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  1. #1
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    small mill project.

    I got a small used cnc mill a year or 2 ago and have not had a chance to go through it and fix it up. The ways (sliding surfaces) look really good - but most everything else needs a little TLC. (ball nut mounts not parallel to the slides and such)

    The mill is torn down to its individual parts and being gone through. Currently working on the Z axis slide. Again - the sliding surfaces look great - but the mating surfaces are a bit off.

    What to do.. Mount it on the big mill of course!



    Using some ground rod/123 blocks to make sure the ways are parallel and perpendicular to the K&T.



    True up the mounting surfaces... (took off about .002")



    And done..



    Things to do yet on the Z axis column..
    - mill the relief for the ball screw nut further. (go into the more later)
    - mill the mounting holes so they are symetrical. (they are all over the place.)
    - mill some line up edges for mounting to the base. (I am adding a 4 inch riser block so there is more space between the spindle and the table)

    I think that is it for now.

  2. #2
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    Re: small mill project.

    This is what really set off the 'go through'



    The x axis ball nut block was not mounted parallel to the ways. (poor thing) and the more I dug into it - the more little problems there was. (not unexpected - this was a prototype)

    This should be one solid machine once I am done.

    sam

  3. #3
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    Re: small mill project.

    Found a chunk of cast iron (part of an old grinder..) to make a 4 inch riser. (this is to raise the Z column)

    I needed a piece about 7"X5"X9".

    - - - Updated - - -

    Started on the base (y axis)

    mounted it similar to the vertical column.. Then trued the feet to the ways then cut some reference points..





    Now - flip it and make some measurements and reference points.





    - - - Updated - - -

    4" Riser block kit... slight machining required. ..


  4. #4
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    Re: small mill project.

    The hacking has started...


  5. #5
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    Re: small mill project.

    Kinda like watching paint dry.. Guess I should work on some other things..



    it is 'squared'... Now on to machining...


  6. #6
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    Re: small mill project.

    the base and vertical off the mill.. I am happy so far.



    Now on to the riser block...

    Mounted - once I get a side flat - it should be easier to square up. I can rotate the table and do 2 sides with one setup - which makes them very square.



    First cut..



    First cut finished... Going to have to take maybe another .05" or so.


  7. #7
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    Re: small mill project.

    3 sides square... Getting there. (just going to eek it out..)



    Finally to the point of machining into the shape I need... (squared on 7 sides)



    Some rough machining...




  8. #8
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    Re: small mill project.

    Other side roughed..



    Some progress... I think I am going to make the over-all riser 5 inches.. (I can always make it shorter...) The column side is done. It fit together perfectly.. Very happy.

    Table rotation for finishing up the angles..


    finished end..


    Like a glove... (back)

  9. #9
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    Re: small mill project.

    Front..


    Line-up grove...


    Top support


    Whole thing...


    Front

  10. #10
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    Re: small mill project.

    Finally got the bottom finished (I think)





    - - - Updated - - -

    Yum...



    - - - Updated - - -

    seems to have bolted together.. Now to make sure it is perpendicular in both planes..




  11. #11
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    Re: small mill project.

    Finally got the little mill back on the big mill.. took a bit if finesse to level/square the base/Y axis. (without warping the casting..) We have a .0005"/10" level that works very well for these situations.

    Currently the column is <.001 square over its distance. (both directions..)



    sam

  12. #12
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    Re: small mill project.

    Now to get the rest lined up...



    - - - Updated - - -

    Redoing oil lines.. It didn't have metering valves and the Y axis ball screw was never plumbed..



    - - - Updated - - -

    I hate plumbing.. Getting there with a few side trips. Had to mount the X axis ball nut. It was so out of square that I machined 2 new holes instead of trying to use the existing 4 holes. (also made it easier to mount with the oil plumbing.)



    Checked clearance with the table...



    Another view.



    - - - Updated - - -

    Good enough.. (if it works)


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