What you can make

Each of these was made in Benchsmith on a phone: pick the bar, then add the operations in the order you'd machine them. You get the 3D part, a dimensioned drawing and the process sheet, ready for the shop floor. Tap Open a copy to change one into your own part.

Reference and design aid. Check every size before you cut metal.

Round bar: everyday parts

Drive dog

Flange with two flats, four bolt holes through it, a slot across the end.

TurnFlatsPCD 4 × Ø9Slot across the end

Process sheet: Ø70 × 60 round bar, 6 ops

1. Op 10 Turn Turn Ø50 × 48 long from the right end.
2. Op 20 Mill Mill two flats 5 deep (60 across flats), 0 to 12 from the left end, at 0°.
3. Op 30 Drill Drill 4 × Ø9 × 12 deep, flat bottom, on PCD 56, start 45°. Left end, centre X0 Y0 (holes A–D)
4. Op 40 Mill Mill a slot 14 wide, 14 deep. Right end, X-32 Y0 to X32 Y0.
5. Op 50 Drill Drill Ø5 × 8 deep, flat bottom. Right end, X0 Y0 (hole E)
6. Op 60 Turn Chamfer the right end 1 × 45°.

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Keyed motor shaft

Threaded end, a collar, an h6 bearing seat with a keyway and a circlip groove, a tapered end, centre hole.

TurnM20 threadh6 seatKeywayCirclip grooveTaper

Process sheet: Ø35 × 112 round bar, 9 ops

1. Op 10 Turn Turn Ø32 full length.
2. Op 20 Turn Turn Ø20 × 30 long from the left end.
3. Op 30 Turn Turn Ø25 h6 (+0.000 / −0.013) × 70 long, starting 42 from the left end.
4. Op 40 Turn Taper from Ø14 at the right end to Ø18, 20 long (half angle 5.71°).
5. Op 50 Turn Cut thread M20×2.5-6g, 22 long from the left end of the Ø20 run.
6. Op 60 Turn Groove for a DIN 471 circlip (shaft Ø25): Ø23.9 × 1.3 wide, starting 87 from the left end.
7. Op 70 Mill Mill a keyway 8 wide × 4 deep, 28 long (DIN 6885 A for Ø25: key 8 × 7), 52 to 80 from the left end, at 0°.
8. Op 80 Turn Chamfer the left end 1.5 × 45°.
9. Op 90 Turn Centre drill the left end A2.5/5.3 DIN 332 (for Ø20).

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Flanged bush

A k6 press fit under a flange, bored through, an oil hole into the bore, an O-ring groove.

Turnk6 fitBore Ø20Oil holeO-ring groove

Process sheet: Ø45 × 43 round bar, 7 ops

1. Op 10 Turn Turn Ø40 full length.
2. Op 20 Turn Turn Ø30 k6 (+0.015 / +0.002) × 35 long from the right end.
3. Op 30 Turn Bore Ø20 thru from the left end.
4. Op 40 Drill Drill Ø5 × 5 deep from the top, flat bottom. Side, 23 from the left end, at 0° (hole B).
5. Op 50 Turn O-ring groove for a 2.62 section (static): 2.1 deep × 3.65 wide, starting 33 from the left end.
6. Op 60 Turn Chamfer the left end 0.5 × 45°.
7. Op 70 Turn Chamfer the right end 0.5 × 45°.

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Threaded pin with flats

Head with a tapped hole, two spanner flats, an M12 thread with an undercut behind it.

TurnFlatsM12 threadUndercutTapped M6

Process sheet: Ø20 × 55 round bar, 8 ops

1. Op 10 Turn Turn Ø16 full length.
2. Op 20 Turn Turn Ø12 × 30 long from the right end.
3. Op 30 Turn Undercut Ø9.8 × 2.5 wide, starting 37 from the left end.
4. Op 40 Turn Cut thread M12×1.75-6g, 30 long from the right end of the Ø12 run.
5. Op 50 Mill Mill two flats 3 deep (10 across flats), 4 to 19 from the left end, at 0°.
6. Op 60 Drill Drill Ø5 × 12 deep, 118° point, tap M6×1. Left end, X0 Y0 (hole A)
7. Op 70 Turn Chamfer the left end 1 × 45°.
8. Op 80 Turn Chamfer the right end 1 × 45°.

