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Thread: The Journey for a Master Square
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28th February 2013, 12:00 PM #31Intermediate Member
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I have almost finished a pattern for a 200 x 300 x 50 (ish) CI square. It should be on its way to a foundry next week. Not yet sure of the price each, or which foundry the patternmaker uses.
Neil
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28th February 2013 12:00 PM # ADSGoogle Adsense Advertisement
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28th February 2013, 12:06 PM #32Senior Member
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28th February 2013, 12:18 PM #33SENIOR MEMBER
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28th February 2013, 12:57 PM #34Senior Member
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I found it on a UK site advertised as a "half box level".
USED METROLOGY EQUIPMENT SUPPLIERS USED ENGINEERING TOOLS TRIMOS TESA SUPPLIERS WESTERN TOOLING BRISTOL UK
I sent an email to ask if it was magnetic and triangular and luckily it was. It was from 2007 and I paid less than what "hotwheelinmum" was asking ).
I'll post a picture in the euro tool thread.
Christian
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28th February 2013, 02:04 PM #35SENIOR MEMBER
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Castings
Neil,
I like your pattern, I would be interested to know where it ends up being cast.
Casting it myself seems the most appealing, second most appealing is getting someone else to do the fun part. Third is finding a crappy set of blocks and getting them up to spec, fourth is chopping up a machine beyond rescue.
I have sent off inquires to three different foundries, Grigsby, Wagga, and Billmans (Castlemain). I will see what comes back. If the price is too high it might be a trip down to the scrappy to find something I can make a cupola out of...
I did a quick FEA on the square and it will take a 100kg sideways force to push it out of square by 1.7µm, the box alone without the struts would move 0.04mm with the same loading.
PS Added a couple of handles.
Master Squares.JPG
-Josh
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28th February 2013, 02:24 PM #36SENIOR MEMBER
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Grisbys got back to me, their prices are very reasonable, enough so to make it a feasible option, cheaper than buying an old worn out block and shipping it.
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28th February 2013, 02:26 PM #37SENIOR MEMBER
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Now just to wait a few years for the cast to stop moving
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28th February 2013, 02:39 PM #38SENIOR MEMBER
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28th February 2013, 03:35 PM #39Intermediate Member
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Hi Josh, try this:
http://www.dtic.mil/cgi-bin/GetTRDoc...c=GetTRDoc.pdf
Stress relief of grey cast iron.
An old US Navy document.
Neil
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28th February 2013, 03:51 PM #40SENIOR MEMBER
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It depends on what temperature you take it to. Basically the hotter the temperature, the shorter the cycle and the more complete the stress relief. However (oh but so often there's so often a "however" ), IIRC there can be some be some metallurgical changes at the higher temperature that may not be desirable. I recall reading a paper on this some time ago, it's possibly on my machine, but I have no idea how to post a pdf. Around 600 C for 6 hours (at full material thickness) with a slow cool rings a bell, but don't for goodness sake quote me on that. I just remember the 600 for 6 rule.
I still have half a cuppa, and not much argon left, so I'll try to chase up the paper and then either see if I can either post it or find it on the net to post the link.
Pete
PS not trying to on any parade, nor doubt your casting ability, but if this is a master square you're building here, and based on some of the tolerances I've seen (admirably I might add) achieved and being called for, I wouldn't suggest casting your own. Anyone who has gone through the process of manufacturing or procuring precision cast references, such as the straight edges we bought a while back, knows that "iron ain't iron" when it comes to this field. My 2 cents for what it's worth, but hey, what would I know.
Edit: Oh Neil beat me to it, I'll need to type faster/drink slower. Yes I think that was the paper I had in mind.
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28th February 2013, 04:42 PM #41SENIOR MEMBER
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I think you are right, a professional foundry has a better control of the quality of the casting than I do.
Cool thanks for info guys, I'm also having a re-read of the cast irons sections of the Heat Treater's Guide - Practices and Procedures for Irons and Steels by The Materials Information Society.
-Josh
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28th February 2013, 05:06 PM #42SENIOR MEMBER
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28th February 2013, 05:38 PM #43SENIOR MEMBER
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For low alloy Grey Iron with 2.5% to 4% carbon and 1 to 3% silicon.
Summary:
Ferritizing 700-760C cool at 110C-290C/hr
Full annealing: 790-900C furnace cooled from 790 to 675C
Graphitizing: 900-955C hold for several hr/inch
For maximum strengh air cooled to 540C
For maximum machineability furnace cooled to 540C
For both cool from 540-290 at rate no more than 110C/hr
Stress reliving with minimum carbides:
540-565C for stress relief > 85% use 595C soak minimum 1hr/inch
furnace cooled to 315C or lower to as much as 95C for intricate parts
Normalizing:
885-925C soak at 1hr/inch furnace cool
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28th February 2013, 06:16 PM #44SENIOR MEMBER
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Another Rendering.
MasterSquare HiRes.jpg
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28th February 2013, 08:14 PM #45Cheers,
Joe
9"thicknesser/planer, 12" bench saw, 2Hp Dusty, 5/8" Drill press, 10" Makita drop saw, 2Hp Makita outer, the usual power tools and carpentry hand tools...
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