Re: [time-nuts] Machining some aluminum help!

Joseph wrote: For _forming_, one needs something very viscous, something that lubricates at very high pressures, at the yield strength of the material being formed. I've had excellent results with STP oil treatment, by itself or with added Tungsten disulfide. I frequently tap under power at

Re: [time-nuts] Machining some aluminum help!

rement <time-nuts@febo.com> Subject: Re: [time-nuts] Machining some aluminum help! Message-ID: <f4dd2bec-d51d-43b2-93f3-28a57cd6e...@gmail.com> Content-Type: text/plain; charset=us-ascii Kerosine is a better tap lube for Aluminum as it is more persistent and less flammab

Re: [time-nuts] Machining some aluminum help!

0400 >> From: Scott McGrath <scmcgr...@gmail.com> >> To: Discussion of precise time and frequency measurement >><time-nuts@febo.com> >> Subject: Re: [time-nuts] Machining some aluminum help! >> Message-ID: <f4dd2bec-d51d-43b2-93f3-28a57cd6e...@gmail.com> &g

Re: [time-nuts] Machining some aluminum help!

> <time-nuts@febo.com> > Subject: Re: [time-nuts] Machining some aluminum help! > Message-ID: <f4dd2bec-d51d-43b2-93f3-28a57cd6e...@gmail.com> > Content-Type: text/plain; charset=us-ascii > > Kerosine is a better tap lube for Aluminum as it is more persistent >

Re: [time-nuts] Machining some aluminum help!

Kerosene as the cutting fluid and use Acetone to clean up the kerosene afterwards. __ Clay Autery, KY5G MONTAC Enterprises (318) 518-1389 On 7/29/2017 7:57 PM, Scott McGrath wrote: > Kerosine is a better tap lube for Aluminum as it is more persistent and less > flammable > >

Re: [time-nuts] Machining some aluminum help!

; Send time-nuts mailing list submissions to >>time-nuts@febo.com >> >> Message: 7 >> Date: Fri, 28 Jul 2017 14:11:09 -0700 >> From: "Gary E. Miller" <g...@rellim.com> >> To: Discussion of precise time and frequency measurement >>

Re: [time-nuts] Machining some aluminum help!

cussion of precise time and frequency measurement > <time-nuts@febo.com> > Subject: Re: [time-nuts] Machining some aluminum help! > Message-ID: <20170728141109.71aad...@spidey.rellim.com> > Content-Type: text/plain; charset="utf-8" > > Yo cdel...@juno.com! &g

Re: [time-nuts] Machining some aluminum help!

Nice! Do you mind posting some photos? Thanks. Edésio On Fri, Jul 28, 2017 at 12:46:30PM -0700, cdel...@juno.com wrote: > Well I did some research and found my new best friend! > > If you remember I needed: "I have a square aluminum tube 5" X 5" with a > .25" wall it's 8 1/2" long. > > I need

Re: [time-nuts] Machining some aluminum help!

Yo cdel...@juno.com! On Fri, 28 Jul 2017 12:46:30 -0700 wrote: > After mounting the tap in the drill > press and putting a dab of Crisco on the tap I was able to tap each > hole to a depth of 7/16" as fast as I could turn the handwheel! Cool! I suggest you get some real

Re: [time-nuts] Machining some aluminum help!

Good even for mild steel too. Best is your good advice to use the drill press to keep the tap aligned. softer aluminum alloys are very "sticky" and demand backing off a turn for almost every turn forward for cutting taps to break the chip. I've found that the 6/32 tap is the most easily

[time-nuts] Machining some aluminum help!

Well I did some research and found my new best friend! If you remember I needed: "I have a square aluminum tube 5" X 5" with a .25" wall it's 8 1/2" long. I need 20 holes in each end tapped for 4/40 and 1/2" deep." This for a Rubidium standard I am working on. I found all about self forming

Re: [time-nuts] Machining some aluminum help!

-nuts@febo.com Subject: Re: [time-nuts] Machining some aluminum help! This is the first time I've looked at time-nuts in about a month, and I noticed the run about this project. I'm very late to the party, but have a few suggestions that may help - if it's not too late. I quickly scanned many

Re: [time-nuts] Machining some aluminum help!

That is one reason people have been recommending heilicoils. The drill an tap size is about 30% larger than for #4 screws without the inserts. It is easier to do and when you are done there are stainless female threads that are much stronger. On Thu, May 25, 2017 at 3:57 PM, ed breya

Re: [time-nuts] Machining some aluminum help!

One thing I forgot to add - if you must use the 4-40 screw size for some reason, you can save a lot of grief by using a slightly larger bit than the standard tap drill. You're not really too concerned with optimal fit and strength here - it's more about being able to make a whole lot of usable

Re: [time-nuts] Machining some aluminum help!

Why not make the enclosure with a round, not square cross section then the end plate can screw in. Only one hole to thread that way. Of course there is plumbing pipe but also stainless steel water bottles, fly rod cases and all kinds of ready made metal enclosures with thread caps that can hold

Re: [time-nuts] Machining some aluminum help!

This is the first time I've looked at time-nuts in about a month, and I noticed the run about this project. I'm very late to the party, but have a few suggestions that may help - if it's not too late. I quickly scanned many of the posts, and agree with many of the ideas. Please forgive if my

Re: [time-nuts] Machining some aluminum help!

Hi > On May 19, 2017, at 5:35 PM, Chris Albertson > wrote: > > Yes, threaded inserts. There are many kinds but they are used almost > universally for cases where the material to be threaded is soft, like > aluminum. They also eliminate or reduce galvanic

Re: [time-nuts] Machining some aluminum help!

I worked on a project like this once. No screws at all. Rather then a 0.1 PSI over pressure. the interior was flush with dry gas then pumped out with to a crude vacuum with a hand pump. Air pressure alone force the cover plate on. OK a couple screws where there just to aid in assembly but the

Re: [time-nuts] Machining some aluminum help!

Yes, threaded inserts. There are many kinds but they are used almost universally for cases where the material to be threaded is soft, like aluminum. They also eliminate or reduce galvanic corrosion which is an issue with steel screws in aluminum. (that said, as long as you keep water away you

Re: [time-nuts] Machining some aluminum help!

We also used helicoils in titanium frames of the supercomputer I used to work with. Meant we could use relatively standard fasteners without fear of falling. On a time nuts related note, I have a u blox GPS-1E that seems to be stuck spewing out in ublox format. With no development sw

Re: [time-nuts] Machining some aluminum help!

Corby Unless you have the tubing and plates machined flat they will leak as the tubing sides are not guaranteed to be flat and parallel wrt each side and aluminum plate stock is not flat unless you purchase 'tooling plate' which is ground parallel on both sides So creating a seal is

[time-nuts] Machining some aluminum help!

Thanks everyone. Not looking for a redesign, just figuring out how to get the holes drilled and tapped. I have come up with a scheme that looks promising and will let you know how it goes. The enclosure only has to hold +.1PSI of dry nitrogen without leaking. It will have a pressure sensor

Re: [time-nuts] Machining some aluminum help!

> > There are a lot of variables involved. Run the screws in and out of the > aluminum a number of times and > the holes will fail first ….There are other gotchas as well. > > Bob > This is where helicoils come in to play. They are used a lot on the CVD furnaces that I used to make parts

Re: [time-nuts] Machining some aluminum help!

To tell the truth I had not worked this out.But I wonder of the screws fail first on they are in aluminum holes with only 1/4 of thread. Which fails depends on the material and the number of engaged threads, But if what you say is right for this case. It strengthens my case for using self

Re: [time-nuts] Machining some aluminum help!

On Fri, 19 May 2017 12:00:01 -0400, time-nuts-requ...@febo.com wrote: > Re: [time-nuts] Machining some aluminum help! It's much easier to use thread-forming taps in aluminum than thread cutting, and the threads are far stronger. Blind holes are not as large a problem. Lubricate with soft

Re: [time-nuts] Machining some aluminum help!

