes, I have several projects which involve phosphor-bronze contact springs.


Are you still trying to cut phosphor bronze contact springs?

It is hard to tell, but from your description, it sounds like you want to
impress score lines rather than cut them.
If this is the case, then you will run afoul of what I like to call the
"conservation of volume."
When you impress a line into metal, the metal is displaced to the sides.
Your center strip will run true but the strips on either side will be wonky
as they move outward because of this displacement.


I may just design this to cut one at a time, but as far as accuracy they will be close enough.

Anyway, Im thinking that the table parts should be mild steel. There will be a slot in the table ends that will seat the main rod. (Ill use shims to adjust the table height relative to the table ends).

Darren Harris
Staten Island, New York.
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Default Manual metal scoring project


I may just design this to cut one at a time, but as far as accuracy
they will be close enough.


Darren Harris
Staten Island, New York.


Be aware that any error in width will cause a cumulative error in accuracy
.. Strips will come out curved , sometimes in odd ways . Saw this in slitting
operations on plastic laminate (formica) used for edge banding and
countertop edging . A long straight guide on the infeed helps a lot .

--
Snag


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Default Manual metal scoring project

On Thursday, June 9, 2016 at 10:39:52 PM UTC-4, Terry Coombs wrote:

I may just design this to cut one at a time, but as far as accuracy
they will be close enough.


Darren Harris
Staten Island, New York.


Be aware that any error in width will cause a cumulative error in accuracy
. Strips will come out curved , sometimes in odd ways . Saw this in slitting
operations on plastic laminate (formica) used for edge banding and
countertop edging . A long straight guide on the infeed helps a lot .

--
Snag


They will not build on one another so there is no cumulative error to worry about.

I'm looking at pipe cutter discs, but I see no sizes, so I'll have to swing by the hardware/BORG stores to get a better idea. I assume I would have no problem sharpening the edges.

Darren Harris
Staten Island, New York.


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Default Manual metal scoring project


wrote in message
...
On Thursday, June 9, 2016 at 10:39:52 PM UTC-4, Terry Coombs wrote:

I may just design this to cut one at a time, but as far as
accuracy
they will be close enough.


Darren Harris
Staten Island, New York.


Be aware that any error in width will cause a cumulative error in
accuracy
. Strips will come out curved , sometimes in odd ways . Saw this in
slitting
operations on plastic laminate (formica) used for edge banding and
countertop edging . A long straight guide on the infeed helps a lot
.

--
Snag


They will not build on one another so there is no cumulative error
to worry about.

I'm looking at pipe cutter discs, but I see no sizes, so I'll have
to swing by the hardware/BORG stores to get a better idea. I assume
I would have no problem sharpening the edges.

Darren Harris
Staten Island, New York.


If you have a lathe and tool post grinder, a tool and cutter grinder
or a surface grinder with tool grinding attachments they should be no
problem. Otherwise keeping them accurately straight and round while
grinding freehand could be tricky.

--jsw


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Default Manual metal scoring project

On Sun, 12 Jun 2016 21:35:20 -0400, "Jim Wilkins"
wrote:


wrote in message
...
On Thursday, June 9, 2016 at 10:39:52 PM UTC-4, Terry Coombs wrote:

I may just design this to cut one at a time, but as far as
accuracy
they will be close enough.


Darren Harris
Staten Island, New York.

Be aware that any error in width will cause a cumulative error in
accuracy
. Strips will come out curved , sometimes in odd ways . Saw this in
slitting
operations on plastic laminate (formica) used for edge banding and
countertop edging . A long straight guide on the infeed helps a lot
.

--
Snag


They will not build on one another so there is no cumulative error
to worry about.

I'm looking at pipe cutter discs, but I see no sizes, so I'll have
to swing by the hardware/BORG stores to get a better idea. I assume
I would have no problem sharpening the edges.

Darren Harris
Staten Island, New York.


If you have a lathe and tool post grinder, a tool and cutter grinder
or a surface grinder with tool grinding attachments they should be no
problem. Otherwise keeping them accurately straight and round while
grinding freehand could be tricky.

--jsw


I'd look at circular knives before going to the trouble of regrinding
pipe cutter wheels. Knives for common converting machines are cheap,
for example:
https://www.carolinaknife.com/catalo..._score_slitter

A search for "circular knives" will turn up many sources.

I used those Dusenbery knives on a high speed cutter I built for a
styrene tubing extrusion line. I think the wheels I purchased were D2
instead of 52100. But that equipment was making something like 50 cuts
per minute, 3 shifts.

--
Ned Simmons
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Default Manual metal scoring project

On Monday, June 13, 2016 at 9:00:02 AM UTC-4, Ned Simmons wrote:
On Sun, 12 Jun 2016 21:35:20 -0400, "Jim Wilkins"
wrote:


wrote in message
...
On Thursday, June 9, 2016 at 10:39:52 PM UTC-4, Terry Coombs wrote:

I may just design this to cut one at a time, but as far as
accuracy
they will be close enough.


Darren Harris
Staten Island, New York.

Be aware that any error in width will cause a cumulative error in
accuracy
. Strips will come out curved , sometimes in odd ways . Saw this in
slitting
operations on plastic laminate (formica) used for edge banding and
countertop edging . A long straight guide on the infeed helps a lot
.

--
Snag

They will not build on one another so there is no cumulative error
to worry about.

I'm looking at pipe cutter discs, but I see no sizes, so I'll have
to swing by the hardware/BORG stores to get a better idea. I assume
I would have no problem sharpening the edges.

Darren Harris
Staten Island, New York.


If you have a lathe and tool post grinder, a tool and cutter grinder
or a surface grinder with tool grinding attachments they should be no
problem. Otherwise keeping them accurately straight and round while
grinding freehand could be tricky.

--jsw


I'd look at circular knives before going to the trouble of regrinding
pipe cutter wheels. Knives for common converting machines are cheap,
for example:
https://www.carolinaknife.com/catalo..._score_slitter

A search for "circular knives" will turn up many sources.

I used those Dusenbery knives on a high speed cutter I built for a
styrene tubing extrusion line. I think the wheels I purchased were D2
instead of 52100. But that equipment was making something like 50 cuts
per minute, 3 shifts.

--
Ned Simmons


Thanks a lot.

This seems to be exactly what I need.

I just have to design a cutting jig around them.

Darren Harris
Staten Island, New York.
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