RE: [TCML] Machining Question - Techniques for Cut-Off Sawing

["Brett Hays" <bretth@xxxxxxxxxxxx>]

Harbor freight's cheapie bandsaw is also good, just replace the crappy blade
it comes with and it's a great saw...I have used the heck out of mine.

-----Original Message-----
From: tesla-bounces@xxxxxxxxxx [mailto:tesla-bounces@xxxxxxxxxx] On Behalf
Of William Noble
Sent: Thursday, February 07, 2008 2:10 PM
To: Tesla Coil Mailing List
Subject: RE: [TCML] Machining Question - Techniques for Cut-Off Sawing


harbor freight sells a cheap metal cutting circular saw that is nice if you
don't need to cut over about an inch thick steel.  beyond that a bandsaw is
good.
 
with your vertical mill, you will need to make sure the head is properly
trammed or you can't be assured of cutting square - but with it trammed you
ought to be able to get .001 or so - but you can't really depend you your
mill for "perfect" square, just pretty good.
 
A facemill is really handy for cleaning up a cut, but what you get depends
on what your mill can handle - my mill has a 6 hp motor, so I can use
relatively larger stuff than the small bridgeports, and if you get the
mill/drill type, you are limited to pretty small facemills before you run
out of rigidy (it's not so much horsepower as stiffness)
> Date: Thu, 7 Feb 2008 19:08:52 +0100> From: f-h@xxxx> To:
tesla@xxxxxxxxxx> Subject: Re: [TCML] Machining Question - Techniques for
Cut-Off Sawing> CC: > > Dan,> > A band saw is the best, a reciprocating
power jig saw the next choice.> > YMMV, but where I come from, it is usual
practice to cut the raw blocks > 2mm or 80thou bigger than the finished
object.> > First you machine one face, next, you clamp this face against the
fixed > jaw of the vice, and machine another face.> To make sure that the
machined face is orientated against the fixed jaw, > you should press
against it with one single point, instead of the whole > moving jaw. A small
block of phenolic, placed btwn. the moving jaw and > the workpiece, is a
good choice.> > You now have 2 faces that are square to each other.> >
Clamping one of these faces against the fixed jaw (with phenolic between >
the moving jaw and the workpiece), and aligning the other machined face > to
be vertical, with a machinists angle, you machine the 3rd face.> > After
this you have 3 faces each perpendicular, and these faces can > serve as
reference to the milling operation that brings the block to > it`s desired
dimension.> > On properly finished parts, all faces are machined.> > Hope
this helps.> > Cheers, Finn Hammer> > > Mccauley, Daniel H skrev:> > > >
Just getting around to finally investing in a vertical mill, and am> >
looking at what options there are for a cut-off saw.> > Do you typically
just make a rough cut and then use the mill to> > "perfect" the cut, or get
the best possible cut right off the bat> > using a cut-off saw?> > > >
Dewalt and Milwaukee (as well as others) sell some inexpensive metal> >
chop-saws, but not sure how well they work for soft metals like> > aluminum,
brass, etc... and plastics.> > > > Any help appreciated!> > Thanks!> >
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