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New turn on rosettes
Question
Forum Responses
From contributor B: In my experience you're going the wrong way with regard to RPMs on the drill press. When I used to do these, I added a secondary pulley on my press to kick the spindle speed up to around 6000 RPM. This worked much better than at the factory max speed of 2300. I also added 3 brass screws drilled and tapped around the quill to tighten against the spindle sleeve. This took a lot of play out of the spindle. I also ran braces from the press table to the floor and wall to try and stiffen it. All these were little bit items that added up to make for about 80 to 90 percent success rate. Took a lot of time to set up, though.
I have an Amana bit and could not make it work with my drill press. I bought a mill/drill from Jet, much heavier than my drill press. The bit fits into a R8 collet instead of a drill chuck. You just need more mass. From contributor B: Actually, I also experimented making them in a friend's Bridgeport. I experienced many of the same issues that I saw on my drill press. My tear out rate remained about the same. I think the runout on a drill press is the big problem. I ran some on mine, had tearout at slow speeds and chatter at high speeds - enough that it bent the tapered shaft! I wondered about mounting it in my mortiser with a chuck, as it seems stiff enough. Anyone tried that? I also felt that the wood (red oak) was too dry and caused some of the tearout - it was less than 6% by my meter. Maybe it would mill better closer to 9%?
I use a 3 1/2 horse electronic plunge router at 500 RPMs with about 20% tear out. I have been using a Carbon-Tech solid body cutter. There is an R200 Rosette Maker, which turns at 7500 rpm with no vibrations for tearout. Air over hydraulics. All automatic. Stock it and come back when rosettes complete. From contributor J: One person mentioned trying a mortiser. We tried our Kolle slot mortiser today to turn 60 alder rosettes. They were flawless with only one reject. Way better than the lathe we had been using. From contributor B: Contributor J, be careful with the RPMs at which you're running your rosette cutter. If it is a removable knife type, it will have a maximum safe RPM speed (as will any large cutter). I know of an accident that occurred 6 or 7 years ago where someone was running a rosette cutter in an overhead router at about 22,000 rpm. The cutter came loose and the guy's wife is a widow.
From contributor J: Thanks for the caution. The Kolle runs at 1500 and 3000 RPM. 3000 seemed to work good. The highest speed allowed for the Amana cutter is 10000, with 6000 advised for wood. I think one of the biggest dangers with this is the cutter itself. I am going to build a guard around it next time. The comments below were added after this Forum discussion was archived as a Knowledge Base article (add your comment). Comment from contributor I:
The comments below were added after this Forum discussion was archived as a Knowledge Base article (add your comment). Comment from contributor K:
Comment from contributor O: I had the same problem with tear-outs. I tried soaking the wooden blocks in water and then turning them. This worked well with no tear-out but the blocks warped. I then stacked them together and clamped them face to face, put them in a 150 deg. oven and let them dry for several hours. Problem solved. I also turned them at about 1800 rpm. If they started to dry I sprayed a little water on the cut.
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