Designing the part s to have all milling operations from one direction keeps the cost down, but also limits the design freedom. The original design process took several weeks of CAD. Once the first design is reached it is always good practice to make atleast one prototype. As with any new ideas it is always good to have a test run and to check the design. It is very easy to fall foul of 'CAD Eyes' where parts look waaaaay bigger than they actualy are.
Having something tangible can be a great help when it comes to designing. At this stage I didn't have the shaft or a chuck. I wanted to see how my design matched up to the reference pillar drill. I'm using the E3D ToolChanger to print the parts. I don't have the facilities to made The Tapping Tool at home from the desired material, Aluminium.
I have to go to machinists to have the parts made for me. I am still waiting for the chucks and shaft to arrive, they come from different suppliers in different shipments. Weight is very important to consider when you are looking to sell a product you have designed. The parts will be very accurately made, the top surfaces with be smooth and flat, and the corners and edges will be square.
This is not something possible with 3D Printing alone. This work is licensed under a Creative Commons Attribution 4. Question 1 year ago. Nice work. Nothing is as good as a properly reamed hole and properly cut threads with a nice sharp tap as your tool delivers, but for 3D printed parts have you tried printing the threads in place?
I found a trick from Kevin Kennedy that works really well. I've printed all the way from M3 to 2" threads that work quite well. Introduction: The Tapping Tool.
For a regular center punch, place the tip against the metal and use a hammer to tap the end and create a divot. Insert the drill bit into the end of your drill. Put the drill bit into the chuck, which is the end of your drill. Apply drilling oil into the divot. Drilling oil, also known as cutting oil or cutting fluid, is a lubricant that helps prevent the drill bit from overheating and makes it easier to cut through the metal. Squeeze a drop of the oil directly into the divot. If the metal gets too hot, it can harden and make it difficult to use your tap.
You can find drilling oil at your local hardware store and by ordering it online. Place the end of the drill bit into the divot and start drilling slowly.
Take your drill and hold it over the divot so the bit is pointing straight down. Press the end of the bit into the divot, apply pressure, and start drilling slowly to begin penetrating the surface.
Be sure to keep the drill bit pointing straight down so the hole is straight for your tap. If you have a drilling machine, also known as a drill press, use that to drill your hole. Bring the drill up to medium speed and apply consistent pressure.
As the bit cuts into the metal, slowly increase the speed of the drill. Keep the drill at slow to medium speed and apply gentle but consistent pressure against it. Once you get to medium speed, keep the speed constant. Remove the drill every 1 inch 2. Metal flakes and shavings will create more friction and cause your drill bit to heat up. It can also make the hole uneven and rough.
Then, replace the drill and continue cutting until you pierce through the metal. Part 2. Insert the tap that matches the hole into a T-handle. A T-handle is a device that allows you to manually tap a drilled hole and create threads for screws and bolts. Apply drilling oil into the hole to lubricate it. Squeeze a drop or 2 of the drilling oil directly into the hole to help make it easier for your T-handle to tap it and create threads.
Wipe away any excess oil that drips through the other side of the hole with a clean towel. Rotate the T-handle to thread your hole with the tap. Turn the T-handle clockwise to start tapping the hole and creating threads. Keep turning the handle in the same direction using smooth rotations. Turn the T-handle the opposite direction to remove the tap. Keep turning the T-handle until it sticks out of the other side of the hole. Then, gently rotate it counterclockwise to start moving it back out of the hole.
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