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Thread: PM45 mill upgrades

  1. #37
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    Default Re: PM45 mill upgrades

    Quote Originally Posted by CS900 View Post
    Ok...so got a little more done over the weekend. I've been thinking about how i'm going to assemble the saddle and realized that having the longer Y axis rails is really beneficial. I think my plan right now is to mount the blocks and rails to the saddle and then bolt the y rails down to the base and then bolt the table to the x rails. I think this is a lot more realistic than trying to bolt the rails to the bast and table and try to slip them into the blocks on the saddle. So I need enough travel on both axis to be able to access all the screws. That's not a problem on the table as it' got lots of travel already, so this weekend I focused on the Y axis.

    Now I know these look a little silly, and by no means to I plan on machining anything on them, but they will make installation a snap.
    fitting the bracket for match drilling...


    Rails all trimmed to length and new brackets all mounted up...



    I also have been reading the installation manual for these rails and it seems the "right" way to do it is to capture the master rail so it can't shift under load. Now I'm way to lazy to machine the base for a nice reference edge and make a bunch of clamps to pinch it in place...so for the fun of it I took one of the pieces of rail that had been cut off and drilled a 1/8" hole in it. Well wouldn't you know it drills like butter! the rails must be case hardened around the ball carriers. So I've now drilled the master rails for 3 1/8" roll pins. that should keep it in place!
    How much longer did you make y rails. I'm doing same thing. Thinking of making a rack on back of table for tool changer so need some extra room. Everything is looking real good so far.

    Sent from my SM-G900R4 using Tapatalk



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    Default Re: PM45 mill upgrades

    That is really interesting. At first looking at those rails I thought it was madness, but then I found this on a Hurco. http://www.hurco.com/sg/cnc-machine-...0angle-web.jpg
    Perhaps there is something in the Hiwin catalogue giving allowable overhang dimensions?
    Of course something underneath would be better.



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    Default Re: PM45 mill upgrades

    Quote Originally Posted by gearhead406 View Post
    How much longer did you make y rails. I'm doing same thing. Thinking of making a rack on back of table for tool changer so need some extra room. Everything is looking real good so far.

    Sent from my SM-G900R4 using Tapatalk
    Thanks. Overall they are about 22.5 in long. its about 3.5 inches longer than my original plan. That's a great idea though I could make a simple tool changer at the back end of the table. I'll never machine with the table out that far, but it would be great for a "pick and place" tool changer.



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    Default Re: PM45 mill upgrades

    Quote Originally Posted by j3dprints View Post
    That is really interesting. At first looking at those rails I thought it was madness, but then I found this on a Hurco. Service Unavailable
    Perhaps there is something in the Hiwin catalogue giving allowable overhang dimensions?
    Of course something underneath would be better.
    I didn't see anything in the NSK manual about it, but i may have a snippet of the full manual. I'm not sure. Either way, i'm not sure how daring I am with it. haha.



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    Default Re: PM45 mill upgrades

    I like it! .. naturally not for cutting .. if you hang anything very far off the back edge of the table it will hit the column when Y retracts.
    But great for tool clearance around the largest piece you are able to machine!
    No doubt much easier to install as you also pointed out!

    Gary



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    Default Re: PM45 mill upgrades

    Good job. Coming along nicely! Be handy having that extra travel for setting up.

    Sent from my SM-N910G using Tapatalk



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    Default Re: PM45 mill upgrades

    Ok...so got some good progress done and will hopefully get a bit more tomorrow.
    Got started on the Z axis mount. I was originally going to reuse the stock dovetail mount and just mill it down to size, but that would require me to trim the dovetails on the column as well. So I started from scratch.
    Getting started:


    I ended up reusing the stock mounting studs. The factory trimmed the bolt heads so one "side" is shorter than the others. Made for easy mounting. I ended up machining the slot about .001 smaller than the bolts and drawed them into place with the nuts.



    So far so good, and everything fits:


    Getting started on the Z axis...


    The 20mm rails give plenty of clearance.




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    Default Re: PM45 mill upgrades

    I like reading about project like this!

    What is the primary goal of adding the rails? Is it to increase X and Y travel so you can make larger parts? The limited travel is the main thing that put me off buying one of the small benchtop hobby mills. They just never seem to have enough for anything I would want to make.



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    Default Re: PM45 mill upgrades

    Quote Originally Posted by Goemon View Post
    I like reading about project like this!

    What is the primary goal of adding the rails? Is it to increase X and Y travel so you can make larger parts? The limited travel is the main thing that put me off buying one of the small benchtop hobby mills. They just never seem to have enough for anything I would want to make.
    It's not about increasing travels. I enjoy working on my machines and this is something I hope will increase the reliability of the mill and surface finish on the parts. I hear what your saying, they certainly are limited on travels, but 99% of the time it's more than adequate for what I need, and the times it's not, i get to do some "creative fixtureing", haha.


    So I was all excited to start bolting up the Z axis rails when it occurred to me that this is an opportune time to get the mill a bit better in tram without using shims. At least in one direction at least. So my new plan is to adjust the rails so the travel is perfectly perpendicular to the table side to side. BUT before I go doing that I have to ensure that the rails on the base and table are shimmed to be perpendicular first. Also before I do that I've been wanting to do an epoxy granite base fill for a while. I'd hate to do all the work of shimming everything only to have it all tweak a bit when the epoxy cures. So that's what I'm currently working on. I went and bought some gravel and sand from Lowes. The gravel is "prewashed" but you can see all the dirt in the bag. So I spent a bunch of time today washing them again. Right now everything is spread out drying, the sand included. It was quite damp.


    Also trying to get ready for the pour. I'm trying rubber cement around the bolts. I was originally going to use wax, and I may still have to, but the rubber cement is so much easier to apply. Even if it takes a few coats to fully cover the threads.



    I'm also taking advantage of the fact that the base is off the table to get started installing the enclosure. My goodness it's bigger than I rember and I'm going to have to move some stuff around, but overall I'm really looking forward to having it!




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    Default Re: PM45 mill upgrades

    more progress...got the base pretty much ready for the epoxy granite.
    started with cutting PVC to cover the column bolts and the base mounting bolts.


    the PVC were hot glued in place and filled with wax to help seal it up. I found that the rubber cement was a little to thin to encapsulate the bolts.



    I also partitioned off the area for the y axis ballscrew with some scrap poly carbonate that i had kicking around. My initial attempt to seal everything up was a disaster! Hot glue just was too thick to fit down in the gaps, but to thin to be able to build up to bridge the gaps. What a mess!


    So a little aluminum foil tape later and it looks much better. still not great, but good enough. I think she's all sealed up and ready for epoxy granite! hopefully tomorrow is the day!





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    Default Re: PM45 mill upgrades

    well tonight was the night! I made the composite 7lbs at a time.


    The first few mixtures were a bit epoxy rich which worked out well getting it in to the nooks and crannies. My starting formula was 8.6% epoxy, 26.9%sand, and 64.5% gravel. At the end i was doing 7.7, 24.3, and 68.


    I'll be happy when it's cured, i need my space back!


    Almost filled..


    But then i ran out of clean rocks! So now I wait for it to cure and then back to the fun.



  12. #48
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    Not much progress made tonight. I removed the plastic block offs and weighed it for fun. 184 lbs of vibration dampening goodness!



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