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Big single point fly cutter - construction approaches

Dabbler means like so. But you have to ensure the tip extends sufficiently because this is usually intended for a hole boring where the head is going through vs traversing across.
And as Tom is suggesting, could be flex depending on max shank diameter & radius.

1618942357724.webp
 
This is a solution for very light surfacing operations, which is what I think Janger was referring to.

There's always many ways to skin the proverbial, each with advantages and disadvantages.
 
Dual cutting tool (staggered vertically). Holy crap I thought he was joking about DOC on the demo but... anyways you'll see. Not sure I would attempt this in steel.

 
Yet another, maybe a bit over-engineered but his take on adapting to spindle arbor. More reasonable rpm.

 
Article in the July/August 2021 edition of "Home Shop Machinist" entitled "A Boring Fly Cutter for the mill". Relatable to this thread -- author builds a 5.75" cutter on an R8 arbor (machines own arbor). Uses HSS inserts etc.
 
In the conclusion of the article, they reference a book from 1991 "The Shop Wisdom of Philip Duclos" which has an article on a "Super Colossal 10" Fly Cutter".
 
@kevin.decelles - I just read that article last night, and I liked how he approached it as well. Props to the guy for making his own arbor too, but a commercial cheap one would work as well. Now got another thing on the "once I have time to do it" list, lol.

Chuck Bommarito also did a video about a month ago about fly cutters and showed one he's had for years called a "Happy Hogger." It looks to be aluminum and sounded like it was a bit loud how he was using it, but he was running it on a Bridgeport style mill. Seems to work ok but his head might need a re-tramming.


He also has one made from bar stock from his buddy Chui, but I don't like the idea of a lawn mower at belly height that is harder to see than a disc. Might not be copying that patent in my shop, lol.
 
Just idle curiousity, but I wondered about feeds and speeds for a effective 10 inch cutter! According to the Little Machine Shop calculator, the recommended rpm for a 10 inch cutter in low carbon steel would be only 34 rpm. (Roughly 1-steambolt, 2-steambolt for one revolution!!) And the suggested feed rate would be 1 inch per minute. with a 40 thou chip load. That would need some serous torque!

OTOH, I have no practical experience with a cutter like that. Maybe the calculator is all wrong?

https://littlemachineshop.com/mobile/speeds_feeds.php

Craig
 
@trlvn I'd go around 60RPM myself and less than half the chip load, around 15 thou per revolution - with lots of coolant. Otherwise it sounds about right.
 
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