deker Posted January 12, 2018 Share Posted January 12, 2018 So, I have a really large pattern welding contract coming up, and I'm working on the final prototype pieces. This set a new record for me today, so I figured sharing would be as good as excuse as any to return to one of the forums that I've neglected for way too long. I can't say what the end product is yet, but trust me, as soon as I can, I will. Today's work was a billet of 1045/1075/15n20. Just a wee tiny thing, it started at 2"x4-3/4"x10" (about 30lbs). This is to date the largest billet I've ever done, and provided that everything works out, I'll only have to do somewhere between 25 and 50 more of them! After the first weld/draw it was down to 3"x1-1/2"x~21" usable That was cut, ground, and re-stacked by 3 for 75 layers and drawn to 2-1/4"x2-3/4"x~13" usable Tomorrow I'll cut, grind, and re-stack this by 2 once more for 150 layers. Then, it will get drawn to 2-1/2" square and get the living bejeezus twisted out of it on the twisting machine I finished building not long ago, dubbed "Screwcifer". Here's a little video of the first "real" test twisting a 2" square billet. screwcifer_first_twist_2_inch.lrv I'm gonna go find some Advil.... 1 Link to comment Share on other sites More sharing options...
Wes Detrick Posted January 13, 2018 Share Posted January 13, 2018 25 to 50 billets you say? Well, I know what you are doing for the next month or so. Are all of the billets going to be the same pattern? “In the midst of winter, I found there was, within me, an invincible summer." -Albert Camus http://www.krakenforge.net/ Link to comment Share on other sites More sharing options...
Gary Mulkey Posted January 13, 2018 Share Posted January 13, 2018 (edited) Twisting a 2 1/2" square? WOW! You must have some serious muscle running your twisting rig. I think that I'll stick with my little hand twisting set-up that will handle 1/2"x1/2" very nicely. You must have a way of keeping the ends of your billet cool to twist something that large. Edited January 13, 2018 by Gary Mulkey Gary ABS,CKCA,ABKA,KGA Link to comment Share on other sites More sharing options...
Eric Morgan Posted January 13, 2018 Share Posted January 13, 2018 Wow! Link to comment Share on other sites More sharing options...
deker Posted January 13, 2018 Author Share Posted January 13, 2018 5 hours ago, Wes Detrick said: 25 to 50 billets you say? Well, I know what you are doing for the next month or so. Are all of the billets going to be the same pattern? This size is half of the contract, I've got another that finishes to ~15lbs ea that I need to do 50 of as well. In all reality, it will be 6-12 months of work. One piece is random, the other is a twist (but I'm randoming the stock some before twisting to make it a little more interesting). Link to comment Share on other sites More sharing options...
deker Posted January 13, 2018 Author Share Posted January 13, 2018 (edited) 5 hours ago, Gary Mulkey said: Twisting a 2 1/2" square? WOW! You must have some serious muscle running your twisting rig. I think that I'll stick with my little hand twisting set-up that will handle 1/2"x1/2" very nicely.You must have a way of keeping the ends of your billet cool to twist something that large. The motivation behind Screwcifer is a 2HP motor spinning a large triple reduction gear reducer. It's built to twist up to 3" square and still have a reasonable safety margin. So far I haven't worried about cooling the ends, though I may with this billet since I may take the ends to 2" square to save a little on waste and keep me from having to build another set of dies right now. It depends a bit on what bits of steel I find around the shop tomorrow that I can hack a tailstock die together from. Here's a video of the second twist I did with it. First was 1" square, this was 2". Edited January 13, 2018 by deker 3 Link to comment Share on other sites More sharing options...
Gary Mulkey Posted January 13, 2018 Share Posted January 13, 2018 Impressive. Gary ABS,CKCA,ABKA,KGA Link to comment Share on other sites More sharing options...
Charles dP Posted January 13, 2018 Share Posted January 13, 2018 Wow. That’s cool. "The way we win matters" (Ender Wiggins) Orson Scott Card Nos, qui libertate donati sumus, nes cimus quid constet. Link to comment Share on other sites More sharing options...
Hoy's Forge Posted January 13, 2018 Share Posted January 13, 2018 there's a hypnotic factor to viewing that rig in action! Great idea. www.hoyfamily.net Isa 54:16 Behold, I have created the smith that bloweth the coals in the fire, and that bringeth forth an instrument for his work; and I have created the waster to destroy.Lu 22:36 Then said he unto them, But now, he that hath a purse, let him take it, and likewise his scrip: and he that hath no sword, let him sell his garment, and buy one. Mr 8:36 For what shall it profit a man, if he shall gain the whole world, and lose his own soul? Link to comment Share on other sites More sharing options...
deker Posted January 13, 2018 Author Share Posted January 13, 2018 (edited) Thanks folks! I'll hopefully have more more video of 2-1/2" square being twisted at a slightly increased speed soon. Edited January 13, 2018 by deker Link to comment Share on other sites More sharing options...
owen bush Posted January 13, 2018 Share Posted January 13, 2018 thats interesting. makes me wonder what my hydraulic rig would do? forging soul in to steel owenbush.co.uk Link to comment Share on other sites More sharing options...
Zeb Camper Posted January 13, 2018 Share Posted January 13, 2018 Pretty slick! Link to comment Share on other sites More sharing options...
deker Posted January 13, 2018 Author Share Posted January 13, 2018 (edited) 2 hours ago, owen bush said: thats interesting. makes me wonder what my hydraulic rig would do? Owen, The press is around 45ton and it seems to handle it fine. Or did you mean a twisting rig? Edited January 13, 2018 by deker Link to comment Share on other sites More sharing options...
deker Posted January 15, 2018 Author Share Posted January 15, 2018 (edited) Ok, so I didn't get more video. I got on a roll and the GoPro wasn't in the shop. It got drawn to 2-1/4" square, then the section to be twisted was octagoned, and into Screwcifer it went! Drawn out to ~1.75"x1.625"x23" The untwisted ends were trimmed, and onto the surface grinder to get cleaned up. Came out to 1.695"x1.365"x19". Customer spec was for 1.5"x1.25"x16", but they're fine rough machining it down. And a bit of a closeup. The 3 colors of steel in this one are going to make it look really nice. Also, once the customer's final machining is done, it will be a good bit more narrow, so there should be a good bit more of the fun bits on the inside. The other size needed for this order is a slab 1"x5"x10.5". Here's a picture of the matching slab to go with this bar. It gives a better idea of the color contrast this steel mix gives. Ignore the big funky looking smudge across this billet, that's just a remnant from where I used paracord to hang it in the etching tank. (Note: This picture was taken with a flash, but it shows the color contrast much better) Edited January 15, 2018 by deker 1 Link to comment Share on other sites More sharing options...
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