Milling cutters are often made of hard, strong materials that can withstand significant stresses without breaking or otherwise being damaged.

I’m building a model using a 3D printer and laser cutter. Here’s a first try at one of those capacitors in the photo above I printed this past weekend.

Milling can be done in different directions on one or more axes, cutting head speed and pressure. This can be done with a variety of machine tools. The milling process requires a milling machine, workpiece, jig, and milling cutter. The workpiece is a piece of pre-shaped material that is attached to the fixture, which in turn is mounted on a platform within the milling machine.

It’s Nikola Tesla’s Colorado Springs laboratory from 1899. This, specifically, is the primary/secondary form. Here’s a few photos and the diagram from Tesla’s notes:

Your response has been very helpful, thank you. I’ve got a mostly finished model, but there’s a couple of issues I’d like to resolve:

The milling process removes material by making many separate, small cuts. This is accomplished by using a multi-tooth cutter, rotating the cutter at high speed, or slowly advancing the material through the cutter; most of the time it is a combination of these three approaches.

image876×110 36.6 KB After modeling this, I know this statement from his journal can’t be true with a spiral because at certain points on the form, the grooves intersect the seams in the planks up to three times. This statement also shows his interest in simplicity. Making this a spiral certainly wouldn’t be simple.

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I’m not disappointed I went through this because I needed to learn how to make spirals anyway, but the more I study and consider this part, I have about convinced myself it’s actually not a spiral after all.

With face milling, the cutting action mainly takes place at the end corners of the milling cutter. Face milling is used to cut flat surfaces into the workpiece or to cut flat-bottomed cavities.

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Milling is typically used to make parts that are not axially symmetrical and have many features such as holes, slots, pockets, and even three-dimensional surface contours. Parts made entirely by milling often contain components that are used in limited quantities, possibly for prototyping, such as custom fasteners or brackets.

The purpose of a milling cutter is to remove material from a workpiece. Cutters do not consist of a single blade. While turning operations with a lathe are usually carried out with a single-edged cutting tool, milling cutters consist of several cutting edges. As the milling cutter rotates against a stationary workpiece, it scrapes off material.

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The material of the turning insert depends on the type of workpiece material. For example, coated carbide inserts are often used for turning stainless steel.

Thanks for the replies, everyone… A turn created with Upright Extruder still has alignment issues mating with a cloned turn. But, unlike Follow Me, it can handle the large number of segments and makes it all the way with the needed 48 turns.

Since you kind of need the geometry, then, we need a different approach. As the .skp file you share is set up you have the profile radius more than half the pitch of the helix. Is that what you want?

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I am trying to create a spiraled, rectangular tube and keep running into “Invalid path” errors. I’ve tried every plugin I could find (Spiral Tool, Shape Tools, Helix Along Curve and Curve Maker) and creating the spiral manually as described in Aron’s video (SketchUp Skill Builder: Modeling a Spring - YouTube). Most all of these work fine with 8 or fewer turns, but I need 48 turns.

Interesting. If you’re modeling the entire lab maybe you could manage with a texture for the forms and windings instead of actual geometry?

The speeds and feeds used are varied to accommodate a combination of variables. The speed at which the workpiece advances through the cutting device is referred to as the feed rate, or simply feed; it is mostly measured as distance per time, although distance per revolution or per cutter tooth is sometimes also used.

With peripheral milling, the cutting action takes place mainly along the peripheral of the milling cutter, so that the cross-section of the milled surface ultimately takes on the shape of the milling cutter. In this case, the blades of the milling cutter can be viewed as the exhaustion of material from the workpiece. Peripheral milling is well suited for cutting deep grooves, threads, and gear teeth.

A milling cutter is a cutting tool with sharp teeth that are also mounted in the milling machine and rotates at high speeds. By feeding the workpiece into the rotating milling cutter, the material is cut from this workpiece in the form of small chips in order to produce the desired shape.

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Milling is the process of machining using rotating cutters to remove material by advancing a cutter into a workpiece. Milling covers a wide variety of different operations and machines, from small individual parts to large, heavy-duty group milling operations. It is one of the most widely used processes of machining custom parts with precise tolerances.

