TigerTail Posted July 9, 2011 Posted July 9, 2011 (edited) I have some 1/2" brass rods that I plan to cut to form the milling media for my 4" jar. First of all, is 1/2" the best possible length for these 1/2" diameter rods? How should I proceed with cutting them in size? I have a drilling machine with a cutting disc which is 1.5 mm thick. Is this okay? Also I have no clue how to use it so can someone please tell me in detail how to proceed? I need to know even the obvious details like how to hold it, when does the disc need replacement, how to keep the rod stationary, how to keep the cut straight and how hot should the machine get before I need to stop? I think I'll be producing a lot of brass dust. Is it of any use? Please excuse me if I am asking for too much. I have never used a power tool before and I think I really need to be spoon fed on this topic. Please bear with me. Any help will be greatly valued.(err.. Do I need to re-frame my paragraphs?) Thanks. Edit: I do not have a vice or clamp so please suggest alternatives. Also, does brass cutting cause sparks? I tried it and it didn't produce any. Edited July 9, 2011 by TigerTail
dan999ification Posted July 9, 2011 Posted July 9, 2011 if your using a pillar drill with a cutting disc i would expect the disc to be horizontal this alone is probably a bad idea at eye/head/chest level. ive been hit by a half mooned disc [paddys motorbike] that went through a fleece jacket a jumper and 2 t shirts before stopping on my skin thank god i had so many layers on. is it a handheld drill?cylindrical media is generally as long as it is in dia but "I" think 3/4" media is better for your jar.if you have never used a power tool before and have no confidence do not hold the rod while cutting, any movements could cause it to bite and snap the blade or pull you in, most diy injurys are caused by people not using the proper tool for the job. there are no alternatives for clamps unless you make some from wood and screws.whos machine is it? ask them.brass dust is no use to us.cutting brass will cause "hot sparks" if you cut fast or with a hot blade slow progress with a hacksaw is what i would choose, you only have to do it once, even cutting with an angle grinder on the ground would probably fling the media around and leave sharp edges that require more cleaning up than the saw method, a chop saw could be used for a straight cut but still messy.wait until you have a safer method before you proceed. dan.
drthrust Posted July 9, 2011 Posted July 9, 2011 (edited) when i first started out in pyro, i had the same thoughts on how to cut lots of brass bar, firstly i tried a hacksaw, ( phew! hard work)then i had great success with a electric jigsaw with a metal cutting blade fitted, with the brass rod simply held by my foot on a wooden block so that the rod protruded out from the block four inch's to facilitate cutting, although i would recommend you bought a vice . if you end up becoming a pyro junkie and have a lot of metal to cut for media and tooling then you'll be needing one of these! http://www.youtube.com/watch?v=4xhsjJwSIT4 Edited July 9, 2011 by drthrust
Bonny Posted July 10, 2011 Posted July 10, 2011 Cutting brass with any sort of grinding/cutting disc is a bad idea. (Most) abrasive wheels will clog from brass grindings, as they are not meant to grind brass. This could cause the wheel to shatter. I know this is not likely to ever happen, but something to consider. Cut it up with hacksaw or a reciprocating saw if you have no access to a bandsaw. Another option is to go to a machine shop or welding shop, they will likely have an ironworker that can shear the rod up into short pcs in a minute or so. As for the burrs, just run the media alone in your mill for awhile and they will get cleaned up nicely.
dagabu Posted July 10, 2011 Posted July 10, 2011 Another option is to go to a machine shop or welding shop, they will likely have an ironworker that can shear the rod up into short pcs in a minute or so. As for the burrs, just run the media alone in your mill for awhile and they will get cleaned up nicely. Absolutely! I worked in a metal shop for a decade after the gulf war and the ironworker is the best way to cut any rod in huge numbers. -dag
TigerTail Posted July 10, 2011 Author Posted July 10, 2011 Machine shop guys seem to be hostile towards my 'petty' job. I have tried them before and so I know they will do some real shoddy work. Also, doing something yourself is the only way to learn it, so yeah I prefer cutting them myself. The machine is mine, bought very recently so I have no experience yet. It is hand held. Now that it is inevitable I'll buy some vice/clamps too. Cutting with a hacksaw is very laborious and time consuming and I am sure after a few cuts I'll learn to cut it neater with the cutting wheel. Is the 1.5 mm thickness of the wheel fine or do I need to find a thinner one? Also is it okay to put the newly cut media in water to cool them? I mean rapid cooling makes steel brittle, does it have an effect on brass? So in a nutshell, if I learn to use the cutting wheel and buy the necessary tools, then what would you guys suggest : Cutting wheel(neater cut, faster) or hacksaw(slow, laborious but safer)? The reason why I wanted to know about sparks is that I fear my cutting wheel doesn't work up to the mark. Actually the wheel isn't originally compatible with the drill. I am using a makeshift adapter for it, leading to my concerns. Thanks.
dagabu Posted July 10, 2011 Posted July 10, 2011 (edited) Brass does not spark at all, hack saws will work but cutting wheels will only load up and not cut. -dag Edited July 10, 2011 by dagabu
guntoteninfadel Posted July 11, 2011 Posted July 11, 2011 (edited) Machine shop guys seem to be hostile towards my 'petty' job. I have the same problem! I had to have a piece turned for my tractor the other day and it was if I was asking the guy for a kidney. I would have easily paid twice what they charged just to get them to act like I wasnt a pain in the ass. That being said they are now turning a piece for my tiller. Guess I like the abuse. TT I do not know what resources is available in India, but in the US individuals can rent some pretty heavy duty tools for the day at local home stores. Here one can rent a nice metal chop saw for not much on Sat and not have to return it untill Mon. Gun Edited July 11, 2011 by guntoteninfadel
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