Flycutter build plan

Although using the previous design you could go directly to the workshop to cut metal, it is safer and more efficient to plan a little bit the operations that will be performed in order to produce the piece. This will help determine possible problems, choose the best order in which all operations should be performed and the tools to use.


Machine availability becomes a factor when planing the sequence of operations to be performed. For instance, you may have a band saw, a file, a hacksaw or a rotational tool to cut a piece of steel. Being the most common, I'll choose between a hacksaw and a rotational-tool.



0. Material selection. Mild steel (1018) should be good enough for the purpose. Its lead content is minimal and its machinability is acceptable. Its rigidity is better than that of Aluminum, which will help when performing the cuts.

0.1. Use eye protection and a mask to protect the lungs from the cutting tool debris.

1. Cut a piece of metal of length 81mm and diameter 1".

For this operation, a rotational tool can be used. A dremel with an abrasive disk can do the job. The disk must have at least 1/2" radius in in order to cut the piece. If those disks are not available, the operation can be initiated with the rotational tool and then completed with the hacksaw. To accomodate for errors, 82mm can be cut.


2. Indicate the piece in the lathe and make it run true.


3. Support the piece in the steady


4. Face the piece to remove saw marks.


5. Drill a 5mm counter-sink on the face


6. Mount the tailstock live center and fix it to the piece.


7. Turn the piece on the lathe using a finishing tool, reducing to 25mm over a length of 50mm. This operation can be performed with a right hand tool.


8. Invert the piece in the lathe


9. Repeat 2-6 on this side


10. Turn the piece on the lathe reducing to 10mm diameter over a length of 30mm


11. Fix the part to the milling machine using a sine vise or angle vise.

The angle needs to be 15 degrees.


12. Mill this base of the part.


13. Mill the screw cuts and the tool cut.


14. Mount the piece horizontally on the vise and drill the screw holes.


15. Tap the holes using the M4 tap.


16. Mill the compensation hole.


17. Chamfer all borders.


18. Grind a cutting tool.


19. Install the cutting tool into the fly-cutter head using two grub screws.


20. Clean the area


21. Clean the area again, use a magnet if available.


This should complete the build plan.


From the design, the fly-cutter will require


Materials:

A rod of 81mm 1"diameter mild steel (1018)

Two M4x4mm grub screws.


Tools:

Dial indicator

Lathe

Fixed steady

Live center

Counter sink 5mm

Right hand finishing tool

Right hand tool

1"-2" Micrometer

25mm Micrometer

Sine vise/Angle vise

10mm mill bit

8mm mill bit

#30 drill bit

M4 tap

File

Milling machine

Rotational tool (Dremel?)

Abrasive disks for the rotational tool

Hacksaw