Manufacturing Plan For Kubotan

The kubotan should be approximately 4 to 5 inches long and .375 to .5 inches in diameter. It should have 6 grooves on it, .100 to 200 deep, spaced 1.0 inch from ends and equally divided. The protrusion, which the key ring will fasten to, is .25 round and .25 in length. It will be made of aluminum, with stock just slightly bigger than finished diameter dimension.

Machining Plan For Kubotan

The kubotan will be turned in the Emco PC Turn 55 Lathe. It will require at least two different operations (removing the piece and remounting). No special fixturing should be necessary other than shim to protect part. The plan is to turn the large diameter and grooves, first by holding the small diameter’s uncut body then reversing the piece in the mill.

Expected problems:

1. Chuck Marking finished piece.
2. Piece unstable in chuck.
3. Restricted area to turn part, due to spindle stop.
4. Piece will need center drilled.
5. Part flipping will make piece out of round.
6. Tool not able to make desired cut due to shape.
7. Programming line by line.

Possible Solutions

1. Make shims to protect piece but still enable a good clamp and centering.
2. Drill Centers, machine lightly.
3. Explore switching tooling to other side of turret.
4. Find out how to center drill lathe.
5. Machine parts that blend is important, together.
6. Grind tooling, change design requirement.
7. Write program and TRY IT!