cutting perfect round .010 brass discs?

[Willing Pell]

I need to cut a large number of 1 inch diameter discs from .010 brass. Any idea how to approach this. Shears will only create irregular shaped discs. I lack a punch large enough to do this. Thoughts anyone? I'm toying with the idea of grinding a old socket but I'm hoping for a niftier idea. Thanks.

[fishermanscancella]

this is from the iforge website.idk might help.heres the web page to see the pics "http://www.anvilfire.com/iforge/index.htm

This is called a tre'panning tool. It has a pilot drill like a hole cutter and a single point tool. Tre'panning tools are generaly shop made, turned on a lathe, but they can be fabricated by welding too. Set screws hold in the pilot drill and the cutter.


Using form tools circular plugs can be cut from wood. We used this nethod to make thousands of wood bases for chess sets.


In metal form tools do not work well but the method can be used to cut blanks. Be sure to use the proper (slow) speeds for large diameters. This requires a stiff spindle and back gears on a drill like the one above.

Wood can be tre'panned holding it by hand but metal must be clamped down.

[Jurgen]

I recommend a disc cutter. You can get them from a variety of jewelry supply companies. You may also be able to get pre cut disks from some places.

Jurgen

[Willing Pell]

The trepanning tool sounds a lot like a large tile hole cutter. I have a 1 inch tile hole cutter, I wonder how that would work, anyone tried something like that before?

[Pendragon]

Your idea of a punch is a good one. I have done this successfully though it would possibly be wise to anneal the brass before doing so. The secret is what you punch it into. a piece of lead is fine, depending on how hard your punch turns out to be even aluminium may do. the ideal of course is the end grain of a piece of hardwood. I have just been into my workshop and used a wad punch (for cutting holes in gaskets) both Aluminium and hardwood endgrain work well. You can pick up a wad punch at an engineering supply store. Good luck

[Leviathan]

Hi,

I second the disc cutter suggestion. I make sterling silver jewelry on a part time basis and a disc cutter is the first thing I thought of when I read your question. Here are some reasonably priced ones:

http://tinyurl.com/63q76

I have ordered from SFJS before and have had nothing but good experiences. You could also make yourself a disc cutter (but if you only need the one size you're probably better off buying). If you are interested in making one then I'd be glad to explain how to do it. Hope this helps.

The Leviathan