Machining A Replacement Pulley With A Keyway

Machining A Replacement Pulley With A Keyway, by Clickspring.

In this video, I machine a replacement pulley for my 1" Delta belt sander. This is a perfect mini lathe project, with some interesting turning between centers, as well as the formation of a keyway using the lathe as a manual shaper.

Be sure to use breathing protection whenever using heat to break a super glue bond.

You can download the dimensioned drawing for this particular pulley for free from the Clickspring website:

Metric: http://www.clickspringprojects.com/up...
Inch: http://www.clickspringprojects.com/up...

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Cameras used in this video:
Panasonic GH5 - https://amzn.to/2rEzhh2
Panasonic X920 - https://amzn.to/2wzxxdT

Tools & Shop Products:
"Solidworks 2013 Bible": http://amzn.to/2FObS1D
Digital Calipers: https://amzn.to/2IkFh4O
Anytime Tools 5 Lathe Mill CENTER DRILL : https://amzn.to/2IThppO
Dormer A190202 Jobber Drill Set, 1.0 mm - 6.0 mm x 0.1 mm Size: https://amzn.to/2DR5fdb
Dormer A190203 Jobber Drill Set, 6.0 mm - 10.0 mm x 0.1 mm Size: https://amzn.to/2ITfeTa
YG1 NC Spotting Drill 8% Cobalt HSS 1/8 to 1/2" 120 Degree 5 Pc Set CNC Machine: https://amzn.to/2G7ylv6
Dykem 80300 Steel Blue Layout Fluid, Brush-in-Cap (4oz): http://amzn.to/2HGPaJJ
Generic Dial Indicator 0.001": http://amzn.to/2FOFTyF
Interapid Dial Test Indicator: http://amzn.to/2FPInwH

For more info on this build, as well as other tool making info and plans, visit http://www.clickspringprojects.com

Ask Me A Question:
http://www.clickspringprojects.com/co...

Language Credits:
Portuguese subtitles courtesy of Emanuel Mendes

Abbreviated Transcript:

00:50 The second is the v-groove for the belt. It's has a 30 degree included angle, and not very deep, so I'll form that with the lathe compound. And lastly, there's the set screw hole, which I'll do on the mill. If you'd like to know the dimensions, I've put a link to some free drawings in the description box below.
01:07 These are the materials I'll be using for the job. I've got this excellent little piece of aluminium that's a left over from another project, although it's a bit too short for chucking, so I'm going to turn it between centers to form the features. So that means I need an arbor, and I've have this nice length of silver steel for that.
01:40 The arbor needs centers on each end, so I set it to run true in a 4 jaw chuck, and then faced and center drilled the ends. Next I drilled and then reamed the slug of aluminium to match the outside diameter of the arbor.
02:35 The work is a nice close fit on the arbor, so a small amount of the glue is enough to hold it firmly in place for the rest of the job provided I don't let the heat from the cutting, build up too much. I formed a temporary center from some hex stock, and then set up the lathe for turning between centers.
03:46 Next I formed the basic profile of the part. I'd like a nice generous fillet in the corner for strength, so I've ground quite a large radius on the cutting tool. a lot of cutter contact when it's right in the corner, but a shallow depth of cut It means there's made the chatter quite manageable.
04:24 Then I set the compound over to 15 degrees to cut the flanks of the groove. I've ground this narrow, blunt nosed cutting tool to do the cutting. It can cut on both sides of the tool, which is going to be handy in this case, to get a matching surface at the bottom of the pulley groove.
05:43 The facing cuts didn't quite get to the arbor, so there's a small burr at each end of the hole to take care of. I used this hand held countersink to knock them off. So with the profile complete, it's time to sort out the keyway.
06:37 I started by feeding in 2 thousandths with each pass to begin with, but as the cut became more established, I had to reduce that to a half thou per cut, and make 3 passes at each depth. I found that any more than that put too much strain on the carriage wheel.
07:11 The cutting action is not unlike that of a
shaper; it makes similar looking chips. And it generates quite a clean cut. So with the keyway finished, the pulley is almost complete; It just needs a quick trip to the mill to drill and tap a hole for a set screw.

References:
MACHINE SHOP TIPS #151 Cutting a Keyway on the Lathe - a new ''abroach" tubalcain
   • MACHINE SHOP TIPS #151 Cutting a Keyway on...  

Machining A Replacement Pulley With A Keyway, by Clickspring.