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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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#1
Posted to rec.crafts.metalworking
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Cutting Disks
I have two sizes of disk to cut, from two or three different materials:
Disk 1: 3/4" diameter, from 6mm thick "Depron" foam. This is a close-cell polystyrene foam (I think it's extruded). Disk 2: 0.125" to 0.150" diameter, from 1/64" plywood or 0.015" styrene (I have the plywood, the styrene matches the color and chemistry of the foam). Both need to have a .025" diameter hole drilled, but that's not the big problem. Currently I'm cutting these by hand, but would like to automate the process. Ideally I'd like tools that a 12 year old kid could wield to good effect, so the less skill needed by the operator the better. A close second place is a tool that needs some care and manual dexterity to use, but it still quick and robust. So -- how to do? Die cut these "Paper punch" style, with a top & bottom die? Make a single-sided die and either press it, or whack it with a hammer like a leather punch? Hole saws? Also, any suggestions on drilling the holes in the small disks? These are fiendishly hard to hold while cutting a hole. Currently the easiest way seems to be to drill holes in the parent stock, then cut the disks around them. Drilling holes in the large disks is easy -- in fact, all I've been doing there is just poking the holes with the right size of wire. -- Tim Wescott Wescott Design Services http://www.wescottdesign.com Do you need to implement control loops in software? "Applied Control Theory for Embedded Systems" was written for you. See details at http://www.wescottdesign.com/actfes/actfes.html |
#2
Posted to rec.crafts.metalworking
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Cutting Disks
On May 4, 6:09*pm, Tim Wescott wrote:
I have two sizes of disk to cut, from two or three different materials: Disk 1: 3/4" diameter, from 6mm thick "Depron" foam. *This is a close-cell polystyrene foam (I think it's extruded). Disk 2: 0.125" to 0.150" diameter, from 1/64" plywood or 0.015" styrene (I have the plywood, the styrene matches the color and chemistry of the foam). Both need to have a .025" diameter hole drilled, but that's not the big problem. How many do you need to make? If it is not too many, I would try making a single sided die and use it spinning in a drill press. It could have a .025 drill so it drills the hole first and then cuts the disk in one operation. Think of a toothless hole saw. I have used something like this for cutting rubber disks. I did not need the hole in the center. Dan |
#3
Posted to rec.crafts.metalworking
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Cutting Disks
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#5
Posted to rec.crafts.metalworking
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Cutting Disks
On 5/4/2011 9:13 PM, Tim Wescott wrote:
On 05/04/2011 06:03 PM, Mouse wrote: On 5/4/2011 8:13 PM, wrote: On May 4, 6:09 pm, Tim wrote: I have two sizes of disk to cut, from two or three different materials: Disk 1: 3/4" diameter, from 6mm thick "Depron" foam. This is a close-cell polystyrene foam (I think it's extruded). Disk 2: 0.125" to 0.150" diameter, from 1/64" plywood or 0.015" styrene (I have the plywood, the styrene matches the color and chemistry of the foam). Both need to have a .025" diameter hole drilled, but that's not the big problem. How many do you need to make? If it is not too many, I would try making a single sided die and use it spinning in a drill press. It could have a .025 drill so it drills the hole first and then cuts the disk in one operation. Think of a toothless hole saw. I have used something like this for cutting rubber disks. I did not need the hole in the center. Dan That's what I was thinking. When I worked in a printing company they had a hole drill that would melt through a 1/2" stack of paper with ease--a sharpened thin tube spinning in a small hand press--had a cutout on the side to eject the paper disks. Should be easy to make one for a drill press. I believe it was sharpened on the inside of the tube since they were after clean holes, for clean disks sharpen from the outside. Hmm. I'd be making batches of 10 or 20. That would certainly do if I weren't going to try to farm the work out to my 12 year old, but I wouldn't want let him close to the power machinery. Well, you know your kid's capabilities/responsibility level best. I won't go into what I was into at his age, lol. Parents are more careful these days. -- :3 )~ |
#6
Posted to rec.crafts.metalworking
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Cutting Disks
On 05/04/2011 06:18 PM, Mouse wrote:
On 5/4/2011 9:13 PM, Tim Wescott wrote: On 05/04/2011 06:03 PM, Mouse wrote: On 5/4/2011 8:13 PM, wrote: On May 4, 6:09 pm, Tim wrote: I have two sizes of disk to cut, from two or three different materials: Disk 1: 3/4" diameter, from 6mm thick "Depron" foam. This is a close-cell polystyrene foam (I think it's extruded). Disk 2: 0.125" to 0.150" diameter, from 1/64" plywood or 0.015" styrene (I have the plywood, the styrene matches the color and chemistry of the foam). Both need to have a .025" diameter hole drilled, but that's not the big problem. How many do you need to make? If it is not too many, I would try making a single sided die and use it spinning in a drill press. It could have a .025 drill so it drills the hole first and then cuts the disk in one operation. Think of a toothless hole saw. I have used something like this for cutting rubber disks. I did not need the hole in the center. Dan That's what I was thinking. When I worked in a printing company they had a hole drill that would melt through a 1/2" stack of paper with ease--a sharpened thin tube spinning in a small hand press--had a cutout on the side to eject the paper disks. Should be easy to make one for a drill press. I believe it was sharpened on the inside of the tube since they were after clean