FILENAMES:

FRW-1-coolant-containment.jpg
FRW-2-cleaning_out_corners.jpg
FRW-4-Pocket_complete.jpg
FRW-5-ready_for_tapping.jpg

DESCRIPTION:

These are pictures of fixturing for a milling job. 

Posted by Fitch R. Williams <frwillia@mindspring.com>. 

The following description was provided:

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This is a tool to hold the material for machining a tone wheel 
to use with a Hall effect sensor for a tachometer.  The tone 
wheel stock will be drilled to match the three tapped holes.  
Then it will be bolted to the tool and the center hole and 32 
teeth on the OD machined using a 1/8" cutter.  I need to make 
a bunch of these - so having the CNC machine to do it is a 
feature.

I have posted the following pictures of the tool as it progressed 
through its machining process in the drop box (www.metalworking.com):

FRW-1-coolant-containment

Shows the aluminum foil containment to keep the cooling oil and 
chips from making a chest high stripe all around the garage.  
With out this it is a big mess, huge.

FRW-2-cleaning_out_corners

This was my first try at area removal.  I set up to remove most 
of the metal between the OD of the circle you can see emerging 
in the middle and the outside of the raw material.  This is a 
1/4" deep cut with a 3/8" 2F end mill.  I use the same mill for 
all the milling.  

FRW-4-Pocket_complete (there is no FRW-3 in case you were wondering <G>)

Here the center pocket (another first for me) has been milled - you 
can also see the completed corners.  The next operation was to mill 
around the OD of the partially machined circle to finish the tool.

FRW-5-ready_for_tapping

This shows the tool nearly completed.  I need to machine two 
registration surfaces on the left rear corner, tap the three 
holes 1/4-20, deburr the edges, and maybe grit blast the top 
surface to get rid of the rust.  

Fitch