DIY lead cutting machine: Sourcing cutoff wheel? Other considerations? - Page 1
Forum section: electronics / general

author: Metatronic_Mods
author_rank: Contributor
timestamp: December 19, 2017, 12:53:03 am
content: So I finally convinced my contractee to ditch the 100% hand assembly for PTH circuit boards, and invest in equipment for manual dip soldering. We'll still be hand populating, but hoping to streamline the rest of the assembly process.One thing we're also trying to figure out a lead cutting machine. Here's a video for those not familiar:Mostly I need help finding a large diameter flush cut blade, ie. a blade without an arbor, or where the cutting surface extends beyond the end of the arbor (otherwise the arbor would interfere with any leads that would cross it's path.)So far the only things I'm finding are type-27 (recessed hub) cutoff wheels for angle grinders. But most all of the pics/videos of lead cutters I've seen look like they use flat blades, where the blade is simply attached to the spindle all as one piece?Any ideas where/what I should be looking for? Looking for something 4.5" or larger diameter.Beyond that, there's the issue of frame assembly for the cutting machine. The initial plan is to use some aluminum channel as tracks for the PCB and mount those in a t-slot frame so that the height of the PCB can be easily (relatively I hope?) adjusted per the desired lead length of a given board. I have some reservations about how sturdy such an assembly might be ...leaning more toward a welded frame assembly, at least eventually (but I imagine the requisite precision needed for uniform lead length will come at a cost for something welded & adjustable).Just wondering if anyone has ever given any thought to designing or building such a machine?

author: phil from seattle
author_rank: Super Contributor
timestamp: December 19, 2017, 02:09:10 am
content: Oh man, that exposed blade makes me cringe.

author: Nusa
author_rank: Super Contributor
timestamp: December 19, 2017, 03:50:34 am
content: I think this is what you're after:http://www.idealez.com/renthang/product-detail/en_US/33621Video of one being installed:

author: schenkzoola
author_rank: Unknown
timestamp: December 19, 2017, 05:00:37 am
content: Is the whole board through hole?The first product I tried to make and sell was through hole since I didn't understand surface mount at the time. Long story short, after making several hundred of them, I found it couldn't be profitable long term due to the high cost of populating.I was using Simonds air tools to do lead cutting and crimping before dip soldering. The MSP-1 with the SMCC-2 jaws fit my needs. Maybe it will be helpful for you too.http://www.simonds-inc.com/

author: NF6X
author_rank: Unknown
timestamp: December 19, 2017, 05:57:28 am
content: Things in the video which make me cringe:Exposed blade.Sound of the leads being cut.Wireless ESD wrist strap.

author: Kean
author_rank: Unknown
timestamp: December 19, 2017, 07:08:42 am
content: For safety you'd probably want one with auto-feed

author: Koen
author_rank: Frequent Contributor
timestamp: December 20, 2017, 08:07:59 pm
content: Call your local woodworking or metalworking shop and ask them who regrinds their tools. Then ask that guy to quote you a custom blade. Customs are usually barely more than stocked items.

author: Mr. Scram
author_rank: Super Contributor
timestamp: December 20, 2017, 08:12:01 pm
content: Quote from: NF6X on December 19, 2017, 05:57:28 amThat little tray over an open blade looks like a recipe to lose your fingers indeed.