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Shaft collar

Bored to slide on a Ø20 shaft, a tapped grub-screw hole into the bore.

TurnBore Ø20Tapped M6 grub screw

Process sheet: Ø42 × 18 round bar, 5 ops

1. Op 10 Turn Turn Ø40 full length.
2. Op 20 Turn Bore Ø20 thru from the left end.
3. Op 30 Drill Drill Ø5 × 10 deep from the top, flat bottom, tap M6×1. Side, 9 from the left end, at 0° (hole B).
4. Op 40 Turn Chamfer the left end 1 × 45°.
5. Op 50 Turn Chamfer the right end 1 × 45°.

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Round bar: complex parts

Flanged sleeve

Bored right through, a bolt flange, a notch through the wall at the far end.

TurnBore Ø36PCD 4 × Ø9Notch

Process sheet: Ø80 × 90 round bar, 5 ops

1. Op 10 Turn Turn Ø50 × 78 long from the right end.
2. Op 20 Turn Bore Ø36 thru from the left end.
3. Op 30 Drill Drill 4 × Ø9 × 12 deep, flat bottom, on PCD 66, start 45°. Left end, centre X0 Y0 (holes B–E)
4. Op 40 Mill Mill a slot 12 wide, 22 deep. Right end, X0 Y8 to X0 Y34.
5. Op 50 Turn Chamfer the left end 1 × 45°.

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Gear shaft

30-tooth gear on the end, a groove and a DIN 471 circlip groove, bored through with a keyway in the bore, an M6 set-screw hole into the bore.

TurnGear 30T m2Circlip grooveTapped M6Bore keyway

Process sheet: Ø66 × 110 round bar, 9 ops

1. Op 10 Turn Turn Ø64 × 14 long from the left end.
2. Op 20 Turn Turn Ø52 × 96 long from the right end.
3. Op 30 Turn Turn Ø48 × 90 long from the right end.
4. Op 40 Turn Bore Ø30 thru from the right end.
5. Op 50 Turn Undercut Ø45 × 1.5 wide, starting 40 from the left end.
6. Op 60 Turn Groove for a DIN 471 circlip (shaft Ø48): Ø45.5 × 1.85 wide, starting 102 from the left end.
7. Op 70 Gear Cut 30 teeth, module 2, 20° pressure angle, 14 wide, 0 to 14 from the left end (tip Ø64, pitch Ø60, root Ø55). Dividing head (40:1): 1 1/3 turns per tooth. Involute cutter: check the cutter chart.
8. Op 80 Drill Drill Ø5 × 9 deep from the top, flat bottom, tap M6×1. Side, 70 from the left end, at 0° (hole B).
9. Op 90 Mill Cut a keyway 8 wide in the left end bore (Ø30), 3.3 deep from the bore wall (33.3 over the bore and keyway), the whole bore, at 0° (DIN 6885 A for Ø30: key 8 × 7): slot or broach.

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Splined pinion shaft

18-tooth pinion, 10 straight splines on the end running out on a Ø63 cutter, centre holes both ends.

TurnGear 18T m310 splinesCentre holes

Process sheet: Ø62 × 260 round bar, 9 ops

1. Op 10 Turn Turn Ø60 × 260 long from the left end.
2. Op 20 Turn Turn Ø40 × 30 long from the left end.
3. Op 30 Turn Turn Ø45 × 180 long from the right end.
4. Op 40 Turn Chamfer the left end 1.5 × 45°.
5. Op 50 Turn Chamfer the right end 1.5 × 45°.
6. Op 60 Gear Cut 18 teeth, module 3, 20° pressure angle, 50 wide, 30 to 80 from the left end (tip Ø60, pitch Ø54, root Ø46.5). Dividing head (40:1): 2 2/9 turns per tooth. Involute cutter: check the cutter chart.
7. Op 70 Mill Mill 10 splines 7 wide, Ø45 outside, Ø39 root, 200 to 260 from the left end, Ø63 cutter (runs out over 14.04). Dividing head (40:1): 4 turns per spline (36° apart).
8. Op 80 Turn Centre drill the left end A3.15/6.7 DIN 332 (for Ø40).
9. Op 90 Turn Centre drill the right end A3.15/6.7 DIN 332 (for Ø45).

