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Machining lugs

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Rich250218/04/2011 18:11:06
83 forum posts
3 photos
How do you machine a round bar with a sqare key, or lug on it ?
 
I have a mill / lathe set up.
John Coates18/04/2011 19:56:15
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558 forum posts
28 photos
Make a square jig to sit the round bar in, clamp to milling table then turn through 90 degrees to mill each face of the lug and then face the end?
 
Dusty18/04/2011 20:25:31
498 forum posts
9 photos
Richard, with great difficulty with the equipment you appear to have. I would turn the dia of the bar to size and then on the milling machine cut a keyway into the bar to whatever length and width you require. Now make up a key to fit the keyway, this can be fixed into the keyway with socket head cap screws (allen screws) with the heads lost in the key.
John Coates18/04/2011 21:03:12
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558 forum posts
28 photos
Ahh
 
I thought the lug was on the end of the bar, not in the middle
 
D'oh!
mgj18/04/2011 22:04:55
1017 forum posts
14 photos
Or you can use a bit of round with a square milled on the end. Raise a coupe of burrs to hold it correctly in its hole and silver solder. Best if the socket isn't a through hole, though that may not matter..
 
If the lug is on the end thin I'd mill a slot across the end and silver solder the appropriate bit of square in.
 
Or you can machine a length of bar with a ring on it and do it in several passes under hte mill with a dividing head - thats less elegant, because you then have to skin the final little facets off with a dividing head too.
 
If its a long slot(s) you can just mill the slots and loctite the bit of "spline" in , which is fine since the thrust is taken on the sides of the slot. If the machining is good and tight to width, the Loctite merely locates.

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