Putting a curve to fit inside a container

1

I am attempting to fit a valve body into a round container, the “puck” is 2.5" diameter and standing it up doesn’t seem to be a option, I have battled this for days and just can’t get it… I have attached photos are generally what I am looking for… Help!

Valve Body
Valve Body1920×2560 246 KB

Valve Body2
Valve Body21920×2560 240 KB

2

Can’t you just cut out the profile and glue two pieces together?

3

Unfortunately that isn’t an option with this project, this product will be subjected to intense heat, steam and pressure so it will need to be 1 piece

4

Okay, model this using a 3D CAD tool, then export as an STL, then import into a 3D CAM tool.

You’ll need a long-reach tool, and workholding will be difficult.

Could you at least provide a dimensioned drawing of what you need and the necessary clearances?

What material will you be cutting?

5

The “puck” is 2.5" round, .50 thickness the outside edge will. be cut down to .30 thick, the material is PEEK plastic, I have been running this on a Genmitsu 3030 with a Makita router. Standing it up on edge would be my biggest challenge but the easiest… I would be afraid of vibration with that much cutting area but it would be considerably easier to do

6

I just had a thought… if I were to take a picture and convert the picture to black and white and do something similar to a mapping graph?

7

Okay, if I understand correctly, this is pretty simple to model using a tool such as Block/OpenSCAD:

image
image2880×1728 444 KB

(but I had to fudge some dimensions)

Code is (adjusted for radius vice diameter):

//!OpenSCAD

difference() {
  cylinder(r1=(2.5 * 25.4)/2, r2=(2.5 * 25.4)/2, h=(0.5 * 25.4), center=false);

  hull(){
    translate([0, (0.3 * 25.4), (0.15 * 25.4)]){
      cylinder(r1=(2.2 * 25.4)/2, r2=(2.2 * 25.4)/2, h=(0.2 * 25.4), center=false);
    }
    translate([0, (2 * 25.4), (0.15 * 25.4)]){
      cylinder(r1=(2.2 * 25.4)/2, r2=(2.2 * 25.4)/2, h=(0.2 * 25.4), center=false);
    }
  }
}

image
image2880×1728 282 KB

and here is the STL:

puck_r.stl (130.6 KB)

which when imported into Carbide Create Pro:

image
image2880×1728 260 KB

and adjusted for dimension:

image
image1920×1152 46.2 KB

seems workable — it’s going to be tough to find a tool of a suitable length.

8

thanks… I’ll give it a go and see what happens… I’m attempting to find a tool that is at least 1.25 of cutting length. I love a good challenge

9

I use this one: https://www.cadencemfgdesign.com/product-page/1-4-extended-reach-upcut

It has 1.5” flute length and a relieved shank above that so in theory you can go deeper.