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chich2 Hafco Metal Master HM-52 CNC... 10-16-2006, 01:15 PM
chich2 My original plans were to... 10-16-2006, 01:42 PM
chich2 Today I finished making the... 10-16-2006, 02:49 PM
jkujawa Great post!! 10-17-2006, 01:28 AM
chich2 Thanks for your kind reply... 10-17-2006, 05:29 AM
epineh Nice work on your mill so far... 10-17-2006, 09:22 AM
jkujawa Coming along very nicely! ... 10-17-2006, 01:41 PM
epineh Hey Chich, you might like to... 10-20-2006, 07:26 AM
Adobe Machine Nice, stout looking... 10-21-2006, 04:37 AM
chich2 Russ, Your a... 10-21-2006, 06:08 AM
chich2 Y-axis anti backlash nut 10-21-2006, 06:45 AM
Mallala_John Judging from the dates on the... 11-07-2013, 04:32 AM
epineh PM sent with all the details,... 10-21-2006, 11:31 AM
chich2 Good one Russ!!!! Once again... 10-23-2006, 07:25 AM
epineh No probs... have you finished... 10-23-2006, 12:05 PM
leeroy hm50 10-23-2006, 01:21 PM
chich2 Z Axis debate 10-24-2006, 07:31 AM
leeroy Chich Thanks for taking... 10-24-2006, 12:52 PM
macona You know, this would be a... 10-26-2006, 09:13 PM
chich2 macona, Great... 10-27-2006, 12:08 AM
macona Bijur (http://www.bijur.com)... 10-27-2006, 12:48 AM
chich2 macona, Thanks for the... 10-27-2006, 02:06 PM
leeroy Air ram to the rescue 10-29-2006, 02:37 AM
chich2 Y Axis Anti Backlash nut 11-13-2006, 03:02 AM
chich2 Leeroy, Yes the air... 11-13-2006, 02:21 AM
macona I would try to use a cylinder... 11-13-2006, 03:55 AM
chich2 Macona, Thanks for... 11-13-2006, 05:38 AM
chich2 Start of the Z Axis 11-14-2006, 02:10 PM
chich2 More Z Axis progress 11-15-2006, 01:08 PM
macona Yeah, coolant will work to... 11-15-2006, 05:50 PM
chich2 Macona, 11-15-2006, 10:41 PM
chich2 Macona, Thanks for the... 11-15-2006, 11:12 PM
leeroy New Quill Finialy Finished 11-18-2006, 01:46 PM
macona Nice work on the quill! As... 11-18-2006, 06:41 PM
macona Oh yeah, ask over at... 11-18-2006, 06:42 PM
chich2 Leeroy, Well... 11-19-2006, 01:53 AM
chich2 Z Axis update 11-25-2006, 01:39 PM
chich2 More on the Z axis 11-26-2006, 03:47 PM
chich2 Z and Y axis update. 11-28-2006, 11:28 PM
macona Hey, I put up a post with my... 12-10-2006, 05:55 AM
chich2 Great thread macona. You have... 12-11-2006, 12:51 PM
chich2 Air cylinder assisted Z axis... 12-20-2006, 01:53 PM
chich2 Chip Guard over bedways 12-21-2006, 01:19 AM
chich2 Z axis Gib adjuster 12-21-2006, 01:26 AM
FPV_GTp hi Nice work chick2 ... 01-02-2007, 12:48 AM
chich2 Thanks FPV GTp, I am... 01-03-2007, 12:05 AM
chich2 Z axis servo mount 01-06-2007, 12:08 AM
epineh Looking good Chich, make sure... 01-06-2007, 12:18 AM
chich2 Khaa Haa! Yes russ I WILL!!... 01-06-2007, 12:40 AM
chich2 FINISHED Z axis servo mount 01-06-2007, 03:42 PM
chich2 Chip cover over coolant tank 01-06-2007, 11:03 PM
chich2 X axis Servo Mount 01-07-2007, 01:43 PM
chich2 Yesterday I ordered my drive... 01-19-2007, 11:06 PM
FPV_GTp hi Chich2 very nice work ,... 01-19-2007, 11:41 PM
chich2 FPV GTp, Thanks for... 01-20-2007, 12:11 AM
FPV_GTp hi Chick2 , ok understand... 01-20-2007, 12:22 AM
chich2 FPV GTp, I have a... 01-20-2007, 12:39 AM
chich2 Mounting the encoders onto... 01-22-2007, 01:12 PM
chich2 Servo Drives Arrived!!!!! 01-25-2007, 11:22 AM
chich2 FINISHED mounting all the... 02-04-2007, 01:49 PM
SimjetAU HI Chich I have been... 01-20-2008, 11:51 AM
chich2 Thanks Peter, ... 02-05-2007, 11:55 PM
chich2 Re-machined Y axis handwheel 02-06-2007, 12:24 AM
