TENON Calculate Spindex rotation angle with this tool.
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TENON Description

A common metal work operation involves cutting a regular polygonal tenon on the end of a shaft. Most frequently, the tenon is square or hexagonal. One generally do this by mounting the cylindrical stock in a Spindex on the milling machine. Zero the cutter against the stock surface, then lower it by the required depth-of-cut (doc). Take a cut, rotate the Spindex by the required angle, cut and repeat these operations until the tenon is formed. Calculating the required doc when the tenon has an even number of sides is relatively straight-forward but recently I wanted to make a pentagonal tenon to serve as an "Allen key" to remove some tamper-proof bolts. Tenons with an even number of sides are easily specified by the "across flats" measurment but, with an odd number of sides that's not easily done with accuracy. A better procedure is to specify the diameter of the circle that just circumscribes the required tenon polygon. Formulas that relate diameter of inscribed and circumscribed circles to other properties of regular polygons are available in most mathematics handbooks. TENON is a simple application designed to help you calculate the required doc (and Spindex rotation angle) given the size of the stock, number of sides on the polygon, and either the distance across flats (for even sides) or diameter of circumscribing circle (for odd sides). It does no checking for idiocy. If you want to cut a 1" across flats hexagon on a piece of 0.25" diameter stock, you need more help than any program can ever supply.

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