tooling question for you machinists

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Nov 8, 2000
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What kind of cutter would you use to resurface an anvil in a bridgeport?

I was just looking at Mcmaster carr and there are way to many options for me to finalize a decision :confused:
 
Since no one has replied yet I will throw my $0.02 in. For that type of cutting I believe you would normally use a fly cutter. However I am not sure that will work with the hardened face of an anvil. I would think that because of it's hardness an anvil would have to be ground (like with a hand held belt sander).

Keep in mind that I have never tried to machine hardened steel, and my knowledge of machining is from High school (although I did finish 2nd in my state's VICA competition:cool:).
 
While there's no single correct answer or tool....it's a tough question without knowing more details.

How hard is the face?
How much material do you want to remove?
What are your expectations of the finished surface?
What kind of tooling do you have to run a cutter..?

It's not important to actually answer this..a little experimentation will guide you.

The first tool that I would try would be an indexible endmill. It'll have carbide inserts. For a BP...nothing bigger than 1" diam.

something like this:

3m-e90ax.gif


If it seems to do OK...then follow up with a Fly cutter for "surfacing".

like this:

fly_cutter_straight_shank.jpg


These tools are for very light cuts and will blend the rows caused from the previous tool. They are delicate and won't tolerate hard spots very well.

Away from the Bridgeport..I would surface grind the face.

For me...this would all be trial and error. I would try one tool and see how it does...if i liked it, I would continue..or try something else.

Hopefully someone will chime in who has been there and done that.

Good luck, Rob
 
I was afraid of the surface grinder recomendation.We tried using the endmills on hand .001 at a time..didnt even touch it.I'll see if my neighbor with the mill wants to split an indexable endmillthey dont look cheap.

As for the hardness of the face,I'm not sure of a number but it is a wrought body/hardened top plate style ( i cant make out a name) I dont need to remove too much material at a time we already wrote a G code to follow the face of the anvil,so multiple passes wont break my heart.
 
G-code...? "Bridgeport"?

OK...at first I thought this was by hand in a Knee/turret mill.

In the CNC...I would use a "Z-Carb" carbide endmill.

SGS-Z-Carb-End-Mills.jpg


They will cut the snot out of almost anything. Get a standard corner radius with weldon flats. Use an endmill holder...not a collet. For this ap..get the stub length since you are only using the face. If this doesn't cut it...then you'll have to grind it.

-Rob
 
Rob's approach to this is a good one, and is probably how he would do it. And since I already have those tools on the shelf, that is how I would do it too. But it is not going to be cheap.

To do this on the cheap, you can get used or new surplus carbide endmills on ebay for cheap. Folks use them to mill aluminum or plastic in production and sometimes throw them out after a few days when the surface finish or burrs become a problem. They're still sharp enough to remove bulk material. Then to put a decent finish on it, you can take a skim cut with a fly cutter with a sharp carbide lathe tool bit. Total tooling cost, under $50.

I'd look for a couple 1/2 carbide endmills. I'd turn them about 1200 RPM, and feed them about .003" per tooth (that's feeding fairly hard, to reduce chatter) and I'd limit the depth of cut to about .010". You should plunge in air beside the part.

The fly cutter might be about 2 1/2" dia. I'd turn it about 700 RPM and feed about 8 IPM. It should only be removing a couple thou. I'm feeding hard here because the flexibility of the fly cutter, and a Bridgeport, will cause something like smearing if you don't feed hard enough on hard material. That is also why I don't recommend a large fly cutter in this application.


After this, you're still going to need to use something like a flapper wheel on an angle grinder to smooth out the tool marks.

I have had problems with fly cutters taking a deeper cut where the cuts overlap in a similar application. I'd use a slightly negative overlap, leaving a tiny tiny hump, which is easier to remove (use a file) than "blending" the entire surrounding surface down with a flap wheel
 
this is a tough one. The face of the anvil is prolly work hardened on top of the original RC it had. Not sure how one can clamp something like an anvil to BP's table to where there's no chatter. Carbides and chatter friends are not. You'd positively destroy a few carbide EMs / inserts.

The make some dirt cheap indexable face mills like this one http://cgi.ebay.com/2-INDEXABLE-END...5|66:2|65:12|39:1|240:1318|301:1|293:1|294:50

Might want to start with something like that - it uses negative geometry inserts and should be able to take some abuse.

Don't underestimate the power of a common angle grinder :) - just how straight do you want the face of that anvil to be ?
 
Thanks guys,that is a hell of a lot of input :thumbup:

I am just tickled to death playing on this machine :D Just trying to find things to do with it.....
I tried about 2 hrs straight with a 9" angle grinder I got the shape roughed out on one and the welded repaired one got pretty close too,just cant seem to get the sway back out( my carpal tunnel thanks me...)

The one anvil is going to be my main working anvil for blades with just the 8"x 4" face,it was found with the heel broken off.The second one was pretty shot,all chipped out and only about 90 lbs. to boot,that one goes to the guy with the bridgeport just for beating on things.
 
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