phomann Chich, While you are... 02-06-2007, 01:14 AM
chich2 phomann, Funy you... 02-06-2007, 03:07 PM
chich2 Servo Drive Enclosure 02-06-2007, 03:13 PM
phomann Chich, Good to see you... 02-06-2007, 09:27 PM
epineh Hey Chich, I did the first... 02-18-2007, 06:29 AM
epineh Take two... the resist is... 02-18-2007, 07:44 AM
chich2 Thanks Russ! Your boards are... 02-18-2007, 02:05 PM
chich2 Servo's are wired up 02-20-2007, 02:39 PM
macona Wait a minute, your running... 02-21-2007, 12:33 AM
chich2 Good question macona. The... 02-21-2007, 07:11 AM
LUCKY13 What size,type & volts are... 02-21-2007, 01:26 PM
LeeWay I know smaller motor... 02-21-2007, 03:33 PM
epineh Hi Jess, I supplied the... 02-21-2007, 10:02 PM
macona Those welders were made by... 03-08-2007, 12:04 AM
chich2 It's............................. 03-10-2007, 12:50 PM
epineh Cool, I know of one sleepy... 03-10-2007, 02:07 PM
chich2 Ballscrews and bigger Z servo 03-18-2007, 01:35 PM
chich2 Bigger Z axis servo motor 03-20-2007, 01:12 PM
chich2 Mounting the encoder and a... 03-20-2007, 01:21 PM
chich2 stihl88, Thanks for... 03-30-2007, 02:43 PM
stihl88 Thanks Chich I think i... 03-31-2007, 01:31 AM
Mallala_John Saw your post and thought I... 09-23-2008, 07:07 AM
chich2 stihl88, Rough costs so far... 04-01-2007, 12:29 AM
chich2 Z axis ballscrew 04-01-2007, 12:40 AM
chich2 Finished Z axis ballnut mount 04-01-2007, 11:46 PM
chich2 Ball Screw end 04-02-2007, 12:18 AM
chich2 Finished Z axis Ballscrew... 04-02-2007, 12:51 AM
DennisCNC ^ Wounder why you put two... 04-04-2007, 12:33 AM
chich2 Dennis, Thanks for... 04-04-2007, 03:50 PM
chich2 Z axis ballscrew keeper bolt 04-07-2007, 10:58 AM
chich2 Finished Z axis Ballscrew... 04-07-2007, 11:34 AM
chich2 My first 3 axis CNC milling... 04-07-2007, 11:59 AM
DennisCNC Nice! 04-08-2007, 07:10 PM
chich2 Thanks Dennis, ... 04-09-2007, 09:42 PM
DennisCNC Hehe, it was my 12 year old... 04-11-2007, 12:23 AM
abomination Excellent work Chich, ... 04-25-2007, 01:58 PM
chich2 Thanks for the kind words... 04-28-2007, 02:56 PM
chich2 Purchased VSD for mill... 05-01-2007, 05:16 AM
epineh Interesting price on the VFD... 05-01-2007, 10:55 AM
epineh Ha, no decent ones, just... 05-01-2007, 12:00 PM
chich2 Variable Speed Drive Arrived 05-04-2007, 06:06 AM
abomination hi Chich, Good to hear the... 05-04-2007, 02:37 PM
turbostang Chich - The whole conversion... 05-07-2007, 04:22 AM
chich2 Turbo, You are close in... 05-16-2007, 01:53 PM
chich2 Started Milling parts to... 05-16-2007, 04:10 PM
turbostang Chich - Looks good! I... 05-16-2007, 04:20 PM
chich2 Turbo, Are you going... 05-17-2007, 12:29 AM
turbostang I'll probably add a small air... 05-17-2007, 03:27 AM
chich2 X axis ballnut mount 05-29-2007, 02:27 PM
turbostang Chich - how much movement are... 05-29-2007, 02:46 PM
chich2 Thanks mate! How's work on... 06-01-2007, 10:00 PM
turbostang I haven't touched it as far... 06-01-2007, 10:10 PM
ozzie34231 Chich, Your X axis nut mount... 06-02-2007, 04:28 PM
chich2 X axis Ballscrew Assembly 06-03-2007, 01:16 PM
ozzie34231 Yes, I like that arrangement,... 06-03-2007, 09:33 PM
chich2 Please read next post.......... 06-04-2007, 04:48 AM
chich2 Ozzie, Sounds like you... 06-04-2007, 04:51 AM
ozzie34231 No pics yet, most of the... 06-04-2007, 06:51 PM
chich2 Ozzie, Hot glue... 06-06-2007, 06:32 AM
chich2 Finished X axis Ballscrew... 06-14-2007, 12:32 PM
