I'm on my phone now where my photos are.
Here are all the sleeve "cups". Because they're only .080" wall I leave .170" solid material on the back so the chuck doesn't crush the cylinder. Next operation will be to part the solid end off to length. I made a plug that goes in the open end so the chuck doesn't crush.
Then after that I have two plugs to mount the cylinder between centers and turn the OD. 3 operations, kind of annoying and time consuming but I don't have a 3" spindle bore to load the whole bar - which is how this part was done previously.
Then it goes into a dividing head between centers in the VMC and the slots get cut. A 4th axis would be nice for that but I'm told it's not economic. So, start cycle, hand crank dividing head, start cycle again, repeat a whooole bunch of times.
Previously I milled them manually with a 1" end mill which is time consuming and creates too much vibration.
The other job on the bench currently is a very large cable link chain roller pedestal. I argued about this one... it's 9.5" OD x 14" long. And everything is minimum .500" thick. The plate is .500", the end plates were 2", the cylinder is 1" wall. All on a 1" shaft....
You can buy this assembly from a catalogue made from 1/4" plate with rolled flanges (pictured). But they want a heavy duty one. Well, heavy duty is what they designed... I turned the end flanges manually. Turned a step on the interior facing side and turned a mating pocket on the cylinder. Machined the 3 pieces to snap together prior to welding. So I could machine them true without relying on weld alignment which was how they designed it. Finished that up Friday.
I popped back in last night to weld it all together. That way Monday it's fully cooled and settled into whatever pretzel it will flex into. Monday I will finish turn it.
Fun point will be, the initial design has the OD Larger than the max swing over carriage of my lathe - which I did not notice during all the design arguing... it wasn't until I grabbed the 10" x 2" end discs and realised my lathes over carriage capacity is only 9.5... crap...
I spoke to Andrey and he just said to make it 9.5. Phew. Except, 9.5" is what's written in the books. I haven't actually tested this yet... I turned the end plugs to 9.5, which is easy to do regardless of the max swing. However, I have protective coolant/chip covers all over the saddle and cross slide I will have to take all that apart Monday to see if it's ACTUALLY 9.5"... I need. Bigger lathe...
I was recently eyeing this guy a few hours from me. I could sell the small 10" hobby lathe I've had forever for enough money.
https://www.kijiji.ca/v-power-tool/brockville/yamazaki-metal-lathe-21-x-80/1654970401Anyways, this is already long winded. Tomorrow's a new day, new challenges.
We really need to find someone to hire. I need some help in a real bad way. I have piles of jobs in the shop. I can run two jobs at once usually (CNC and manual) but I often need two manual jobs happening at once.