Hole inside a plate. How to mill?

[petersi]

I have a alum plate on hand. It has a hole mill like the attachment. I want to know how to mill a hole at that positing? Using what kind of tool to reach at that angle? thanks

 

[berkshire]

You need a woodruff key seat cutter.

Here is a link to Enco

http://www.use-enco.com/CGI/INPDFF?PMPAGE=131&PARTPG=INLMK32

B.E.

The good engineer does not need to memorize every formula; he just needs to know where he can find them when he needs them. Old professor

 

[dvd]

Good luck with this. You need a tool with zero shank diameter to get that geometry. Might try to edm that feature. You need to ask the designer why they need it.

 

[juergenwt]

I am with dvd. The only other way I can think of is to mill a pocket half way thru the bottom section, mill one half the thickness of the radius and than make an insert with the other half and rivet or screw it together.

 

[MikeHalloran]

Plunge EDM can do it.

Consultation with designer strongly advised.

Mike Halloran
Pembroke Pines, FL, USA

 

[petersi]

Thanks everyone. Your information is very helpful!

 

[racookpe1978]

Couldn't he broach cut the hole with a rectangular broach? (Drill out the plate first with two overlapping holes, then force the broach through.

Then use the key cutter by bringing it down into the hole, then moving either the mill sideways into the part, or the part sideways into the rotating mill.

 

[MikeHalloran]

Look again at the side pocket dimensions; they require a key cutter with a shank diameter of zero.



Mike Halloran
Pembroke Pines, FL, USA

 

[racookpe1978]

Thank you. I see it now.

Yeppers - Gonna need one of them there elliptical-shaped key cutters. Made of Instanteum and Miraculum alloy. 8<)

 

[KENAT]

Not everything is easily machined from stock, additive processes sometimes come in handy.

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[BillPSU]

Using an EDM would be the only way to produce the slot as it is currently shown.

Of course, you could use a CNC controlled metal eating nanobot. But they are really expensive and delivery is really out there. Or maybe you could borrow a replicator.

 

[moldcore]

I would suggest looking at a casting if the quantities and tolerances allow for it. If only a couple of parts then an die sink EDM is the only logical solution as presently designed.

 

[KENAT]

What grade of aluminum, I think some places maybe able to rapid prototype parts using some kind of laser sintering. There are at least a couple of different techniques but it may be possible.

This and casting is what I meant by additive techniques.

The other option is bolt (or otherwise join) 2 plates together to get the shape.

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[dicer]

This looks more like a test of knowledge than a real part. I see no reason for a part like that. The only thing I can see that used for is to lock a mating part in that hole. If it is something that is meant to be removed from the hole there are many other things that can be done other than that key way to accomplish it. If it is to stay stationary in the hole and never be removed then again other ways to do it as well. Welding for one.

 

[dicer]

Hmmm unless it is a part for microwave.

 

[Wrenchbender]

OP implies he has only one piece to make. Besides the EDM, casting, or fabrications mentioned, another would be a weldment: arc or friction-stir a cover plate on top of a milled out area.