davo727 That looks awesome Chich, ... 06-15-2007, 04:45 AM
chich2 Wireless Pendant 06-17-2007, 11:28 AM
epineh Cool Chich !!! now you just... 06-17-2007, 12:06 PM
ozzie34231 Hot glue seals 06-17-2007, 12:34 PM
chich2 Started converting the Y axis... 06-24-2007, 01:55 PM
chich2 More Y axis ballnut mount. 07-11-2007, 02:08 PM
chich2 Oliomio, Thanks for... 10-29-2007, 02:55 AM
chich2 Seperated Column from Base 10-29-2007, 03:21 AM
chich2 Filing, Scraping, Linishing,... 10-29-2007, 01:38 PM
chich2 Bottom of the Column 10-30-2007, 02:06 AM
philbert Slightly off topic, but I'd... 11-21-2007, 04:45 AM
davo727 Hi Chich, Nice work!! Thanks... 11-21-2007, 05:58 AM
chich2 Phill, Welcome to... 11-21-2007, 10:46 AM
chich2 Upgrade to 2.2Kw 3 Phase... 11-21-2007, 11:34 AM
chich2 Horizontal Spindle Motor 11-24-2007, 04:29 PM
chich2 MY MILL IS BACK TOGETHER!!!!!! 11-25-2007, 02:41 PM
chich2 Thanks Digits. Yep... 11-27-2007, 03:08 PM
philbert Hey Chich, Are you... 11-28-2007, 01:48 AM
chich2 Phill, I am adding a... 11-28-2007, 02:27 PM
chich2 CNC Horizontal Milled motor... 12-15-2007, 12:48 PM
philbert Thanks for the update chich. ... 12-15-2007, 09:38 PM
epineh Hey Chich, I am just doing... 12-16-2007, 03:21 AM
chich2 Phil, I have the VFD set... 12-16-2007, 11:30 AM
chich2 Russ, I can't find... 12-16-2007, 11:54 AM
chich2 Hopefully my previous post... 12-16-2007, 12:09 PM
epineh 'Tis done, attached are pics... 12-16-2007, 02:16 PM
RotarySMP Thanks for posting this... 12-16-2007, 04:44 PM
epineh No prob Mark, the components... 12-17-2007, 03:26 AM
davo727 Looks good chich, Im still... 12-17-2007, 12:47 AM
chich2 Good one... 12-17-2007, 11:45 AM
epineh Hey Chich, I should be able... 12-17-2007, 12:27 PM
philbert chich, How much did the... 12-20-2007, 08:13 AM
chich2 Phil, I belive the... 12-23-2007, 05:39 AM
chich2 New Spindle Control Enclosure 12-27-2007, 01:02 PM
epineh My ... that is a very nice... 12-28-2007, 01:42 AM
RotarySMP Hi Russell, Sorry, I... 12-28-2007, 06:42 PM
epineh Ah, my bad... I think I will... 12-29-2007, 12:50 AM
RotarySMP No hurry, I think a number of... 12-30-2007, 09:42 AM
chich2 VFD Enclosure cooling fan 01-19-2008, 01:25 PM
chich2 Thanks for the post SimjetAU,... 01-21-2008, 12:52 AM
SimjetAU ballscrews 01-21-2008, 01:20 AM
chich2 Mark, Yes I got my... 01-21-2008, 02:00 PM
chich2 More work on the VFD enclosure 01-27-2008, 11:14 AM
chich2 Finished Spindle VFD Control... 01-27-2008, 12:14 PM
chich2 New X axis motor mount 03-04-2008, 01:59 PM
chich2 Hey Apples, Thanks for... 03-09-2008, 12:28 PM
Apples I've been reading up about... 03-10-2008, 11:49 PM
chich2 Apples, Yes the RHS... 03-12-2008, 10:35 AM
chich2 New Bigger X Axis Servo 04-01-2008, 02:42 PM
chich2 3D Face 04-02-2008, 01:12 AM
chich2 Milling 3D Face 04-17-2008, 02:22 PM
epineh That is cool ! Also one of... 04-17-2008, 10:18 PM
yosefi83 Nice work chich2! Tell me... 04-18-2008, 08:22 PM
chich2 Hello Daniel, Thanks... 04-22-2008, 07:36 AM
yosefi83 Hi Chich, Thanks for the... 04-23-2008, 07:17 AM
chich2 Daniel, I own a Roland... 04-25-2008, 01:14 PM
yosefi83 Thank Chich! I'll look at... 04-25-2008, 01:54 PM
chich2 Poor Repeatability on Z axis 06-24-2008, 12:37 PM
chich2 Column Brace 06-24-2008, 01:01 PM
epineh Hi Breck, I think we could... 07-27-2008, 01:20 PM
chich2 John, I would like to... 07-27-2008, 11:53 PM
chich2 Cooling Water Jacket 08-05-2008, 01:23 PM
