[llilrex]

it has been a while since I have posted. so I figured that its about time I be a bit more active.

I decided I needed a live tooling spindle on my lathe, my concept is that it will be mounted on a 1 inch quick change tool post. It also needs to run a 5/8 HSS cutter on steel. that would give me a spindle RPM of about 500, I happen to have a large closed loop stepper motor lying around that would do nicely. I decided to cast the housing out of aluminum, it is soft enough to make for a very solid connection to the QC toolpost. I have some very cheap angular contact bearings.They are standard size though, so if they become a problem, I will change them out for a higher quality bearing. (Each bearing might have cost me $2.00) currently I am running DA100 collets on a BT40 holder, in my CNC mill, so I machined the spindle to accept those collets too. pictures will follow.

[llilrex]

The design starts with the spindle casting, I modeled it with fusion360, then 3d printed it, I used the 3d printed part as a pattern to sand cast it. it was the first time I used a 3d printed part as a pattern, it worked really well. the coupling from the spindle is not yet made, it is designed as a general mount for the motor in other project, I am just reusing it here.

[Pierke]

Nice work, alsoo good pouring.
Are you using greensand or petrobond?
Are you melting the aluminum with an electrical oven?

Pierke

[llilrex]

thanks,

I used petrobond, with an electric furnace. this picture is from the melt on this project. I have since fixed the element that fell from its groove.

[Pierke]

Hello Ray,
whats the power of the elments 3 -4000 watts?
how many hours to meld the aluminum?
Pierke

[llilrex]

there are two elements, totalling 2600W I have a furnace controller on it too in order to control the maximum furnace temp. I am not usually in a hurry, but I think it takes about two hours to melt 6lbs of aluminum and prepare for a pour.

[Pierke]

Hello Ray,
2.72 Kg in two hours, thats nice. The furnace controller is one with an K-sensor or Pid ?
I'am looking for Petrobond (Brusslese aarde) hier in my nabor, and give Pouring a try this summer.
Thanks for your explanation,
Pierre

[llilrex]

the heating elements are Kanthel 110V 1600W each, the furnace is fairly well insulated with light firebrick, I am using a heavy duity exposed K type Thermocouple, the elements are controlled with a solid state relay by a PID Temperature controller. I currently use the furnace primarily for heat treating steels. a PID temperature control isnt neccesary, but its nice.

[Pierke]

Hello Ray, thanks for dealing this knowledge.