holes, for clean disks sharpen from the outside. Hmm. I'd be making batches of 10 or 20. That would certainly do if I weren't going to try to farm the work out to my 12 year old, but I wouldn't want let him close to the power machinery. Well, you know your kid's capabilities/responsibility level best. I won't go into what I was into at his age, lol. Parents are more careful these days. #1 son may have been OK, but #2 son gets anxious when there's a need for honest caution. Then he locks up and stops thinking. If you're not afraid of power tools at all then you won't think about the hazards, and you shouldn't use them. If you're so afraid of power tools that the hazards make you stop thinking -- you shouldn't use them. Hopefully he'll grow out of this. -- Tim Wescott Wescott Design Services http://www.wescottdesign.com Do you need to implement control loops in software? "Applied Control Theory for Embedded Systems" was written for you. See details at http://www.wescottdesign.com/actfes/actfes.html |
#7
Posted to rec.crafts.metalworking
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Cutting Disks
Only because you think you, as a parent, are more careful than your parents
were. That would be doubtful and I would believe they thought the same thing of their parents It's only the view on the other side of the coin, only. You will have no idea what your kids are really doing until they tell you the stories, a few decades from now, over a few beers. ------------- "Mouse" wrote in message ... Well, you know your kid's capabilities/responsibility level best. I won't go into what I was into at his age, lol. Parents are more careful these days. |
#8
Posted to rec.crafts.metalworking
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Cutting Disks
On May 4, 9:13*pm, Tim Wescott wrote:
Hmm. *I'd be making batches of 10 or 20. *That would certainly do if I weren't going to try to farm the work out to my 12 year old, but I wouldn't want let him close to the power machinery. -- Tim Wescott Wescott Design Serviceshttp://www.wescottdesign.com After you have made the tool and chucked in the drill press, the amount of time to make 20 ought to about one minute. I would just do them yourself and figure out something else for you son to do. Dan |
#9
Posted to rec.crafts.metalworking
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Cutting Disks
On May 4, 3:09*pm, Tim Wescott wrote:
I have two sizes of disk to cut, from two or three different materials: Disk 1: 3/4" diameter, from 6mm thick "Depron" foam. *This is a close-cell polystyrene foam (I think it's extruded). Disk 2: 0.125" to 0.150" diameter, from 1/64" plywood or 0.015" styrene (I have the plywood, the styrene matches the color and chemistry of the foam). Both need to have a .025" diameter hole drilled, but that's not the big problem. Currently I'm cutting these by hand, but would like to automate the process. *Ideally I'd like tools that a 12 year old kid could wield to good effect, so the less skill needed by the operator the better. *A close second place is a tool that needs some care and manual dexterity to use, but it still quick and robust. So -- how to do? *Die cut these "Paper punch" style, with a top & bottom die? *Make a single-sided die and either press it, or whack it with a hammer like a leather punch? *Hole saws? Also, any suggestions on drilling the holes in the small disks? *These are fiendishly hard to hold while cutting a hole. *Currently the easiest way seems to be to drill holes in the parent stock, then cut the disks around them. *Drilling holes in the large disks is easy -- in fact, all I've been doing there is just poking the holes with the right size of wire. -- Tim Wescott Wescott Design Serviceshttp://www.wescottdesign.com Do you need to implement control loops in software? "Applied Control Theory for Embedded Systems" was written for you. See details athttp://www.wescottdesign.com/actfes/actfes.html This looks like a cheap solution: http://www.handhelditems.com/12pc-ho...h-p-47273.html Roger Shoaf |
#10
Posted to rec.crafts.metalworking
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Cutting Disks
On May 4, 3:09*pm, Tim Wescott wrote:
I have two sizes of disk to cut, from two or three different materials: Disk 1: 3/4" diameter, from 6mm thick "Depron" foam. *This is a close-cell polystyrene foam (I think it's extruded). Disk 2: 0.125" to 0.150" diameter, from 1/64" plywood or 0.015" styrene (I have the plywood, the styrene matches the color and chemistry of the foam). Both need to have a .025" diameter hole drilled, but that's not the big problem. Currently I'm cutting these by hand, but would like to automate the process. *Ideally I'd like tools that a 12 year old kid could wield to good effect, so the less skill needed by the operator the better. *A close second place is a tool that needs some care and manual dexterity to use, but it still quick and robust. So -- how to do? *Die cut these "Paper punch" style, with a top & bottom die? *Make a single-sided die and either press it, or whack it with a hammer like a leather punch? *Hole saws? Also, any suggestions on drilling the holes in the small disks? *These are fiendishly hard to hold while cutting a hole. *Currently the easiest way seems to be to drill holes in the parent stock, then cut the disks around them. *Drilling holes in the large disks is easy -- in fact, all I've been doing there is just poking the holes with the right size of wire. -- Tim Wescott Wescott Design Serviceshttp://www.wescottdesign.com Do you need to implement control loops in software? "Applied Control Theory for Embedded Systems" was written for you. See details athttp://www.wescottdesign.com/actfes/actfes.html Part 2: For the center hole it depends on how close you needed to be. If you got a set of dividers and a center punch, you could scribe the circles, drill the holes and then punch the gaskets by eye. If you needed more precision then you could make a little fixture with a drill guide bushing. Roger Shoaf |
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