Shaft cutters?

[Tommy-D]

> I've read everything anyone on here has ever posted about cutting shafts with sawblades,various router bits,variations on slot/flycutters,etc.

Is there no value at all to using a 1/2 4 or 6 flute HSS endmill or even a reamer?

The only complication I see is having to cut with reverse spindle rotation and start from the chuck moving to the right to get the flutes pointed in the right direction,or the exact opposite,forward rotation and the cutter on the back side.

Ideas? Tommy D.

 

[qbilder]

The relief is as important as the sharpness. If there's nowhere for the dust & chips to go then it won't cut well. No matter what you use, be sure it can dispose of the debris as rapidly as it creates it.

 

[cueman]

I used end mills in my router in my early days for tapering. I found the wood wanting to climb the bit occasionaly. The blade angle just was not right for cutting wood. Router bits have proven much better for me. It was a disaster with the end mill horizontal or vertical, especially for cutting shafts.

 

[JoeyInCali]

The thinner the kerf ( as long as it is safe ) the better imo.
Less push-off and no interrupted cuts, the better.

 

[scdiveteam]

Hi,

I have tried all machine set ups and my opinion is that shaft machines with carbide blades and vernier control trimmer pots on separate controllers for the lathe and travel speeds rules. DC Motors with controllers are expensive but are worth it because the less sanding the better. The shafts are more consistent to your shaft profile geometry blueprint.

I spent a very long period of time specing motors for this operation. The motors and controllers I choose are absolutely perfect considering HP and RPM requirements. These motors run all day long and barely get warm.

Final cut passes at a very slow lathe and linear motion speeds dialed in produce shafts that are perfect. The rough cuts can be done very fast by just adjusting a dial.

A shaft machine that is geared or has fixed pulleys using one motor work well but it is hard to find the perfect combo without vernier control, thus more sanding.

I have two saw machines, one for shafts and one for butts with E-Stop switches. It is like having two extra employees in my shop who don't get paid.

Also cutting the wrap groove with the saw is incredible. Dial in the depth after final cut and leave a 1/2" on each side to be blended on the lathe. It does not get any easier.

Anyone interested in this type of gear should contact Darrin Hill as he can build you one.

Rick Geschrey


Modified Bludworth CNC Shaft Machine Changed to Manual Operation With DC Motors and Controllers with Interrupted Lead Screw:

Darrin Hill Shaft Machine with same motor and controller set up: