How best to make this flyweel.

Hello, I am not new to this forum, but was having problems logging on so I have had to open a new account.

I have to make two flywheels 13mm wide 95mm dia out of a 50mmx100mm aluminum round. The axle is 3mm

I have a sx2p milling machine and a lathe, the chuck will take 100mm if I reverse the jaws.

I have my own ideas how I can do this,but would like to know other techniques, other problem is parting off 95mm, or go so far the use a hacksaw.

Thanks for any replies

Hi Robert

This is how I would do it.

Pre face the workpieces if they are hacksaw cut.

As it is aluminium and fairly easy to turn I would glue the disk to another 10mm smaller diameter disk fitted in the chuck.

There are lots of adhesives Loctite for example, that will release if you heat them.
Jewellers often use shellac

Then:

Drill a 2.5mm hole in the center.
Bore the hole to 3 mm (You will need to make a tiny boring bar from high speed steel).
Face the disk.
If the flywheel is recessed, recess one side.
Turn the edge of the disk to 95mm diameter.
Turn the back 5mm of the edge of the disk, this will assist setting it up to machine the other side later.
If the edges need chamfering do them now.

Then:

Unglue the disk from the mounting disk
Using a 4 jaw chuck remount the disk (protect the turned edge with thick paper)
You can use the two turned edges to set up the piece accurately with a dial indicator.
Face and cut the second recess if needed.

Cheers
John

Thanks for your advise John, but I have to get two flywheels out of a 100x50mm round billet, and parting off is going to be a problem.

I think my only way is to part off around 20mm then use the hacksaw.

I was going to buy two 100x 25 disks but I thought I could get three out of the 100x50, but I have created hard work for myself.

Thanks Bob

Hi Robert,

Buy a band saw, and make jaws to hold short parts. You will never regret it.

Hope this helps.

Peter.

I think I would put the 50mm long billet in the chuck, face the end and turn about 16mm length to the 95mm dia. Then spot or ctr drill followed by drilling and reaming and add a small chemfer to teh hole.

Now with tailstock centre for added support see how far you can get with a parting tool and finish with hacksaw.

Do the same again and then finish the opposite side of the two flywheels to remove the saw/parting marks

This is one I did a couple of weeks ago, pic shows first side and OD machined just prior to parting/sawing.