chich2 Cooling Water Jacket Video's 08-05-2008, 01:31 PM
cjmerlincnc Hi Chich2, Nice work mate.... 08-05-2008, 02:58 PM
epineh Awesome job on the water... 08-10-2008, 11:20 AM
evo4wrx Quill or Knee. 09-10-2008, 04:20 PM
FPV_GTp wooooooooooooooo CADSmill is... 09-11-2008, 04:52 AM
chich2 evo4wrx, Good question... 09-11-2008, 01:01 PM
chich2 Start of the Horizontal... 09-22-2008, 03:13 AM
chich2 Horizontal spindle Gang Lathe 09-22-2008, 05:11 AM
chich2 Horizontal spindle Gang Lathe 09-22-2008, 05:30 AM
CROSSHATCH Thats really awesome :) Nice... 09-23-2008, 03:04 AM
chich2 Jason, Thanks Mate! ... 09-23-2008, 08:03 AM
chich2 Finished Horizontal Spindle... 09-23-2008, 08:14 AM
chich2 HERE'S THE VID 09-23-2008, 01:21 PM
chich2 NEW Power Supply for my mill. 11-01-2008, 01:17 PM
epineh Nice work on getting all that... 11-02-2008, 12:08 PM
oceanvision Read through your project,... 12-07-2008, 09:42 AM
chich2 Hello again. Sorry for not... 12-15-2008, 10:06 AM
chich2 Y axis upgrade 12-15-2008, 12:29 PM
chich2 New Y axis Servo Mount 12-15-2008, 12:44 PM
chich2 Finished Y axis Servo Mount. 12-17-2008, 12:35 PM
epineh That is cool Chich, looking... 12-22-2008, 11:28 PM
chich2 Rigid wood router it is!!!!! 12-23-2008, 12:13 PM
epineh Hey Chich, looks like the... 12-23-2008, 12:24 PM
chich2 Video of the Mill with the... 01-25-2009, 12:42 PM
chich2 Mill converted to a CNC Lathe 01-28-2009, 12:29 PM
LeeWay Very versatile machine. If I... 01-28-2009, 03:00 PM
chich2 amacf1, Thanks for... 10-19-2009, 01:43 PM
amacf1 Thank you 10-20-2009, 03:09 PM
chich2 amacf1, Yes I would... 10-27-2009, 01:47 PM
amacf1 Thanks again I have a... 10-27-2009, 02:55 PM
amacf1 In hindsight what size motors... 10-29-2009, 10:10 AM
chich2 amacf1, WOW that is... 10-30-2009, 12:56 PM
amacf1 Thanks for replying – Yes it... 10-31-2009, 12:54 PM
amacf1 I am going for Servo motors 11-28-2009, 06:26 AM
TMF im not really sure on the... 11-28-2009, 07:37 AM
chich2 Nice!!! Sounds like a neat... 11-01-2009, 12:41 PM
TMF your thoughts 11-28-2009, 03:56 AM
chich2 Hello, The Hafco mill... 01-22-2010, 01:50 PM
epineh :) .... still I don't know... 01-22-2010, 02:29 PM
RayGardiner Hi Chich2, I'm about to... 02-27-2010, 03:25 AM
Krauss_loco HM52/50 02-03-2011, 02:34 AM
chich2 Krauss loco, Sory mate, I... 02-08-2011, 02:57 PM
macarms Hi every one, I am new to... 07-01-2011, 02:03 PM
chich2 Hello Mac, Welcome to... 07-08-2011, 12:19 PM
macarms Thats a bugger about the BBQ,... 07-10-2011, 09:51 PM
macarms Well its all back togeather... 07-21-2011, 12:52 PM
ELM3060 G'day chich2, can I... 09-05-2011, 01:36 PM
ELM3060 G'day chich2, can I... 09-05-2011, 01:37 PM
Krauss_loco Could ayone tell me the ratio... 11-16-2011, 01:02 AM
Davo J Hi Mac, Nice job, your nut... 12-15-2011, 12:05 PM
chich2 The Big move! 11-10-2012, 01:24 PM
epineh Awesome !!! Looks like you... 11-11-2012, 12:32 AM
chich2 Fired up the old HM-52 today... 10-30-2013, 01:50 PM
arvidj I would like to say "glad to... 11-01-2013, 03:19 PM
chich2 Haa haa, Yes im still... 11-18-2013, 11:50 PM
Mallala_John Hi again Chich, How long was... 12-10-2013, 05:26 AM
chich2 Re: Hafco Metal Master HM-52... 11-28-2014, 12:47 PM
  1. #1
    Join Date
    Apr 2006
    Posts
    158
    You know, this would be a great time to install a oneshot lube system. Since it will be CNC a motorized one would be even better. It will extend the life of the mill. And since everything is in pieces...

