sometimes you can amaze yourself

[44man]

I have been milling mold blocks and all of my large end mills went dull. I had to keep switching them until one cut OK. I tried sharpening one of the good ones with a stone, then the Moto tool. It cut for crap.
I had just made an order to Enco too and did not order new ones, WHAT A DUMBY I AM! :(
Every single end mill I have, even new ones will leave a ridge between passes too. It gripes me.
I decided to grind one on my bench grinder. First I jointed it by putting it in my mill and locking a stone in the vise. I gently lowered it to the stone and ran the end across the stone with the feed. It came out nice and flat.
Then I clamped a piece of metal to my grinder tool holder at the correct angle and set it to the stone at that correct angle. I did the rest by hand, then changed the angle for more back relief. Then I used the Moto tool with a cut off wheel to take the center down.
I tried a test cut and the chips flew. The cut is as smooth as a fly cutter and there are NO ridges.

[handyrandyrc]

I tried a test cut and the chips flew. The cut is as smooth as a fly cutter and there are NO ridges.

That thing is a BEAUTY. I'd love to see a close-up (macro) view of it.

[44man]

That's about as good as I can get with my Kodak. I have a heck of a time taking pictures. I can do a little bit of everything there is but I am a master of none. Taking pictures or writing really elude me. :mrgreen::mrgreen:

[Cactus Farmer]

A few years ago I bought a tool and cutter grinder for about $ 1200. One of the best buys of my live. I have bought and built many fixtures to sharpen all manner of tools. Yes there is a learning curve but I have enjoyed it all. No excuse for dull tools in my humble shop. I have also aquired some dedicated drill grinders. I have the capability of sharpening from a #52(very small) to 1 1/4". No excuse for dull drills either. I do some custom grinding too. I spend the cash on more toold to broaden my capacity. Your sharpened mill looks very good to me. Congrats on finding another way to save more funds for shooting supplys. :castmine:

[leftiye]

I tried putting this in yesterday, but I guess I did something wrong. Your endmill sharpening job looks muy bueno. Beyond that, pretty is as pretty does ( many women should be told that - ya think?). If it cuts like a razor, what more can ya ask? There is an inexpensive jig they sell to hold the endmill at the proper angles for sharpening, BTW. Amazing one's self is a gooood feeling!

[quasi]

Nice looking grinding job, and it works so you are that much more independant. What kind of a drill grinder does #52 drills?

[spurrit]

I have GOT to get a mill and learn to be a machinist!

[44man]

I have a drill doctor and it does a nice job. But no. 52??? I can't even see the end of the things! :bigsmyl2:
I found a solution to those tiny drills, buy them by the dozen! [smilie=1:
That reminds me of the story about a company here sending the smallest drill bit ever made to Germany. It came back with a hole drilled in it! :mrgreen:

[leftiye]

Try # 83, hee hee..... (you'll need magnification = watch work)

[44man]

:bigsmyl2::bigsmyl2:

[Boomer Mikey]

Good job 44man!

It's twice as much fun when you do it yourself.

Get this book 44man; the book will show you how to make a decent cutter-grinder from a small bench grinder and the fixtures to sharpen most cutters including end mills.
http://ecx.images-amazon.com/images/I/515NRXX53XL._SS500_.jpg

Some websites for inspiration:

http://gadgetbuilder.com/index.html

http://metal.duncanamps.com/index.php

http://www.truetex.com/machinery.htm

http://homepage3.nifty.com/amigos/index-e.html

http://www.homemetalshopclub.org/projects/project.html

http://www.janellestudio.com/metal/

http://www.wrathall.com/Interests/interests_index.htm



I'm not retired yet... I wish I had the time to play with this stuff.

I'm jealous 44man,

Boomer :Fire:

[44man]

Thank you very much. I printed it up so I don't lose it.

[Cactus Farmer]

A Black Diamond Grinder will sharpen a #52. Number 52 bits are not the smallest that this machine will do,It's the smallest collet that I have that fits the holder. I have found three of these amazing tools. NO excuse for dull tools in my shop.:)

[spurrit]

I have a drill doctor and it does a nice job. But no. 52??? I can't even see the end of the things! :bigsmyl2:
I found a solution to those tiny drills, buy them by the dozen! [smilie=1:
That reminds me of the story about a company here sending the smallest drill bit ever made to Germany. It came back with a hole drilled in it! :mrgreen:

I'd heard about that, too. Ya just have to love good old American pride and one upsmanship.

[Boomer Mikey]

The book mentioned above includes plans for a four facet sharpening jig that will do small drills but they are so reasonable in cost that I usually buy new drills for 1/8" or smaller by the dozen.

The book is inexpensive at $12.50 and his milling book is OK too for about the same price.

Both books have many DIY project plans for useful home shop gadgets and fixtures.

Be careful, these books are addictive,

Boomer :Fire:

[Echo]

44 Man - John D Craig (inventor of SCUBA), in his book 'Danger Is My Business', tells of his machinist drilling a hole in a straight pin, to show the crew of an adjoining Japanese boat how precise he could do stuff. A couple of days later, they got the pin back - with a brass bushing in the pin's hole...

[44man]

Now thats a good one. I have to remember that. :mrgreen: