flat belt pulley pattern

[dallen]

(09-13-2013, 07:43 PM)Mayhem Wrote: Nice work Dave - I'd be very happy with that and given the age of the machine those few, minor flaws I would imagine it will look the part.

Thanks, its taken me a spell to get here at one point I though I was going to have to re do one side of pattern to get it to release from the mold, but for some reason the foundry gods saw fit to smile on me just once.

the flaws don't look the part as the one that was originally made for the shaper didn't have sand inclusions in it or the end of the hub shrunk in slightly, the shrinkage is machinable. the sand inclusions can be welded up if I was making this to sell. the hot tears the only way to fit them is to recast the part with a larger fillet which will spread the metal out and give a more gentle sweep for the metal to pull over as it cools.

I don't know yet if I will have to re pour this pulley or not (really depends on if I mess up the machine work on it) if i do have to re pour I will put in a larger fillet.

But I think I have it figured out how to get it back in the lathe, first I'm going to try a flap sander wheel to open the thing up one of two thousands thats all I need for it to fit on the input shaft of the shaper.

DA

[dallen]

cleaned the casting up some and cut the taper were the flat belt runs

need to get some inserts that will fit the bar that are for aluminum.

[EdK]

(09-14-2013, 04:44 PM)dallen Wrote: cleaned the casting up some and cut the taper were the flat belt runs

need to get some inserts that will fit the bar that are for aluminum.

...

David,

It looks like you bored the shop supervisor to sleep. It must be the soothing sound of chip making.

Ed

[doubleboost]

Made my day watching that
A great achievement that casting
John

[TomG]

Excellent work David. A casting like that is well beyond the ability of most amateur foundrymen and you pulled it off on the first try.

How did that casting machine with the addition of the copper?

Tom

[dallen]

(09-14-2013, 04:56 PM)EdK Wrote: David,

It looks like you bored the shop supervisor to sleep. It must be the soothing sound of chip making.

Ed

Ed he see's thing thru closed eye's that would scare most people. but I like him, we're in the middle of battle of the fleas at the moment, damn pest.

(09-14-2013, 05:22 PM)doubleboost Wrote: Made my day watching that
A great achievement that casting
John

Thanks again John it was a pretty good day yesterday when I shoveled the sand back and found a whole casting hiding in it.

(09-14-2013, 05:56 PM)TomG Wrote: Excellent work David. A casting like that is well beyond the ability of most amateur foundrymen and you pulled it off on the first try.

How did that casting machine with the addition of the copper?

Tom

Tom that casting is well within the reach of any home caster, you just have to have the right size equipment to do it, to tell the truth many times making the pattern I had my doubts about me being able to finish the pattern I don't have wood tools except for a couple of wood planes and a jig saw.

the metal machined ok, acted dry but to me most home cast does that, I added the copper to help with the machining, I think my biggest problem with turning was not having the right inserts for aluminum, I have one left hand boring bar that is 1 inch in diameter that uses a cnmg 3 insert but of the three inserts I have they were all for ferrous metals.

It may of helped if I had thrown in some silicon, but I think one of the biggest problems with the machining was the way I had it in the lathe, (only way I was able to put it back so i could cut the outside concentric with the bore, if I had of been able to of put it on the shaft like I wanted I could of turned the rpm up some.

Ok here's the picture that I have been waiting on, the one that shows it on the machine BUT REMEMBER i ONLY SAID i WAS GOING TO MAKE IT.

damn but don't it look good on there.


one thing thou I said I was going to make it, never said anything about it lining up with the other one. there's about an inch of difference in alignment.


and all the things except the clamp handle on the ram couldn't get it in the pic without backing way up.

[dallen]

did a little video editing tonight cut out a bunch of the stuff poeple don't want to watch and speeded it so so that it won't take all night to watch. I didn't put in anything about ramming up the cope (top half) as it would just be a repeat of the drag.

[doubleboost]

I really enjoyed that
Thanks for posting & very well done
John

[DaveH]

Fantastic David

DaveH

[Rickabilly]

Lets not forget that there probably isn't a machine tool made that doesn't have some sand inclusions somewhere, as long as they are not on functional surfaces, they get through, in the same way as welding porosity is just a part of welded joints and "rolled seam inclusions" will invariably turn up on any black steel rod or bar.

Well done, I want one despite having no practical use for it.

incidentally A little heat treatment goes a long way towards improving the machinability.

Best Regards
Rick