    There is one more option for using the Z that you have not mentioned. It is the method that was used on my Supermax. It consists of a 4" ID air cylinder. the rod is removed replaced with the screw attached to the piston. the nut rotates on top of the cylinder on a thrust bearing. A timing pulley is fitted around the nut and is belt driven. Then the screw goes up into the knee. A pressure regulator is then used to adjust the pressure through the bottom port and balances the knee. Mine balances out at around 40 PSI (Guess that meand my knee/table weighs about 500 lbs. When the knee goes up the regualtor keeps it at 40 and when it goes down it dumps to keep it at 40. I think this is the regulator used on mine: http://store.norgren.com/US/en-US/ca...-300-RGLA.html

    Seems to work well. I have done some peck routines and it seems pretty responsive. Plus it leaves your head so you can do manual drilling and the like.

  2. #2
    Join Date
    Jun 2006
    Posts
    474
    macona,
    Great post! Yes your system would work perfectly. Nice and lite too. A simple chart could be made up with pressure versus weight on the knee therefore eliminating the worry of heavy jobs and mass..... Good one!

    A one shot lube system would be great. I will do a search for home made set ups but do you have any in mind that has details on how it is made?

    Chich

  3. #3
    Join Date
    Apr 2006
    Posts
    158
    Bijur (http://www.bijur.com) Is a pretty big name in oiling systems. I hear the parts are pretty cheap. You can get either manual or automatic pumps. These feed into manifolds with flow dividers and then steel lines to your points where you want oil. My mill has a chiba oiler hooked up to the servo power supply so whenever it comes on it starts pumping (Very slowly)Lines are also ran to the nuts to keep them nice and lubed (Well, not on mine anymore, I have ball screws now).

  4. #4
    Join Date
    Jun 2006
    Posts
    474
    macona,
    Thanks for the info. By the way what do you bolkes pay un the US for ball screws. The cheapest ones I can find down under for 18dia X 5mm pitch come in at around $700.00 AU per preload nut assembly and a couple hundred bucks for all the screw.

    Chich

  5. #5
    Join Date
    Oct 2006
    Posts
    19

    Air ram to the rescue

    G'day Guys

    Thanks for the posts Macona. I think a lube system is a pretty good idea also. On my machine i have those little brass ball bearing oil valves. I think these should easily push out then tap the hole for a bsp pipe fitting. Probably run some 3mm anealed copper tube to a central manafold. If there is nothing comercialy avaliable, shoud be a fairly easy job to make up a small hand driven pump. Just give a few pumps before every job..

    As for the air ram on the z axis, man what a great idea!!! :idea: Why didn't we think of that Chich?? I think a single 75mm ram mounted on the side of the knee would be ideal for my machine. Mabe even 2 smaller rams one on each side? There is room at the top of the knee lead screw to mount a pully for drive and plenty of room to mount the drive motor. At 100 psi a 75mm ram would give arround 320 kg of force.
    If i can't find a ram at the right price, I think i can make a simple air ram from some extruded alloy tube. Use black delrin (Plastic) for the piston and some "O" ring seals. I have a length of 20mm Dia chrome bar salvaged from an old photo copier for the piston rod. Should be bale to find a supplier in Aus for the regulator valve. I will look into this idea further over the next week and will keep you guys posted..


    Cheers

    Leeroy

  6. #6
    Join Date
    Jun 2006
    Posts
    474

    Y Axis Anti Backlash nut

    Well I'm back home for the week so I have been busy on the backlash quest again. I have stripped down the Milling machine to acsess the Y axis lead screw and nut. Since My mill is pulled apart to do this, the design of this nut has to be such that it can be entirely machined in the lathe. I will go through this photo by photo:

    1. The standard y axis nut and a piece of brass stock that I made the new nut from.
    2. The stock cleaned up and square.
    3. I parted off a chunk. This will be the 2 nut half's
    4. Faced the chunks flat and smooth.
    5. Both segments bolted together and the mounting pin machined to size.
    6. Nut squared up and boared and threaded.
    7. and 8. Next was to ensure the surface the nut bolts to on the mill was paralell to the slide. I flipped the Y slide over and milled it flat using the quill and dovetail ram.
    9. Made a new retainer washer nice and solid and increased the retainer thread size to M10. You can see how light the standard retainer is.
    10. The finished product. The nut comes apart and you shim the 2 halves apart to achieve the correct preload. This can be done on the bench before it is installed and can be easily accessed from under the knee for future adjustment. All that is left to do on the nut is to dowel the 2 segments together.