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Helical gear

38 helical teeth, 15° right hand, normal module 2, on a hub, bored with a keyway in the bore.

TurnHelical 38T m2 15°Bore keywayHub

Process sheet: Ø86 × 40 round bar, 6 ops

1. Op 10 Turn Turn Ø82.68 full length.
2. Op 20 Turn Turn Ø50 × 15 long from the right end.
3. Op 30 Turn Bore Ø25 thru from the left end.
4. Op 40 Gear Cut 38 helical teeth, normal module 2, helix 15° right hand, 20° pressure angle (normal), 25 wide, 0 to 25 from the left end (pitch Ø78.68, tip Ø82.68, root Ø73.68, transverse module 2.071). Lead 922.5: gear the table to it (change gears not worked out here). Dividing head (40:1): 1 1/19 turns per tooth. Involute cutter for 42.2 teeth (z ÷ cos³β): check the cutter chart.
5. Op 50 Mill Cut a keyway 8 wide in the left end bore (Ø25), 3.3 deep from the bore wall (28.3 over the bore and keyway), the whole bore, at 0° (DIN 6885 A for Ø25: key 8 × 7): slot or broach.
6. Op 60 Turn Chamfer the left end 1 × 45°.

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Forked spindle

Threads both ends, a 27-tooth gear, a fork slot across the threaded end and a DIN 6885 keyway.

Thread M30Thread M42×2Gear 27T m2Fork slotKeyway

Process sheet: Ø60 × 200 round bar, 9 ops

1. Op 10 Turn Turn Ø58 × 200 long from the left end.
2. Op 20 Turn Turn Ø30 × 20 long from the left end.
3. Op 30 Turn Turn Ø50 × 35 long, starting 45 from the left end.
4. Op 40 Turn Turn Ø42 × 120 long from the right end.
5. Op 50 Turn Cut thread M30×3.5-6g, 20 long from the left end of the Ø30 run.
6. Op 60 Turn Cut thread M42×2-6g, 25 long from the right end of the Ø42 run.
7. Op 70 Gear Cut 27 teeth, module 2, 20° pressure angle, 25 wide, 20 to 45 from the left end (tip Ø58, pitch Ø54, root Ø49). Dividing head (40:1): 1 13/27 turns per tooth. Involute cutter: check the cutter chart.
8. Op 80 Mill Mill a slot 12 wide, 60 deep. Right end, X-30 Y0 to X30 Y0.
9. Op 90 Mill Mill a keyway 12 wide × 5 deep, 40 long (DIN 6885 A for Ø42: key 12 × 8), 95 to 135 from the left end, at 90°.

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Square / flat bar: everyday parts

Slotted flat bar

Two bolt holes 550 apart and an adjusting slot between them.

Drill2 × Ø11Slot 12 wide

Process sheet: 600 × 50 × 10 block, 3 ops

1. Op 10 Drill Drill Ø11 thru. Top face, X25 Y25 (hole A)
2. Op 20 Drill Drill Ø11 thru. Top face, X575 Y25 (hole B)
3. Op 30 Mill Mill a slot 12 wide, thru. Top face, X200 Y25 to X400 Y25.

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Drill jig plate

Fifteen holes on a 20 × 15 grid: the drawing lists them in a hole table.

