square column mill conversion

[triberman]

I've been reading like crazy 'round here and need a little help. I really like the lathemasters and Ind. hobbies mills, but it looks like the ind. hobbies kit won't allow manual operation? I really need this.


I've been a toolmaker for 13 years and feel like I could do it myself if I had plans. The whole servo driver/power supply/encoder/controller thing has me a bit overwhelmed.


Has anyone done this conversion successfully that can help me? I'd be more than happy to buy plans but I've yet to find them.


Thanks in advance..

[ChrisJ]

Let me give you one idea of what you would need in addition to the brackets, belts, pulleys, bearings and other hardware stuff:

1. Modeling software to model your parts.
2. CAM software to generate Gcode.
3. CNC controller software (Mach2 or other).
4. Gecko Drives or Rutex drives to drive your stepper or servo motors.
5. Stepper or servo motors. Servo motors will need encoders.
6. Limit switches for each axis. BTW: IH makes some really good optical limits.
7. Power supply to feed the drives which ultimately feed your motors.
8. Breakout board by Cambell Design or other. Used to isolate your PC parallel port from the Geckos and provides 5 volt power to the Geckos.
9. If you want spindle speed control, then a spindle control board (Campbell Design or others) and a VFD.
10. Possibly some relays for interfacing your PC to your coolant pump, etc.

You can read up on Gecko's white papers at Geckodrive.com. This will give you some good understanding of the power supply and the wiring of the devices.

I probably left a few things out, but this gives you an idea. I figure by the time you finish buying all the components you need for each axis (ballscrews, ballnuts, gecko drive, servo motor, etc) you'll have spent $1K for each axis. When you look at what IH is charging, it isn't a huge difference between what you will spend doing it yourself versus buying their kit. At least with their kit, you are already protected with the use of flood coolant. And you can start making chips much faster.

Regarding needing manual control. I am setting up my machine to be fully automatic (IH mill with IH 3 axis kit). Based on what I read on what people are doing with Mach2/3 with pendants that have an MPG wheel, if you incorporate a pendant into the package, I believe this will give you a mill that can be operated through the software in a manual operation far more convenient than rotating the handwheel of each axis. But then again, this is only my impression. I haven't executed this configuration just yet.

Chris

[triberman]

I've got Rhino and Bobcad 20 with bobart so I guess I've got a start. The square column mill on ebay looks to be good, he said he laps the ways and installs a belt drive with the vfd for smooth high speeds. I just can't lay down all the cash and wait to see what happens, ya know? 4 week wait, no returns, ect..a risk IMHO.

C.S.< Thanks...I look forward to getting started!

[ChrisJ]

What! Let someone else lap your ways for you. That would be taking all the fun out of the CNC conversion process.

I am guessing you found a mill on Ebay???

[Bubba]

triberman,
If you put ballscrews on it, you will have a problem trying to do manual wheel turning. The force of the cutter or any other external force will move the table! If you try to leave the steppers/servos "locked" and do it that way, it won't work either. If you apply enough force (and it will be quite a bit), the motors will either return the table to original position or it will fault out and freewheel.

When I started this cnc thing, I also thought I "need" to be able to do the manual thing. How wrong I was. I have now gotten used to the keyboard input and my machine doesn't even have handwheels on it.

[triberman]

I've gotten in the habit of holding the idle handwheel on the ez-trak cnc I run when I do something manual. It seems to work for me, but then again the amount of "drift" is minimal. The ajax cnc looks sweet too, hardened and ground ways and all..
I talked to american express about covering me if something goes wrong with a machine purchased through paypal on ebay and they said no problem. Just report a fraudulent action and they go after the seller for the money. I guess I have to think about it. Thanks for the replies!

[triberman]

Has anyone used these servo's? I can't seem to find many sources for servo's that say they will work with gecko's and are powerful enough for the IH mill. Or maybe know another source?
The site does'nt give rpm, amp, or nothin'. Thanks...

http://www.lowcostcncretrofits.com/

[CNCadmin]

I'm converting my Seig X3 using steppers from Industrial hobbies and I will be able to use it manually. The stepper motors are double shafted so all I have to do is add a handles. If you do a servo set-up that may not work.

[ViperTX]

Originally Posted by CNCadmin I'm converting my Seig X3 using steppers from Industrial hobbies and I will be able to use it manually. The stepper motors are double shafted so all I have to do is add a handles. If you do a servo set-up that may not work.

I bet that will be fun...kclunk....kclunk.....last time I used steppers you could feel very detent...

[Nono]

I have an industrial hobbies mill and it is pretty cool.. I am not sure but have read you will not have to use it manualy if using mach 2,, Use the jogging feature for whatever you do.. I will let you know when I get there. I just finished dismantling it to move to the table and have put it back together.. I am working on connecting it to power and when I get that far will start converting it to cnc. I plan on doing my own retrofit using the mill for making the mounting plates/brackets. I have posted some pictures http://www.cnczone.com/gallery/showg...00/ppuser/3289 and will add more soon

[dammachines]

Nono,

Just wondering, do Industrial Hobbies do anything "extra" to their mills before shipping them out. Like lapping the ways or anything special?

I'm considering purchasing a mill from them with the intention of converting it to CNC almost immediately. I know it's the same mill that lathemaster sells, with a little more travel in all three axis I believe. However, I think it's close to twice what the lathemaster mill costs.

Just wondering if that cost is justified...

Thanks,
Dave.

[Nono]

This mill has hardened gears in the head so you can upgrade the motor to one that is higher speed and the table is larger. You might want to call Aaron and ask. I am not sure of all the differences but the guy is confident in what he sells and that makes a difference to me. His site has lots of information, made it easy for me to tear it down and set it back up on my bench in an afternoon.(advise, use a hoist that is rated for the job) One thing that I kind of overlooked is that this mill is 800+ pounds, That should reduce vibration as well.