    Chich
    Attached Thumbnails Attached Thumbnails Standard Y Axis Lead Nut and stock for new nut.jpg   Y Axis Nut Square.jpg   Y Axis Nut parted in 2.jpg   Y Axis Nut faced segments.jpg  

    Y Axis Nut mounting dowel.jpg   Y Axis Nut finished and tested.jpg   Underside of swivel before milling flat.jpg   Underside of swivel after milling.jpg  

    Y Axis Nut with new retainer beside old retainer.jpg   Y Axis Nut in place.jpg  

  7. #7
    Join Date
    Jun 2006
    Posts
    474
    Leeroy,
    Yes the air ram idea pushes a very strong argument to automating the knee. In fact there are some industrial machines that use this system of offsetting weight. I have changed my mind and pretty much decided to go ahead with doing the knee over the quill on my my machine as I have plenty of ideas for different configurations on my mill that require the knee to be Z rather than the quill. I have a very acurate air regulator that reacts to very minor pressure variations and a friend of mine is sending a pneumatic cylinder to me for free so a Z knee for me is looking good at this point.

    once I have Compleated the CNC Conversion of my HM-52 and done all 4 axis X,Y,Z knee and A, My future plans for my machine at this point are:

    1. I will extend the dovetail ram all the way out. Bolted firmly underneath this will be an electric bench grinder. Hey presto! a rigid surface grinder. X axis will sweep backwards and forwards and Y will inch across once per back and forth stroke of X. Z knee will be depth of cut.

    2. The HM-52 has a horozontal spindle. In the lathe I will machine a INT30 taper out of a large piece of high tensile stock. I will then place the taper into the horozontal spindle of the HM-52 Mill. I will bolt a turning tool to the table of my Mill and Hey presto! again My mill is now a CNC Lathe! I will turn the piece of stock to a face plate to hold a small 4 Jaw chuck. Sweet! I will then use the macine to CNC turn another INT30 taper which means I can make as many of them as I like. The second taper will go into the spindle and It will be a face plate for a small 3 jaw chuck.

    3. Tool changer will be next. The tool changer will be bolted frmly to one end of the mill table pointing up. In this configuration It will be a tool changer for the quill. Standing up on it's edge it will be a tool changer for the horozontal spindle (if it fit's without smashing the other tools into the pillar). It will have a removable head so I can take off all the milling tools and put a head on it that holds turning tools. In this configuration it will look very similar to an industrial CNC lathe tool changer. So that leaves my machine as a very multi use machine. It will be a cnc knee mill, a cnc surface grinder, and a cnc lathe all in one! What a great machine!

  8. #8
    Join Date
    Apr 2006
    Posts
    158
    I would try to use a cylinder co-axial with the leadscrew for the knee. This eliminates potential binding issues i using one or two cylinders elsewhere.

    I would seriously rethink the idea of using the mill as a surface grinder. First there is the highly abrasive grinding dust. This WILL get everywhere and it will wear out your machine in no time. Second the x axis of a surface grinder is usually a rack and pinion affair. With the amount of going back and forth you are going to wear out you leadscrews in no time.

    If you are really dedicated in needing a surface grinder you could always buid one from scratch. I have seen it done. Dont risk your mill for something like this!

  9. #9
    Join Date
    Jun 2006
    Posts
    474
    Macona,
    Thanks for the concern. I have already designed these problems out by fully shielding the slide ways and containing the dust. The use of coolant almost compleatly eliminates dust as well. Secondly the amount of grinding I will do will be extreemly minimal.
    The issue with binding is not that of the screw but however the slides. The HM-52 has a large dovetail slide about 500mm of contact. I assume binding in this area will not be an issue. Once again thanks for the concern but I am going to give it a go.

    Chich

  10. #10
    Join Date
    Jun 2006
    Posts
    474

    Start of the Z Axis

    Today I started the conversion of my Z axis. I am definately going ahead with converting the knee to cnc over the quill. I need a flat machined surface to bolt the servo mount and air cylinder to so I flipped over the knee and secured it to the machine up side down so I can face it using the dovetail ram. Up until tonight I have the knee in place and locked off square to the collumn. Tommorrow I will re-fit the dovetail ram and vertical spindle assembly and do the job of actually facing the knee.

    I won't go through each photo and give a description but if you hold your mouse pointer over the thumbnail it will display the file name of the photo. The file name has a brief description of the photo.

