Milling Angle Plates – Part 1

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Recently we salvaged some nice off cuts of 25 x 200mm flat bar from a scrap bin. We were also in need to some angle plates for use on the CNC mill. Hence started the build of  a matched pair of angle plates for the machine. I will be breaking this post into 3 parts, The fabrication/Welding of the plates in Part 1, Part 2 will be the machinign of the surfaces and Part 3 will be the finishing of the plates including tapping.

So you can look forward to some pictures of very average welding and some nice machining.

The pieces of material we had were roughly 350mm, 200mm and 250mm long. The longest and shortest pieces were cut in half with a grinder to be 100mm wide and the remaining piece was cut on an angle between the corners to make the gusset.

The mating faces of the pieces were then milled flat and square. This was done using a 25mm 4 insert cutter. It cut like butter.

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The edges to be welded were given a 10mm chamfer, This was done on the mill using a 80mm 45degree cutter. The finish is almost too nice to weld on.

Weld Prep

With the machined faces and the weld prep done, the fitup was excellent with no gaps between the plates and the mating surfaces.

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Each part was then tack welded in place, checked for square and then the root pass was welded using 3.2mm E7016 low hydrogen electrodes.

Once all of the root passes were completed the final cap pass was welded using ER70S. This is mostly for cosmetic reasons and to provide some volume to the weld. The root pass provides more than enough strength for the parts.

The parts were then cleaned up with a wire cup wheel and were then ready for machining.

Angle Plates after welding

 

Part 2 will cover the machining of the faces

 

 

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