trapper
Member
:befuddled::befuddled::befuddled:I need to make a hexagonal recess in the end of a metal bar does anyone have any ideas how i can do this...... if it was wood or acrylic I could cope. I dont have suitable milling or casting facilities
not sure if this is the right place to ask
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txbob
Member
Buy a hex socket the right size and braze/solder/weld/epoxy it to the end of the bar?
txbob
txbob
Dan26
Member
File?
Odd shaped holes -square, hex, etc- are usually accomplished with a broach.
An expensive tool to buy for only a single hole, but maybe you could find a local small machine shop to do it.
A more advanced way would be with EDM machining, something which is in the reach of hobbyists if you make your own (it isn't that hard to do it on a workable scale, try an Internet search). Again, you might find a small machine shop with the equipment to do it.
There's also the possibility of finding with a hex hole already in the end of it -maybe some kind of drive shaft- and using that.
Depending on the size and depth you need, you also might be able to drill and thread the end for an Allen head set screw and solder or braze that in place.
An expensive tool to buy for only a single hole, but maybe you could find a local small machine shop to do it.
A more advanced way would be with EDM machining, something which is in the reach of hobbyists if you make your own (it isn't that hard to do it on a workable scale, try an Internet search). Again, you might find a small machine shop with the equipment to do it.
There's also the possibility of finding with a hex hole already in the end of it -maybe some kind of drive shaft- and using that.
Depending on the size and depth you need, you also might be able to drill and thread the end for an Allen head set screw and solder or braze that in place.
Last edited:
KenV
Member
The answer will depend on the precision and tolerances needed, and the size.
If you can accept some rounding at the corners, a mill can remove metals but is limited by the mill diameter (which can be very small).
If you can accept some rounding at the corners, a mill can remove metals but is limited by the mill diameter (which can be very small).
gwilki
Member
What is the metal bar made of? Steel?
I was thinking that, if it were softer than steel, you could drill a hole slightly smaller than the end result and drive an allen key into it as a punch. I have no idea if this would work, but the allen key is the only thing that I could think of that could make a hex hole.
I was thinking that, if it were softer than steel, you could drill a hole slightly smaller than the end result and drive an allen key into it as a punch. I have no idea if this would work, but the allen key is the only thing that I could think of that could make a hex hole.
That would basically be the same as broaching it.
A regular broaching operation usually does it in several steps, each bing closer to the finished form, rather than in a single one.
trapper
Member
Thanks for the thoughts so far guys, What I'm trying to do is make a section that can take micro tool bits....... these are 3.5/4mm across flats rather than apen or fountain pen set up the metal is copper,or brass or aluminium.
I'll let you know how I progress
I'll let you know how I progress
randyrls
Member
Oh; That is much easier. Drill a hole in the end of the bar to hold the bit. Drill two small holes from the side and tap for set screws. Clamp the bit into the end of the bar with the set screws. You could also epoxy glue the bit into the end of the bar, but if it gets very warm, the glue could loosen. Soldering or brazing could also work.
trapper
Member
Thanks Randy,
Simple is alway best I guess. But point well taken. Me thinks I have work to do tomorrow (yeah I know it's Sunday but what an excuse to avoid the mall and christmas shopping but don't tell her indoors!!!!! Merry Christmas
Simple is alway best I guess. But point well taken. Me thinks I have work to do tomorrow (yeah I know it's Sunday but what an excuse to avoid the mall and christmas shopping but don't tell her indoors!!!!! Merry Christmas
trapper
Member
Broaching a hex update
Ok guys firstly thanks all for the responses.
This is how I'm progressing with the project.
I've decided to abuse some old allen keys, or is that wrenches,
What I am doing is maching crocodile teeth in the allen key across opposing flats. The allen key so cut is then being tapered (approx1.5-2 degrees toward the front of the tool. The teeth provide as it were castlelated cutters on opposing sides.
The tool is then held in the tailstock vis either a mandrel holder or a chuck.
The work piece will be held in the headstock chuck and drilled to fractionally under the af measurement of the tool.Without the lathe being
turned on The tool is forced through the softer metal workpiece so cutting the hex hole.:bulgy-eyes: Thats the theory
so time to try it will report back
Ok guys firstly thanks all for the responses.
This is how I'm progressing with the project.
I've decided to abuse some old allen keys, or is that wrenches,
What I am doing is maching crocodile teeth in the allen key across opposing flats. The allen key so cut is then being tapered (approx1.5-2 degrees toward the front of the tool. The teeth provide as it were castlelated cutters on opposing sides.
The tool is then held in the tailstock vis either a mandrel holder or a chuck.
The work piece will be held in the headstock chuck and drilled to fractionally under the af measurement of the tool.Without the lathe being
turned on The tool is forced through the softer metal workpiece so cutting the hex hole.:bulgy-eyes: Thats the theory
so time to try it will report back