example

I have found a niche for my casting and CNC machining desires. It is the designing and creating small custom bells to be cast in silver, brass and bronze; also using bell metal if I can find or make it. Bell metal is high tin content brass.

I am currently working on obtaining the correct wax for CNC detail machining of the designs. My two Taig mills, one of which set up for fourth axis millings are perfect for the size of bells I am considering. That is, bells with a diameter between one and two inches at the open end. I figure they may be one to two times the diameter in height for the bell section. Then whatever is used as the handle or bell mount.

I will pocket mill the bell interior from the end of the wax cylinder, probably using a ball end 2 flute tool. Tool size will depend on the bell diameter and depth. Perhaps 0.250″ on larger size bells down to 0.125″ on small bells. No interior details, just hollow out. The 2nd set-up to do the exterior will be milled on 4th axis rotary, roughed with perhaps 0.25” ball end before details. As far as the detailing I have used as small as 0.003 tapered wax milling bits Like an engraving bit (many hours of run time) making medallions. That is probably not typical for my bell project but could be the extreme. Most likely I will use 0.010-0.020 mill end sizes. I buy my wax bits from Bits&Bits and they are especially made for detailed wax carving, spiral open flutes, etc. Initial trial runs will not be detailed. Just get something basic to carve then cast and see results.

I am thinking this is a perfect combination of my skills and… Continue reading →