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Old October 3, 2011, 09:31 PM   #1
4V50 Gary
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Drill a square hole anyone?

Drill square holes anyone? This video is amazing and (besides pretty women) is Japan's greatest gift to mankind. Link

Milling just got easier.
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Old October 3, 2011, 09:51 PM   #2
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Here I was, expecting some kind of new broaching tool...

...watching a milling process that resembles a rotary engine, more than a drill.

Pretty sweet.
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Old October 3, 2011, 09:55 PM   #3
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I must have missed the pretty women. Now the next question is are they going to make square bolts for the square holes?
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Old October 3, 2011, 10:41 PM   #4
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Square bullets anyone?
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Old October 3, 2011, 11:18 PM   #5
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Not new.

Invented in the 1800s.
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Old October 3, 2011, 11:18 PM   #6
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"Square bullets anyone?" Puckle-Gun..cylinders for both round & square bullets..round one for Christians..square for Turks.

Last edited by Ideal Tool; October 3, 2011 at 11:24 PM.
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Old October 4, 2011, 03:25 AM   #7
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I did not go to the link,but as I recall,a three flute drill in a floating holder will give a four sided hole.
Most of us know how to drill a three sided hole in sheet metal with a two flute drill.
I spent some time running an old 1950 something American Broach machine.
The limitation on a broach is how much chip you can pull in the gullet of a tooth.But,doggone,what an efficient,amazing,simple machine!!Squares,dees,splines,.Its perfect for a part like an AR barrel extension.Old school,but,load the part,load the broach,and draw it though!!
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Old October 4, 2011, 09:17 AM   #8
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I just use our EDM machine.
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Old October 4, 2011, 10:53 AM   #9
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It doesn't drill square holes , it squares drilled holes , big difference !
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Old October 4, 2011, 02:08 PM   #10
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mkk41,I have done a lot of sinker edm work,and they are a great tool.
But,for many applications,the broach is far more efficientThis thing stood about 8 feet tall,and part of it was below the floor.I'd guess the hydraulic ram was 6 in or 8 in.It had a chuck type fixture that would hold the lower end of the broach,easy load/unload.It worked below the table.There was a floating center for the upper end of the broach.The broaches themselves were 2 to 3 feet long,most of them,except for the real small ones.

But you just clean the fixture on the table,load the part, the broach through a hole in the part,and draw the broach through.A typical "cut" might take 3 to 5 seconds,to to what an edm would take several minutes to a chunk of an hour to cut.If you are blasting with the EDM,surface finish will be rough.To get a fine finish,takes time,and generally another electrode..And,the broach leaves no recast skin,subject to cracking.

A man on a broach can go through,say 5 or 8 different setups in a shift,and pull 30 or 50 or 100 parts each setup.

I love the EDM,I built molds.But an old broach is a producing machine!!

I have also used similar tooling on an old Monarch EE toolroom lath to make 6 sided allen wrench pockets.

And,agreed on reshaping a drilled hole,the broach is a through hole machine.It wont do a blind hole

Last edited by HiBC; October 4, 2011 at 02:13 PM.
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Old October 6, 2011, 06:55 PM   #11
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Oh, a mortising machine! Wood guy here.
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