    Chich.
    Attached Thumbnails Attached Thumbnails 1.Main Isolator off and locked in position Mains power also Disconnected.jpg   2.Dissmantled the Knee lead screw and nut.jpg   3.Horizontal spindle assembled.jpg   4. Front Before removing the horizontal Spindle.jpg  

    5.Back Before removing the horizontal Spindle.jpg   6.Horizontal spindle removed and bearing numbers recorded.jpg   7.Verticle spindle motor wires labled and disconnected.jpg   8.Ram and vertical spindle removed.jpg  

    9.load of knee supported to remove the gib.jpg   10.Knee comming off.jpg   11.Knee back on up side down and locked ready for machining.jpg  

  11. #11
    Join Date
    Jun 2006
    Posts
    474

    More Z Axis progress

    Today I replaced the dovetail ram and vertical spindle assembly and bolted it down tight. Following that was another check for square then set up my small boring head to do some facing. The travel on the dovetail ram does not allow me to go any further back towards the column so I set the diameter of the boring as big as I could get it to fit inside the underside of the knee without it hitting any thing. I will either use a mount skinny enough to fit in the gap or carefullt grind and file away the radiused ends of the cut.

    I have attached more photo's for you to look at. Once again hover your mouse over the thumbnail to see the file name description.

    Chich
    Attached Thumbnails Attached Thumbnails 1. Putting the Vertical spindle and drive back on.jpg   2. Bolted on tight.jpg   3. Boring Head set up for maximum swing without hitting Knee..jpg   4. Another Set up of the Boring head.jpg  

    5. Machining Z axis mounting surface - First pass.jpg   6. Machining Z axis mounting surface - Finished.jpg  

  12. #12
    Join Date
    Apr 2006
    Posts
    158
    Yeah, coolant will work to help with the dust. One further note though, the bearings in a bench grinder will not be good enough to get a decent finish with the grinder. Probably best to build your own arbor. Maybe you can belt drive it and run it from your horiz spindle. something like 1:2 ought to get enough speed.

  13. #13
    Join Date
    Jun 2006
    Posts
    474
    Macona,

  14. #14
    Join Date
    Jun 2006
    Posts
    474
    Macona,
    Thanks for the great info. I have been enquiring about suitable grinding wheels to use as a surface grinder. Eg. Type - Alli oxide, Sillica Carbide, size, grit, recomended speed, suitability to what kind of coolant. Do you know where I could get this type of information? I like your idea of using the horizontal spindle and belt driving a seperate arbor. Good one! Bearing manufactures like SKF and FAG make a ready to go bearing housing with a shaft on 2 bearings preloaded ready to go for this type of application. Normally used on high speed fans and simmilar assemblies this unit would be perfect for the job. Designation "PDN two-bearing housing". You can purchase just the housing by itself and fit 2 deep groove ball bearings and make a shaft to suit OR there is a part number for the complete assemblies.

    I'm off back to work for another week so there will be no further progress post's from me until I get back next week,

    Chich

  15. #15
    Join Date
    Oct 2006
    Posts
    19

    New Quill Finialy Finished

    G'day Guys

    Well after two weeks of "A bit here and there" the new quill is done.

    It was all pretty straight forward as the photos sudgest, with a few exceptions.

    Firstly the dia of the chrome bar was 89.995mm as supplied. This was a almost perfect fit on the bore of my mill head(90.005mm).
    However i had a feeling it might expand slightly when i drilled the center out. Which it did by almost 0.03mm!!! There must have been some residual stresses in the steel which i "releaved" when i drilled it out. This ment some honing of the bore was required to get the fit right, which was done with an automotive cilinder hone in a cordless drill.

    Secondly, Hard chrome plated bar is REALLY FRIKIN HARD!!
    When i went to cut the rack teeth, HSS hardly left a mark on it let alone cut it! I had to resort to using a few old solid carbide end mills, reground to a "v" shape. One roughing tool ground slightly undersize, held in the collet chuck and used in the conventional way, and another form tool carfully ground to fit the original teeth and held in my boring head. I also marked the teeth positions and using a 4" angle grinder, ground the some of the chrome away in each tooth position. This gave the cutter tip much better life.

    The finial result is even better than expected. Due to the top end being about 0.005 larger than the rest (Mostly due to the interference fit of the top bearing) the quill actualy gets slightly tighter as it is lowered, just what i needed!

    The name if each pic is a shot description.

