File buttons

Hi All
This is a method I use whenever possible as it is quick easy and accurate to file a radius on a component. I have a tin of these I have made over the last 30 years all types and sizes. Sometimes I get lucky and find a pair of buttons I have previously made. The photos below show the method taken to put two radius on a key. The holes in the end of the key are, drilled 3mm to be a close fit on the clamping bolt. Once the radius are, filed to shape, these holes will then, be opened up to 3.3mm and tapped M4. The reason for this is, if I ever need to remove the key, I can use these M4 threads as jacking points.

Turning and drilling silver steel rod
Attachment 22008

Parted off and faced both end square
Attachment 22009


Heating the silver steel to harden, I do not bother tempering as I feel there is no need.
Attachment 22010

The harden buttons, are clamped in place with a M3 socket cap screw, which is a snug fit in the holes of both the key and the buttons (good engineering term lol)
Attachment 22011

Attachment 22012

Held in a vice and just file down until the file is in contact with the buttons.
Attachment 22013

Attachment 22014

Finished radius.
Attachment 22015

Key fitted with no additional fitting. Nice tight snug fit
Attachment 22016

Thank you for taking the time to view
The Home engineer

The Home engineer,

I have not seen this before and a great method for hand filing a perfect radius.

Thank you for the advice,

Paul

Hi Paul
Thank you for the kind words.
Just another point about using buttons:
You do not have to use silver steel sometimes I make them out of steel due to the size of radius to be cut and leave soft. I could case harden I guess but often it is only one or two radius’s that need filing so I don't bother. I just go a bit more careful when filling with these softer buttons. Soft steel buttons also work on the softer materials Brass, Aluminium etc. However, for best results whenever possible use the hardened buttons.
Thank you for taking the time to view
The Home Engineer

Unusual. Thanks!
---Joe

Hi All
This is a follow up to my post on file buttons. I had to file two radiuses on one component last night and made a button for this application. The other two buttons are the ones I previously made for the key.
The middle button was, machined with a flat so it would fit on the correct centre line of the component and tapped M3. The reason for tapping the button, I did not have a long enough M3 bolt so used tw0 shorter ones bolted from either side. Once finished the two items fitted a treat with no fettling needed. It takes longer to make the buttons and harden them, then to file the radiuses on the work piece but well worth the effort. The tin box is a selection of buttons I have made in the past.

Attachment 22023 Attachment 22024
Attachment 22025 Attachment 22026
Attachment 22027 Attachment 22028
Attachment 22029
Thank you for taking the time to view.
The Home Engineer

<!-- BEGIN /var/www/html/homemadetools/protected/modules/zeus/views/tool/postUpdate.php -->
Thanks thehomeengineer! We've added your File Buttons to our Metalworking category,
as well as to your builder page: thehomeengineer's Homemade Tools. Your receipt:

<div id="blocks"> <div class="block b1 pngfix"> <div class="bimg"> <div> <a href="http://www.homemadetools.net/homemade-file-buttons"> <img src="/uploads/210230/homemade-file-buttons.jpeg"/> </a> </div> </div> <div class="head pngfix"></div> <div class="left pngfix"></div> <div class="right pngfix"></div> <div class="blockover b1 pngfix"> <div class="title"> <a href="http://www.homemadetools.net/homemade-file-buttons">File Buttons</a> <span> by <a href="http://www.homemadetools.net/builder/thehomeengineer">thehomeengineer</a></span> </div> <div class="tags">tags: <a href='http://www.homemadetools.net/tag/file'>file</a>, <a href='http://www.homemadetools.net/tag/radius'>radius</a> </div> </div> </div> </div>
<!-- END /var/www/html/homemadetools/protected/modules/zeus/views/tool/postUpdate.php -->

A good demonstration for something we always need in the workshop, if you have old rotating guides for centering chambering tools like the Ifanger system, it's a cheap solution too for hardened rollers in small diameters.

The key end radii locate the key lengthwise, Bolting the key also provides location. Belt and braces ?

Fantastic!
I love manual methods that simply WORK.

And, the art of hand-filing is all-but-dead (though you have retained and are promulgating it)
:-)

Hi a great tool thanks for sharing.

Just a question from a noob. Wouldn't this method dull your file?

Quote:

---

Originally Posted by eimerbuilt

Just a question from a noob. Wouldn't this method dull your file?

---

That concern always bothered me as well. It's a technique that harkens back to the time when a homeshop mill was a rarity, so I took a different path.

If you have a mill, consider making something like my rounding-over jig...

https://www.homemadetools.net/forum/...ll-parts-27242

Hi
Thank you for your interest
The buttons act as a guide, but when rough filling with a course file this prevents any damage by filling it down too far. So initially there shouldn’t be any contact with the buttons. The buttons are really a safety feature so you don’t file the radius under size and as soon as any contact is made with the button you just stop filing in that area. Damage to your file will only be an issue if you allow the file to run on the button with a lot of pressure. This is a really quick and easy way to produce small radius’s on components that could be difficult to clamp down to a table therefore less chance of damage and setup time ext and a file is definitely cheaper than a milling cutter. This is definitely my preferred way to finish radius’s on components rather than using a milling machine and rotary table when ever possible. Once the buttons are made I simply put them in a designated tin for next time. The buttons don’t necessarily have to be hardened if worried about damage to your files. This method I use frequently both at home and with in my job as a skilled craftsman making components for science research. So I would disagree with Marv that this is old hat. However with modern CNC machines I would definitely agree with Marv that this is not a necessary skill but in my manual workshop it works really well.

Attachment 47028 Attachment 47029 Attachment 47030

This is a copper diesink for spark eroding two castings, as can be seen this component doesn’t offer a lot of clamping area to be clamped down to a rotary table safely.

I hope this has convinced you to try this method and I am sure like me you will like the results.
many thanks again for your interest
The Home Engineer

Home Engineer, I have used this method for some years and it was a favorite with model engineers, I tend to fix the soft buttons to rotate freely on the jig so as not to damage the files. A great way to form cosmetic radius and quicker than setting up a machine thanks for posting.

Nice project, I have a few of these I purchased over the years for modification on gun frames. Thanks.