Drill15 × Ø6Hole table

Process sheet: 120 × 60 × 12 block, 15 ops

1. Op 10 Drill Drill Ø6 thru. Top face, X20 Y15 (hole A)
2. Op 20 Drill Drill Ø6 thru. Top face, X20 Y30 (hole B)
3. Op 30 Drill Drill Ø6 thru. Top face, X20 Y45 (hole C)
4. Op 40 Drill Drill Ø6 thru. Top face, X40 Y15 (hole D)
5. Op 50 Drill Drill Ø6 thru. Top face, X40 Y30 (hole E)
6. Op 60 Drill Drill Ø6 thru. Top face, X40 Y45 (hole F)
7. Op 70 Drill Drill Ø6 thru. Top face, X60 Y15 (hole G)
8. Op 80 Drill Drill Ø6 thru. Top face, X60 Y30 (hole H)
9. Op 90 Drill Drill Ø6 thru. Top face, X60 Y45 (hole I)
10. Op 100 Drill Drill Ø6 thru. Top face, X80 Y15 (hole J)
11. Op 110 Drill Drill Ø6 thru. Top face, X80 Y30 (hole K)
12. Op 120 Drill Drill Ø6 thru. Top face, X80 Y45 (hole L)
13. Op 130 Drill Drill Ø6 thru. Top face, X100 Y15 (hole M)
14. Op 140 Drill Drill Ø6 thru. Top face, X100 Y30 (hole N)
15. Op 150 Drill Drill Ø6 thru. Top face, X100 Y45 (hole O)

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T-nut

For a 14 mm T-slot: a tongue left by two steps, an M12 tapped hole through.

MillStepsTapped M12

Process sheet: 40 × 24 × 18 block, 5 ops

1. Op 10 Mill Mill a step 5 in × 8 deep along the Top–Front edge, Ø10 cutter.
2. Op 20 Mill Mill a step 5 in × 8 deep along the Top–Back edge, Ø10 cutter.
3. Op 30 Drill Drill Ø10.2 thru, tap M12×1.75. Top face, X20 Y12 (hole A)
4. Op 40 Mill Chamfer the Bottom–Back edge 1 × 45°.
5. Op 50 Mill Chamfer the Bottom–Front edge 1 × 45°.

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Strap clamp

A slot for the clamp stud, a tapped hole for the heel screw, chamfered top edges.

MillSlotTapped M10Chamfers

Process sheet: 100 × 25 × 14 block, 4 ops

1. Op 10 Mill Mill a slot 12 wide, thru. Top face, X25 Y12.5 to X55 Y12.5.
2. Op 20 Drill Drill Ø8.5 thru, tap M10×1.5. Top face, X85 Y12.5 (hole A)
3. Op 30 Mill Chamfer the Top–Front edge 1.5 × 45°.
4. Op 40 Mill Chamfer the Top–Back edge 1.5 × 45°.

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Motor mount plate

A spigot bore and four bolt holes for a flange motor, two slots to tension the belt.

DrillBore Ø30PCD 4 × Ø72 slots

Process sheet: 150 × 100 × 8 block, 4 ops

1. Op 10 Drill Drill Ø30 thru. Top face, X50 Y50 (hole A)
2. Op 20 Drill Drill 4 × Ø7 thru, on PCD 60, start 45°. Top face, centre X50 Y50 (holes B–E)
3. Op 30 Mill Mill a slot 9 wide, thru. Top face, X115 Y20 to X135 Y20.
4. Op 40 Mill Mill a slot 9 wide, thru. Top face, X115 Y80 to X135 Y80.

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Square / flat bar: complex parts

Air gun body

Passages drilled from three faces that meet inside, G1/4 and G1/8 ports, a slot for the trigger.

DrillHoles that meetG portsSlotChamfer

Process sheet: 90 × 30 × 70 block, 9 ops

1. Op 10 Drill Drill Ø6 × 55 deep, flat bottom. Bottom face, X15 Y15 (hole A)
2. Op 20 Drill Drill Ø11.8 × 14 deep, flat bottom, tap G1/4. Bottom face, X15 Y15 (hole B)
3. Op 30 Drill Drill Ø6 × 80 deep, flat bottom. Left face, X15 Y55 (hole C)
4. Op 40 Drill Drill Ø8.8 × 12 deep, flat bottom, tap G1/8. Right face, X15 Y55 (hole D)
5. Op 50 Drill Drill Ø6 × 15 deep, flat bottom. Top face, X60 Y15 (hole E)
6. Op 60 Drill Drill Ø8.8 × 10 deep, flat bottom, tap G1/8. Top face, X60 Y15 (hole F)
7. Op 70 Mill Mill a slot 8 wide, thru. Front face, X35 Y25 to X35 Y45.
8. Op 80 Mill Chamfer the Top–Back edge 2 × 45°.
9. Op 90 Mill Chamfer the Top–Front edge 2 × 45°.

