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Thread: A double edged fly cutter.

  1. #1
    [email protected] tonyfoale's Avatar
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    A double edged fly cutter.

    A while back there was a thread on fly cutters, but I can't find it now. I didn't start the thread but I mentioned my use of multiple cutters and preference for inertia. I have just needed to use one of my fly cutters and had a camera handy, so here is a full description with pix.

    Firstly I needed a substantial mounting method for the heavy rotor containing the cutting tools. An R8 to 100 mm chuck mounting flange was ideal, these are cheap and it saved me a lot of work.

    A double edged fly cutter.-flycutter-01.jpg A double edged fly cutter.-flycutter-02.jpg

    The R8 to chuck mounting flange.

    This has a 72 mm diameter spigot for location and three holes for M8 mounting bolts. The rotor was made from an old chuck plate which gives plenty of the inertia which I regard as important for fly cutters. It was faced off, drilled and tapped for mounting and a register bored to suit the spigot on the mounting plate. Two opposing holes were drilled to take 0.25" tool blanks, holes were drilled and tapped M6 at 90 deg. to take grub screws to hold the tools. This allows me easy depth of cut adjustment, and the circular tools allow rotational adjustment to change the rake angle for different work piece material. I have a choice of grinding tools from HSS blanks or more usually I grind the tools from old 0.25" carbide milling cutters.

    A double edged fly cutter.-flycutter-03.jpg A double edged fly cutter.-flycutter-04.jpg

    On the left is the base rotor, 190 mm diameter. There are a few surplus holes, a legacy of its prior use. To the right is the complete assembly.

    A double edged fly cutter.-flycutter-05.jpg

    The assembly mounted on my static crankshaft balancer. I think that I have described that in a prior posting.

    Now we come to the reason for the two cutting tools. One is set at a slightly greater radius, about 6 mm, than the other. The tool at the larger radius will hit the work first on each revolution followed by the second tool. I set the first tool at a height suitable for a roughing cut and the second tool gets set an amount lower to act as a finishing cut. In effect this gives me two passes in one. Each tool can be ground differently to suit the different needs of roughing and finishing.

    A double edged fly cutter.-flycutter-06.jpg

    Here we can see the two surfaces made by each tool in turn. In this case the second cutter was set about 0.5 mm deeper than the first for demonstration purposes. In reality one would take a shallower finishing cut.

    Alternatively, both tools could be set such that each removes a similar depth of material, this allows the fly cutter to take double the material in a single pass as compared to a single tool cutter.

    This video shows the setting procedure and a demonstration work piece cut.
    Last edited by tonyfoale; 10-08-2017 at 02:39 PM. Reason: Added video link

  2. The Following 20 Users Say Thank You to tonyfoale For This Useful Post:

    aphilipmarcou (10-15-2017), bigtrev8xl (03-21-2018), Carlos B (10-08-2017), Cascao (10-09-2017), Christophe Mineau (10-10-2017), Jon (10-08-2017), Kevic (07-20-2018), LMMasterMariner (10-09-2017), Moby Duck (10-09-2017), mudnducs (10-10-2017), Okapi (10-13-2017), olderdan (10-09-2017), Papa Bill (10-15-2017), Paul Jones (10-14-2017), Seedtick (10-09-2017), thevillageinn (10-22-2017), Toolmaker51 (07-21-2018), Tule (10-10-2017), UncleBob (07-20-2018), UncleRuss (11-28-2017)

  3. #2
    Carlos B's Avatar
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    Great idea and very nicely done. I will have to keep this one in mind. Thanks.
    From a popular rap: "If time is money then I need a loan."
    Carlos B, http://www.hobbyworkshopprojects.com/

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    Outstanding idea. Nice job

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    WOW!!

    I teach precision machining in a career center and am always looking for great projects to teach manual and cnc machining. YOU HAVE A GREAT PROJECT. It would teach a lot of techniques and can be kept in a future tool maker's tool box. Meet both of my biggest criteria for a project.

    Will be getting a hold of you for a set of plans.

    WELL DONE!

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    tonyfoale (10-10-2017)

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    Really good idea, this dual radius cutters for roughing out and finishing in a single pass.

    I must say I like this photo :
    Quote Originally Posted by tonyfoale View Post

    Click image for larger version. 

Name:	FlyCutter 05.jpg 
Views:	220 
Size:	211.6 KB 
ID:	19965

    The assembly mounted on my static crankshaft balancer. I think that I have described that in a prior posting.
    it reminds me of that :




    Cheers !
    Christophe
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  8. The Following 4 Users Say Thank You to Christophe Mineau For This Useful Post:

    olderdan (10-10-2017), Paul Jones (10-14-2017), tonyfoale (10-10-2017), Tule (10-10-2017)

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    Content Editor DIYer's Avatar
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    Thanks tonyfoale! We've added your Double Edge Fly Cutter to our Fly Cutters category,
    as well as to your builder page: tonyfoale's Homemade Tools. Your receipt:




  10. #7
    [email protected] tonyfoale's Avatar
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    Quote Originally Posted by Christophe Mineau View Post
    Really good idea, this dual radius cutters for roughing out and finishing in a single pass.

    I must say I like this photo :

    The assembly mounted on my static crankshaft balancer. I think that I have described that in a prior posting.
    Christophe,

    My memory has gone, I could not find a prior posting of the balance tool so I have just made one.
    MC crankshaft alignment and balance tool.

  11. #8
    [email protected] tonyfoale's Avatar
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    Quote Originally Posted by vegerj View Post
    WOW!!

    I teach precision machining in a career center and am always looking for great projects to teach manual and cnc machining. YOU HAVE A GREAT PROJECT. It would teach a lot of techniques and can be kept in a future tool maker's tool box. Meet both of my biggest criteria for a project.

    Will be getting a hold of you for a set of plans.
    WELL DONE!
    Thank you, glad that you enjoyed it. I have to disappoint you about the plans, there are none. I very rarely even sketch these simple jobs, they just get made from what I have laying around. More complex things with alternative solutions may get some concept sketches. If it is really important then i draw the minimum on a drawing board. If it is for CNC then i write the G-code directly or use my own G-code generating software written for specific tasks.

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    Jon
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    Congratulations tonyfoale - your Double Edge Fly Cutter is the Homemade Tool of the Week!

    Some nice entries this week: a Lathe Taper Turning Attachment by brianhw, a Finishing Rotisserie by morsa, a Polyurethane Foam Sprayer by Mehanol, a Test Socket by rendoman, Metal Sawhorses by Monte Bennett, a Drawbar Wrench by Markj, and an Angle Grinder Nest by rgsparber. There was also a related Crankshaft Balancing and Alignment Tool by tonyfoale.

    tonyfoale - we've added your tool entry to our All Homemade Tool of the Week winners post. And, you'll be receiving a $25 online gift card, in your choice of Amazon, PayPal, or bitcoin. Please PM me your current email address and gift card choice and I'll get it sent over right away.


    This is your 6th Homemade Tool of the Week win! Here are all of your winning tools:


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    great tool. simple

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