[Leoo5van]

Those are photos of some of my machine products under hypertherm.

[Islam]

Finally, have installed a rotary axis for cutting pipes and square tubes that has been implemented by my plasma machine according to my simple design.
These are some photos for my 1st cut of pipes and square tubes.

[Islam]

The new simple rotary axis

[Islam]

Simple 4-jaws chuck the made by my plasma machine which installed to the 3-jaws chuck as any circular pipe, it can hold up to 3"x3" square tube:

[Islam]

Here is my simple procedure in order to cutting rectangular tubes.

The main issue in cutting rectangular tubes is how to adjust the 4-jaws chuck which holds the rectangular tube so as to ensure that the center of the rectangular tube must be located in the center point of the 4-jaws chuck.

The 4-jaws chuck has been made as illustrated in the preceding post so as to be installed to the machine by the 3-jaws chuck, this means that the rotation axis of the 4-jaws chuck is the same rotation axis of the 3-jaws chuck of the rotary axis which is parallel to X axis in my machine.

I adjust the center of the rectangular tubes as follows:

1- Before installing the 4-jaws chuck , use a calibrating pipe with a certain diameter (I use 4" pipe), install it in the 3-jaws chuck and adjust the holding rollers across the length of the pipe so as to ensure that the 4" pipe axis is parallel to the rotary axis. (This could be implemented by using a water balance as in the attached photo.

2- We must made two special clamps for the rectangular tube that we want to cut by our plasma machine as in the attached photos.
Each clamp made of 4.0 mm sheet metal and consists of two circular cut with a diameter similar to the calibrating pipe diameter (4" in our case) and with an inner rectangle in the center with a dimensions similar to the rectangle tube cross section.

3- insert the two clamps in the rectangular tube and tight them by their holding screws (as in the attached photo)

4- install the 4-jaws chuck to the 3-jaws chuck.

5- open the 4 jaws and insert the rectangular tube inside without tightening them, adjust to position of each clamp holding the rectangular tube to be located above the holding rollers which have been adjusted in step no. 1.
The rectangular tube axis now is parallel to the rotation axis and aligned with the rotary axis.

6- Tight the 4 jaws of the chuck to hold the tube in its position above the holding rollers.

7- You can uninstall the outer clamp to allow cutting, the tube now is hold by the 4-jaws chuck and one clamp.

[Islam]

clip showing the (40 x 60 mm- 2.0mm thicknes) rectangular tube cutting.

https://www.youtube.com/watch?v=8nGktXogixg

[Frank W]

Looks good. I never thought I would need a rotary cutter until I saw this thread. After I get my machine up and running I may look into building one.

Do you think you could send me the file for the helicopter? My little boy would love that.

[Islam]

Looks good. I never thought I would need a rotary cutter until I saw this thread. After I get my machine up and running I may look into building one.

Do you think you could send me the file for the helicopter? My little boy would love that.

With my pleasure for your little boy,
N.B: the drawing in the file is adjusted for 3.0 mm thickness.

[Frank W]

Thank you sir!

[Islam]

Some of my products of 3.0 mm sheet metal - 400 x 1500 mm made by DIY machine.

[Islam]

coffee table 48" x 23" - 3.0 mm sheet metal - 60.0 mm dia. tube
Using rotary axis to produce the tube profile.

[dnelso]

Very nice.

[Islam]

Wall clock of 600.0 mm dia. (23 1/2") made by a combination between 3.0 mm sheet metal cut by my diy cnc plasma and 16.0 mm plywood engraved by my diy cnc router.

[Kerryfisher]

Fine job!!
I like your 4 jaw chuck design,,,,well done!

[Frank W]

Looks good!

[Islam]

Vase - 750 mm height made of 2.70 mm sheet metal and pine wood.