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MakingandUsingReamers

part1

BillHaneman

Dbits

ifendisformedproperly,theyareselfcentering requirefrequentchipclearing userelativelyslowly relativelyeasytokeepsharp

simpleboringtools

seeD.M.Quinn,Lowtechbits,Pipesand PipemakingCDROM

parrotnosebit Dbit

anglednose,reliefincuttingedge

gundrills

fast,selfcenteringandcoolrunning

still,betterfinishandcenteringifnot pushed ideallywant90110psi 3m3/hrifusinglargerbits,largereservoir helpful notallthesame;get'modifiedhighland' profile

chipclearingisautomatic

differentcouplingsavailable

usinggundrillstostepbore

borefromlargetosmall

smalltolargecausesdrift,aslargerholetendsto runtangenttoprevioushole therearereportsofspeciallyprofiledgundrillsthat selfpilotlargetosmall(pilotonnose) eventhoughsurfacefinishforstepboringprobably isnotimportant

pilotingbitsareimportant

remember,speedisoverrated

stepdrilling(cont.)

allowforanynonconcentricity

myapproachistostepdrillwith0.5mmclearance onsides

fixedsteady

socketreamers

Iusecommerciallefthandspiralflutedstraightreamersforfinalreamingof dronesocketsandinafewotherplaces

holeispreboredtoatmost1mmundersize onlythefirstmmorsoactuallycuts reamershouldspinslowly,withfrequentchipclearing whenboringdronesockets,Iguidetheslidewiththetailpiece,ontothe reamer(aidsparallelismandconcentricity)

Makingconicalreamers

firstdecidewhatyourreamerprofile(s)should looklike multiplereamersgiveflexibility,alsosolve problemofdifferenttooledgespeeds

onnarrowerpartsofbore,reamermovesmore slowly alsoeasiertocorrectforamistake,lessworkto discardifyouscrewup

Asamplereamerplan

planforreamer stepsof510mm length

'fit'thistoyour targetbore(s) checklengthto allow adjustment, perhapsallow forreuseona longerchanter?

turnsuitabletoolsteelrodin'steps'

chucksecurelywithminimumoverhang

colletchucksareideal,anindependent,handcentered3 jawisfinebutslow,selfcentering3jawprobablyOK

firststepmaybeacylindrical'nose'

mustbeundersizetoavoidhigherpartsofbore helpswhenclampingpieceformilling

borepilotholefortailstock nosemayneedtobeturnedwithouttailstocksupport

onestepatatime

turneachsteptothe'maximum'sizeforthesegment,or~0.001/0.03mm oversize carbideisOKbutdecenttoolsteelseemsevenbetter,forcuttingnonheat treatedrod checkwithmicrometerasyougo

stopthelatheofcourse

takeoffthe'steps'

engineer'sbluingisgood carefulnottogoundersize

canbecorrected,painfully,bymovingyourtargetdiameterslaterally

goslowwhenonlylinesremainabrasivesarebestatthispoint accuracywillimprovewithpractice,butislimitedmostlybyyourpatience

remeasureandfinetune

remeasurewithmicrometeronewitharatchetisagoodidea

bestisonewithflatanvils,butcanmakedowithroundonesifyouare careful markthedistancesfromthetipwithathinindeliblemarker

checkagainstyourtargetbores,lookingforbestinsertiondepth youcanputbackonlatheandadjustwithfiles/abrasivesifyoudon'tlikethe results

thisisthelastchancetofixthis,asyoucan'treallydoitoncethereamer hasbeenmilleddowntoaDprofile

(calibrated)verniermicrometer,0.001mm incrementwithratchet

from'cone'toreamer

millingoperationonlyneedstobe approximatelymidline

butnotovermidline! justover50%thicknessallowsforsharpening

initialclampingistricky,butshimsofsoftmetal shoulddoit

thereshouldn'tbemuchlateralforceontheblank anyway,sincecuttingspeedsanddepthsshouldbe modest

amicromillisenough

oryoucanusehacksaw(ugh!) smallthroatreamerscanbe groundonawetgrinder

thistendstobehardon wetgrindingwheels

thentheresultcanbefiled moreflat,ifuneven theninsidecanbehollow groundonwetgrinderand dressedwithfinestone/hone

withluck,youcanreusereamers foranotherdesign...

thereareotherformsofreamers

forinstanceflatreamers 'bayonet'reamers 'squaresection'reamers flutedreamers

spiralflutedreamersthataren'tstraightarevery hardtosharpen

'spoon'reamers

JohnHughesreamer4straightflutes

asdescribedin'AMethodofMakingReamers',SeanReidSocietyJournal v.2,Mar.2002

MichaelCarneytools

flatreamers

usedtogoodeffectbysomemakers resharpeningchangestheirdimensions maybepronetochatterorcreate'lobes' dimensioningtheminthefirstplacecanbe difficult

theycutonthediagonal,whichchangeswith thickness/widthratio

initialreamingablank

Iliketoholdthereamerinthelatheatslow speed(125RPMorless) allowscontroloverblank goslow

avoidoverheating ditto Ilikelinseedoil,haveusedpastewax

clearchipsoften

usenonwaterbearinglubricant

finishreaming

checkborewithgaugestojudgefinalreaming depth

reamerinsertiondepthcanbemisleading,dueto woodmovementandelasticity

somethermalmovement,remember mostbilletswillshrinkabit

givesometimetosettlemonthsideally youmaywishtoreducelubricationatthisstep,to avoidbuildup

handreamuntilspotchecksmatchup

cautions

carefulwithbilletsthatmayhavewarped

reamtoogently,andyourboremaynotmatch reamerprofile useenoughpressure,ifpractical,thatthereamer flexeswhennecessary toomuchpressureorspeedcancause overheating,orevenwithhandreamingcancause unevenresultsduetotimberelasticity

ovalborescanresult