These threads where there is not enough information to define the problem can grow forever, because they are based on speculation, not facts. Corby, you have decided what you need based on what you know, but the rest of us need a more general statement of the problem. Unless, of course, that is

Re: [time-nuts] Machining some aluminum help!

> On May 18, 2017, at 8:13 PM, jimlux wrote: > > On 5/18/17 2:36 PM, Chris Albertson wrote: >> It would be easy to re-design the job for cheaper machining.. Do you >> really need to tap the holes? You might use self taping screws. Id the >> would work then you can do

Re: [time-nuts] Machining some aluminum help!

On 5/18/17 2:36 PM, Chris Albertson wrote: It would be easy to re-design the job for cheaper machining.. Do you really need to tap the holes? You might use self taping screws. Id the would work then you can do the work yourself with just a hand drill. OK it you must use machine threads and

Re: [time-nuts] Machining some aluminum help!

] Machining some aluminum help! Well that generated a lot of advice and thanks for it! I think I might do it myself and go with a 1/2" hole depth and 1/4" threaded depth. I'll get some of that Aluminum Tap magic, some new taps and new drill bits. Good idea about drilling the end plates first an

Re: [time-nuts] Machining some aluminum help!

So the goal is not to attach end plates, that is the solution. The real goal is a sealed container that can be re-opened.I suggest a trip to the plumbing supply store.Why not just use screw-on end caps It you need it sealed 4-40 screw are not able to provide any reasonable clamping force.

Re: [time-nuts] Machining some aluminum help!

Andy, Although this is a hydraulic cylinder, this is along the lines of what you described. On Thu, May 18, 2017 at 19:18 Andy ZL3AG via time-nuts wrote: > > > Or go for thicker wall aluminium tube, oversized endplates and long bolts > or threaded rods running the entire

Re: [time-nuts] Machining some aluminum help!

Or go for thicker wall aluminium tube, oversized endplates and long bolts or threaded rods running the entire length down the outside of the tube so you're clamping both ends in one operation. No tapping required. Simples! On 19/05/2017, at 6:16 AM, Tim Shoppa wrote: > I bet you went to

Re: [time-nuts] Machining some aluminum help!

Why are my eyes watering? On 19/05/2017, at 5:03 AM, Bob Darlington wrote: > I had > to soak my cavity ring in nitric acid for a month to get the tap out. > ___ time-nuts mailing list -- time-nuts@febo.com To unsubscribe, go to

Re: [time-nuts] Machining some aluminum help!

It would be easy to re-design the job for cheaper machining.. Do you really need to tap the holes? You might use self taping screws. Id the would work then you can do the work yourself with just a hand drill. OK it you must use machine threads and they must be #4 size try "rivets" these work

Re: [time-nuts] Machining some aluminum help!

On 5/18/17 1:34 PM, cdel...@juno.com wrote: Well that generated a lot of advice and thanks for it! I think I might do it myself and go with a 1/2" hole depth and 1/4" threaded depth. I'll get some of that Aluminum Tap magic, some new taps and new drill bits. Good idea about drilling the end

Re: [time-nuts] Machining some aluminum help!

Content by Scott Typos by Siri > On May 18, 2017, at 4:34 PM, wrote: > > Well that generated a lot of advice and thanks for it! > I think I might do it myself and go with a 1/2" hole depth and 1/4" > threaded depth. > I'll get some of that Aluminum Tap

Re: [time-nuts] Machining some aluminum help!

Yes, generally when something is expensive to manufacture it is because the designer was not thinking about costs. A design with 40 size "tiny" thread holes in just not cost-effective. A redesign could save hours work. On Thu, May 18, 2017 at 11:16 AM, Tim Shoppa wrote: >

Re: [time-nuts] Machining some aluminum help!

If you need pressure moisture tightness you are going to want to have machinist mill tube ends and plates flat if you take off say 075-100 thousands deep and .225 thousanths around edge of plate and have machinist predrill holes in cover plate you will have both a tight seal and drill guide for

Re: [time-nuts] Machining some aluminum help!