    Cheers

    Leeroy
    Attached Thumbnails Attached Thumbnails 1Machine end for collar.jpg   2Shrink fit collar on-Note weld prep..jpg   3Drilling 65 Dia hole!.jpg   4Setup to bore for bearings.jpg  

    5New and old together.jpg   6Roughing the rack teeth.jpg   7Finishing the rack teeth.jpg   8Teeth debured and ready to install.jpg  


  16. #16
    Join Date
    Apr 2006
    Posts
    158
    Nice work on the quill!

    As for grinding wheel types I am not sure. I have never done surface grinding.

    As for the spindle I think you are going to want something with anguar contac bearing. Even deep groove bearings still have some annular play. I tried deep groove on a lttle tool post frinder I made oce and coulnt get a finish worth a darn.

    Maybe of you got one of those spindle housings and installed angular contact you could do it, though you are going to need an arbor that has a not to preload the bearings.

  17. #17
    Join Date
    Apr 2006
    Posts
    158
    Oh yeah, ask over at www.practicalmachinist.com for info on wheel selection.

  18. #18
    Join Date
    Jun 2006
    Posts
    474
    Leeroy,
    Well done!!!!!! Nice work on your new Quil.

    Chich

  19. #19
    Join Date
    Jun 2006
    Posts
    474

    Z Axis update

    Well Im back home for another week. Today I drew some plans and made a bearing block to house an angular contact bearing for one part of my Z axis. I want to keep this machine usable as a manual machine so I have made the new components fit into place where the standard thrust bearings were and make sure the bevel gears still mesh correctly for the knee hand wheel. (crank)

    My saw is not running at the moment so I parted off a piece of 2.5inch dia high tensile 4140 bar. Then made the bearing block out of that. The bearing is a 7205B angular contact bearing. It will be preloaded against another 7205B using the standard nuts that retain the bevel gear. As can be seen in the sketch.

    That's all I got done today but will be back at it tomorrow.

    Chich
    Attached Thumbnails Attached Thumbnails Hand drawn plans for Z axis.jpg   Hand drawn plans for Y and Z axis.jpg   2.5 inch dia 4140 high tensile rod 1 meter long.jpg   Bar stock with part ready to be cut off.jpg  

    Dialled in ready to be boared out.jpg   Finished to size to fit a 7205 B bearing.jpg   Finished bearing block with bearing size for size fit.jpg  

  20. #20
    Join Date
    Jun 2006
    Posts
    474

    More on the Z axis

    Thanks for the link Macona,
    Today I machines up a few parts for the Z and Y axis's. For the Z axis I made some stepped collars and washers that go up hard against the angular contact bearings. The collars and washers space the spinning component away for the fixed race of the bearing. The spacer ring that sits up against the shoulder of the lead screw has the bottom angular contact bearing sitting on it supporting all the weight. Directly below it is where I mounted my toothed pulley to drive the screw. I do not want lubricant from the bearing getting onto the pulleys or belt so I made the bottom spacer with a lip seal running on the outside of it. On the inside of the spacer I machined a groove and installed an o-ring between the spacer and the shaft of the leadscrew.

    The first photo is of all the new components sitting beside all the standard components. Both setups share the lead screw, bevel gear for the hand wheel and the 2 preload/lock nut's.

    Second Pic is of all the new components on the lead screw.

    No.3 is the Z axis drive pulley dialed up in the lathe ready to be machined.

    4. Is the pulley with the Boss faced off.

    5. is the pulley boared out and a slight tap fit onto the leadscrew.

    6. Toothed pulley in position on Z axis lead screw. 2 M6 grub screws will later secure the pulley into position.

    7. Is my pneumatic cylinder that I'll use to assist lifting the weight of my knee. In this photo I have cut one clevis eye off the bottom using a hacksaw. The cylinder has a 100mm piston and 400mm stroke from a 25mm rod.

    8. I decided to do some work on the Y asis as well so I chucked the standard bearing mount and dialed it true.

    9. I then bored out the Y axis bearing mount to fit 2 x 7203B angular contact bearings. The 2 bearings seat up against a shoulder inside the mount back to back for preloading. I faced the mount true to the axis in one operation so later when I attach the motor mount it will all be square.

    That is it for today. I have drawn up a sketch for the servo mount and the cylinder mount an will start on that tomorrow.



    Chich
    Attached Thumbnails Attached Thumbnails 1. New and old components for Z Axis bearing mount.jpg   2. Z axis bearing mount assembled with the new bearings and mounts.jpg   3. Z axis drive pulley dialed in.jpg   4. Z axis pulley with Boss removed.jpg  

    5. Z axis pulley test fitted to lead screw.jpg   6. Z axis pulley in position on lead screw.jpg   7. Z axis pneumatic cylinder with clevis cut off.jpg   8. Standard Y axis bearing mount set up in lathe.jpg  

    9. Standard Y axis bearing mount modified and new bearings installed.jpg  

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