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Bearing block

Skimmed and pocketed, a bearing bore with a tapped PCD round it, a step, a rounded edge and a slot.

SkimPocketTapped M5 PCDStepRound-over

Process sheet: 100 × 50 × 40 block, 9 ops

1. Op 10 Mill Skim the Top face down 1.
2. Op 20 Mill Mill a pocket 40 × 30 × 10 deep (corners R5), Ø10 cutter. Top face, X30 Y10.
3. Op 30 Drill Drill Ø20 thru. Top face, X50 Y25 (hole A)
4. Op 40 Drill Drill 4 × Ø4.2 × 12 deep, 118° point, tap M5×0.8, on PCD 32, start 45°. Top face, centre X50 Y25 (holes B–E)
5. Op 50 Drill Drill Ø9 thru. Top face, X12 Y25 (hole F)
6. Op 60 Drill Drill Ø9 thru. Top face, X88 Y25 (hole G)
7. Op 70 Mill Mill a step 8 in × 6 deep along the Top–Front edge, Ø10 cutter.
8. Op 80 Mill Round the Top–Back edge R4 (corner-rounding cutter).
9. Op 90 Mill Mill a slot 6 wide, 5 deep. Front face, X20 Y20 to X80 Y20.

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Hydraulic manifold

Three passages drilled from three faces that meet inside, G1/4 and G1/8 ports over them, two bolt holes.

DrillHoles that meetG portsSection

Process sheet: 80 × 60 × 40 block, 8 ops

1. Op 10 Drill Drill Ø6 × 25 deep, flat bottom. Top face, X20 Y30 (hole A)
2. Op 20 Drill Drill Ø11.8 × 14 deep, flat bottom, tap G1/4. Top face, X20 Y30 (hole B)
3. Op 30 Drill Drill Ø6 × 60 deep, flat bottom. Left face, X30 Y20 (hole C)
4. Op 40 Drill Drill Ø11.8 × 14 deep, flat bottom, tap G1/4. Left face, X30 Y20 (hole D)
5. Op 50 Drill Drill Ø6 × 30 deep, flat bottom. Front face, X50 Y20 (hole E)
6. Op 60 Drill Drill Ø8.8 × 10 deep, flat bottom, tap G1/8. Front face, X50 Y20 (hole F)
7. Op 70 Drill Drill Ø9 thru. Top face, X68 Y10 (hole G)
8. Op 80 Drill Drill Ø9 thru. Top face, X68 Y50 (hole H)

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Bearing cover

A blind bearing recess with six tapped holes round it (measured from the recess), two M8 tapped holes in the side.

DrillDatum: the recessPCD 6 × M6Tapped M8

Process sheet: 100 × 60 × 30 block, 4 ops

1. Op 10 Drill Drill Ø20 × 15 deep, flat bottom. Top face, X50 Y30 (hole A)
2. Op 20 Drill Drill 6 × Ø5 × 12 deep, 118° point, tap M6×1, on PCD 40, start 0°. Top face, centre X0 Y0 from hole A (holes B–G)
3. Op 30 Drill Drill Ø6.8 × 18 deep, 118° point, tap M8×1.25. Front face, X20 Y15 (hole H)
4. Op 40 Drill Drill Ø6.8 × 18 deep, 118° point, tap M8×1.25. Front face, X80 Y15 (hole I)

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Fixture block

A step along one edge, a pocket underneath, a rounded corner, a chamfer and a locating hole in the end.

MillStepPocket underneathRound-overChamfer

Process sheet: 90 × 40 × 30 block, 5 ops

1. Op 10 Mill Mill a step 10 in × 8 deep along the Top–Front edge, Ø10 cutter.
2. Op 20 Mill Chamfer the Top–Back edge 2 × 45°.
3. Op 30 Mill Round the Front–Left edge R5 (corner-rounding cutter).
4. Op 40 Mill Mill a pocket 50 × 20 × 6 deep (corners R4), Ø8 cutter. Bottom face, X20 Y10.
5. Op 50 Drill Drill Ø8 × 30 deep, flat bottom. Right face, X20 Y15 (hole A)

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