Attached is the spiral as generated by Helix Along Curve. As you can see, the Follow Me tool reports the path as invalid.

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All milling machines have a milling cutter. During a typical milling process, the milling cutter moves perpendicular to its axis, allowing it to remove material from the workpiece at the circumference of the milling cutter.

I’ve tried drawing an eight turn and then cloning it, but I’ve not been able to join the cloned section with the original one because they don’t perfectly align.

2021414 — Strain hardening, also referred to as cold working or work hardening, is the process where metals are made stronger and harder through permanent deformation.

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The Speed-Feed 400 trimmer head is perfectly balanced for vibration-free operation, and its smooth cover design glides while trimming.

Tesla was in a time crunch - Winter was coming and he wanted to get back to New York. As electric saws weren’t available until the 1920s, devising an apparatus to make these grooves a spiral would have likely been more complicated than the coil itself.

When the milling cutter moves into the workpiece, the cutting edges of the tool are cut into and out of the material again and again, which means that chips are scraped off the workpiece with each pass.

Stainless steels will work harden to some extent when subject to deformation i.e. bending, drawing, pressing. Read more here.

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Nine9 boring tools and boring bar head have high efficiency and easy adjustment. Also feature improved cycle time, position accuracy and so on.

I made the groove by exploding the spiral inside the form and deleting the faces. Of course they didn’t perfectly align either as the measurement from the groove’s back to the face is in a 1/64th. So I dropped one turn over it as a group, then trimmed all 64 sides, top and bottom, raised it up and duplicated it 48 times. Cleaned up the faces, dropped it back down and exploded it. This was kinda brutal and the whole time I was doing it, I was thinking, “There has to be a better way!”, LOL.

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Milling cutters are cutting tools that are typically used in milling machines or machining centers to perform milling operations. They remove material by moving it within the machine or directly from the cutting die.

Milling is a cutting process that uses a milling cutter to remove material from the surface of a workpiece. The milling cutter is a rotating cutting tool, often with several cutting edges. In contrast to drilling, in which the tool is advanced along its axis of rotation, during milling the milling cutter is normally moved perpendicular to its axis so that the cutting takes place on the circumference of the milling cutter.

You might want to look at Truebend for this. You could set up all the wires etc and bend them in one go then stack them. This is a simple trace of your profile, I then extrude it and lift one end so it is one step up. I coloured it so you can see it is a continuous structure. Then bend, stack and outershell.

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A variety of operations can be performed on the workpiece during the process cycle to obtain the desired shape of the part. The following operations are each defined by the type of milling cutter used and the path this cutter takes to remove material from the workpiece.

Watching, and nice work! Does this mean the Extruder tool you used doesn’t have the limitations of Follow Me and will make it all the way with the 48 turns of the form I’m making?

The cutting action is a shear strain; the material is repelled from the workpiece in tiny clumps, which are more or less connected to chips. This makes cutting metal a little different from cutting softer materials with a blade.

Following up on this… I spoke with Richard Hull, author of a book on this subject, and he insists that Tesla was a perfectionist with regard to winding and would have had a spiral. Richard believes the moldings were pre-cut with the two grooves and themselves, arranged in a spiral.

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Another application of milling is the production of tools for other processes. For example, three-dimensional shapes are typically milled. Milling is also often used as a secondary process to add or refine features on parts made with another process. Because of the high tolerances and surface finishes that milling can provide, it is ideal for adding precision features to a part whose basic shape has already been formed.

Maybe for something like this you could consider using basically the process I use for model machine screw threads. There’s a video of the process here:

1000 segments appears to be the fail point. Your inability to make one turn and repeat it is down to the way follow me works. The profile will always rotate to be perpendicular to the first and last segments of the curve. This stops the ends aligning as you would want. Simple fix, rotate your spiral half a segment and cut on axis so you have one turn beginning and ending on the red axis( Easiest to cut and remove most of the spiral first). Create the profile centered on the path on the red axis. Run follow me. Select the result and move/copy up on the blue axis and they will align.