I'll definitely second the "sharp tools" advice. I ended up making new reamers for that very reason (and not just for Delrin). I used to use D-profile reamers, but they only have one cutting edge and they produce massive amounts of friction. So instead I manufactured 4-flute reamers and distributing the cutting load over four different blades really made a difference. Much less friction, sharper edges and of course they don't dull as quickly. Sharp is good.an seanduine wrote:When I trained as a machinist, I found I had to adjust the cutting geometry for efficient machining of small delrin parts. Threading in particular, especially cross sections of about .375 in.,were especially problematic. The delrin exhibited a lot of 'rebound' due to the 'toughness' of the material. I think a 'scraping' action would have been more effective, but rather that modify the rake of my cutters, I abandonned the project.
My experience making chanters is limited to three or four prototypes. The throat diameters were between .281 in. and .187 in. To successfully ream such bores with accuracy would probably involve hand reaming with very sharp tooling and very little force. Considering all the other hours involved with making all the other parts of a set, I, for one would view such a prospect with apathy.
Other plastics might be more appealing from a machining perspective but I'm not sure about customer acceptance. Woods of various types are well accepted. Even with wood, the reamers could be seized, and are quite 'wiggly' as it is. I used a single reamer method. Even using staged reamers still confronts the narrow bore problem, and demands acute sharpness to maintain the integrity of your designed bore profile. But, don't let me discourage you
Bob
I had heard similar observations about Delrin on a visit to the Practical Machinist forum. I've been fortunate so far because I do cut threads in Delrin for my Boehm headjoints (I have developed a threaded metal tenon that screws into a Delrin-lined, threaded socket on the headjoint, obviating the need for glues). Basically a removable tenon. There was a learning curve with the Delrin, for sure, but it's such a versatile material I find all sorts of applications for it (I also use it for bore rings on some of my wooden flutes when they need reinforcement around sockets).