On 18/05/2017 4:34 PM, cdel...@juno.com wrote: I think I might do it myself and go with a 1/2" hole depth and 1/4" threaded depth. Or go back to the shop and get a new quote with them knowing it's not bottom tapping, only 1/4" threaded depth. Michael

[time-nuts] Machining some aluminum help!

Well that generated a lot of advice and thanks for it! I think I might do it myself and go with a 1/2" hole depth and 1/4" threaded depth. I'll get some of that Aluminum Tap magic, some new taps and new drill bits. Good idea about drilling the end plates first and drilling thru to match. Between

Re: [time-nuts] Machining some aluminum help!

On 5/18/17 11:53 AM, jimlux wrote: On 5/18/17 11:16 AM, Tim Shoppa wrote: I'm very dubious that you need a tapped 4-40 hole to be threaded any deeper than 0.25". If you work with the machinist I'm sure you can come up with some reasonable spec that does not require a bottoming tap and will save

Re: [time-nuts] Machining some aluminum help!

I agree, tapping that depth in aluminum is just asking to gall the threads. If you have a decent alloy (6061 7075) you only need 1/8” to hold what ever is save to hold with a #4. If you need more strength then it would be best to use helicoil inserts. Where are you located? There are a number

Re: [time-nuts] Machining some aluminum help!

I'm very dubious that you need a tapped 4-40 hole to be threaded any deeper than 0.25". If you work with the machinist I'm sure you can come up with some reasonable spec that does not require a bottoming tap and will save you a lot of money. I bet you went to 0.25" wall square tubing only because

Re: [time-nuts] Machining some aluminum help!

People's (mis)perception of machine shop costs always amazes me. All too often they equate the fact that they could do it themselves (inaccurately) on an old drill press and then hand tap with what a real shop will do - all while that real shop has a $100k - $500k investment in a single machine.

Re: [time-nuts] Machining some aluminum help!

Tap Magic for Aluminum will be your best friend for this operation. I've been using it on some extrusion for a 3D printer project. It makes an amazing amount of difference. Good luck with you project. Todd On 05/18/17 12:18, Pete Lancashire wrote: Price sounds reasonable to me. Tapping

Re: [time-nuts] Machining some aluminum help!

Price sounds reasonable to me. Tapping 40 each 4-40's that deep in to a closed hole is the killer. If I still had my old Bridgeport J and was NC'ed Your looking at say 1 hour to program, 10 minutes to mount in a vice and get aligned, drill 40 each #44 or #43 holes would be easy, but then slow

Re: [time-nuts] Machining some aluminum help!

On 5/18/17 10:03 AM, Bob Darlington wrote: Ask them what they'd do it for without the tapping. Normally I'd do something like this for free but 40 tapped 4-40 holes in heavy wall aluminum is a pain. It would be a miracle if I didn't break the tap off at least once. Very much so.. 40 tapped

Re: [time-nuts] Machining some aluminum help!

This is fairly easy to do on a vertical mill, but it can be done using a drill press. I would machine and drill the end plates first. Then I would use hot-glue or double-sided tape to attach one of the end plates to the tube ends and use the end plate as a drilling guide to drill and tap the

Re: [time-nuts] Machining some aluminum help!

Ask them what they'd do it for without the tapping. Normally I'd do something like this for free but 40 tapped 4-40 holes in heavy wall aluminum is a pain. It would be a miracle if I didn't break the tap off at least once. Last time was for a resonant cavity amp (23cm band) and I had to soak my

Re: [time-nuts] Machining some aluminum help!

On 5/18/17 9:54 AM, cdel...@juno.com wrote: Hi, I have a square aluminum tube 5" X 5" with a .25" wall it's 8 1/2" long. I need 20 holes in each end tapped for 4/40 and 1/2" deep. So you're putting 5 holes in each side? in the ends? (i.e. the long axis of the screw is within the wall?

[time-nuts] Machining some aluminum help!

Hi, I have a square aluminum tube 5" X 5" with a .25" wall it's 8 1/2" long. I need 20 holes in each end tapped for 4/40 and 1/2" deep. This is for a Rubidium project. The local machine shop want's $360.00 Anyone have a machining setup that could do the work a bit cheaper? If not I'll