Welcome to the blog! Today, we’re diving into the intricate process of crafting a new tool holder for the Morrie vertical shaper.
This is a fascinating journey that involves precision machining, creative problem-solving, and the use of various tools and techniques.
Let’s get started!
Understanding the Project
The project begins with a six-inch square bar of 1045 steel, measuring twelve inches long. The goal is to create a new tool holder that fits the Morrie vertical shaper, which is currently limited by the height of the existing holder.
The challenge lies in the machine’s twelve-inch stroke, which restricts the ability to cut ten and a half-inch long internal keyways. A shorter holder is necessary to accommodate this requirement.
Initial Setup
Initially, there was a plan to square up the block using a horizontal boring mill with a large face mill. However, the current inserts on hand were not suitable due to their angle. Thus, the decision was made to switch gears and start the machining process on the lathe instead.
Turning the Shaft
With the workpiece secured in the lathe chuck, the first step is to indicate the part and ensure everything is trued up. The setup includes a pusher plate and a center drill mark for stability during machining.
Once everything is aligned, the lathe is set to a moderate speed for facing off the block. The operator takes small passes to ensure a clean cut, gradually increasing the speed to improve efficiency as confidence in the setup grows.
Shaping the Tool Holder
After achieving a clean surface, the next step is to create the necessary steps on the tool holder. Measurements are taken to ensure precision, and the operator sketches out the dimensions needed for the steps.
The steps include specific lengths for both large and small sections, which will be machined accordingly.
The machining process involves making interrupted cuts, which require careful attention to vibration and stability. The operator monitors the machine’s performance closely, adjusting the feed rate and speed as necessary.
Final Touches and Drilling
With the steps cut and the tool holder taking shape, it’s time to drill and tap the holes for mounting. The operator switches to a new product called Anchor Lube, which is a water-based lubricant designed for metalworking.
It’s important to ensure that the drilling process is smooth and efficient to avoid any issues.
After successfully drilling the holes, the operator moves to a different tap holder to ensure a secure fit during tapping. This step is crucial for the durability and functionality of the tool holder.
Finishing Touches
Once the drilling and tapping are complete, the final adjustments involve rounding the corners of the tool holder for a neat finish.
The operator returns to the lathe to make these minor adjustments, ensuring that the holder is both functional and aesthetically pleasing.
Conclusion
This project highlights the importance of precision and adaptability in machining. By creating a new tool holder tailored to the Morrie vertical shaper, it not only resolves the height issue but also enhances overall efficiency in the workshop.
Stay tuned for more updates and future machining projects!
The full video guidance here:
