wefalck Posted April 12, 2015 Share #1 Posted April 12, 2015 The work on SMS WESPE has once more stalled a bit, because I got side-tracked by some engineering work. I wanted to first complete the model, but then realised that a filing-machine would come handy when making certain parts … The die-filer is a machine that has all but disappeared from modern workshops. I suppose there are several reasons for this. Many consumer goods and toys that once would have been made from (folded) sheet-metal parts are now made from injection-moulded parts. For more delicate sheet-metal parts also photo-etching is being used. I believe the watchmaking and jewelry industry still uses stamped parts. However, also the methods for making dies has changed. While the stamp can be worked on using milling- and grinding-machines, this is often not possible with the dies, particularly, when they have to have sharp internal corners. The die-filer with its reciprocal, rather than rotary, movement allowed to do this. An inclinable table was needed to work-in the relief that permitted the stamped parts to drop out of the die. Today, electrical discharge machining (EDM) and laser erosion has replaced the old technique. Hand-held filing machines are still in use for work on injection moulds and similar tasks on complex surfaces. In a small model-engineering workshop, the die-filer still has its uses, mainly to work on precision sheet-metal parts and when one has to ensure that the worked-on surface has a defined angle with respect to another. A die-filer can also be used as a scroll saw. For this reason, castings for constructing a simple die-filer are still being sold commercially and and some small specialised machine maufacturers still produce different machines, mainly for the jewelry manufacturers. However, the latter ones are rather heavy and costly. Filing-machine for the jewel-making industry (http://www.walther.ch/hwz/d-fm77.htm) Kit for a filing-machine (http://www.martinmodel.com/MMPtools-subfiles/MMPtools-sub.html) Some bench-lathe manufacturer also offered filing-attachments that were driven from the lathe headstock. As the filing-machine is useful for clock-making, e.g. for working on the spokes of clock-wheels, some people made their own attachments for WW-type lathes and they are highly priced, when they appear at auctions. Cataract filing-machine for their bench-lathes (see: http://www.lathes.co.uk/cataract/index.html) Filing-machine from a 1913 catalogue of an unknown German maker Drawings for a filing-machine from a 1913 catalogue of an unknown German maker Building a filing-machine has been on my agenda for quite some time. With this in mind, I was able to purchase a treasure lot of rare Vallorbe machine-files. The lot contained round, half-round, tri-angular, and square files starting from 1 mm diamater resp. 1 mm x 1 mm cross-section, going up to 4 mm x 4 mm, and of various cuts. Unlike most other types of files, machines files are prismatic across their whole length and have uncut shanks at both ends. Treasure-box with machine-files A selection of machine-files I first thought about converting my only moderately useful Proxxon DS 230/E scroll-saw into a filing machine. However, the table would not tilt and the holders for the saw blade were difficult to adapt. Then a broken jigsaw attachment for a power-drill came into my possession. Having no need for such attachment, the idea of converting it into a filing-machine emerged. The jigsaw was completely stuck nothing moved, and the sole plate was broken off. After having drilled out the screws that held the lid, the reason was obvious: it was completely filled with saw-dust, including the ball-bearing, presumably because it was upside down used under a saw-table. After dismantling and thorough cleaning it worked again. This meant, that I had the mechanism and the casting forming the basis for a filing-machine. The disassembled jigsaw According to the tables in the machine catalogue fo 1913, from which above illustrations were taken, the maximum stroke frequency would be around 400 per minute for hard materials, or less for softer materials. I sourced in China a geared electric DC motor that is rated to have 400 RPM at 12V. The output torque should be sufficient for the machine to be driven directly. Geared 12 V DC motor to drive the filing machine In order to minimise the slot for the files, allowing to work on small pieces, the rotational axis for the tilting machine table should be in its surface plane and also should not move out of the centre line. The foot of the jigsaw was arranged in a similar way and only needed to be adapted. The table will rest on a half-round barrel that can be clamped down onto a corresponding bearing surface. I had some 40 mm diameter alumium in my stock from which I turned the barrel. It will be sawn into half and screwed to the aluminium machine table. The bearing for the barrel was milled accordingly. Similarly, some of the future bearing surfaces on the casting were milled flat, which just went up to the capacity of my milling machines. Luckily the zinc die-cast material of the jigsaw housing is easy to mill. Set-up for milling the bearing of the tilting table Part-machined jigsaw casting To be continued, once I got over my flu ... avsjerome2003, Keith_W, flying_dutchman2 and 14 others 17 Quote Link to comment Share on other sites More sharing options...
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