New Machine Build- Kelly's Machine Tool Warehouse - MD001

[kregan]

Last week I was messing around with the power drawbar setup and realized after talking to Richard I had the wrong spring washers... I ordered some new ones and tonight I was able to test out the system. It works!!!

I now need to go back and finalize the setup but I need help with the air switch... I purchased a foot pedal thinking I could use the exhaust port to pushe the cylinder back up but did nto consider that the upper part of the cylinder would still have air pressure in it. DOH !!!

I am thinking I should probably just go ahead and get a electric powered air switch now because I can see the ATC setup coming real soon even if it is just a simple rack on the end of my table.

Any idea's ?

Power Drawbar Test - YouTube

[HimyKabibble]

Originally Posted by rwskinner I sure would like the know more about your home made fogbuster type nozzle Himy. I ran across an old yahoo message but never saw much detail. Richard

Below is everything you need to know....

Regards,
Ray L.

[cornbinder23]

Datron's use an Alcohol mist system, but it is only recommended for non ferrous metals (Ethanol)
I used to work at a chocolate factory and we had 5 of these for making dies for injection molding the chocolate molds.
Its a pretty intricate cooling system with it firing from both sides intermittently depending on the direction the axis is moving.

DATRON CNC Machines - YouTube

DATRON CNC Machines - YouTube

JTCUSTOMS

[pete from TN]

Never knew Willie Wonka was that high tech!! Those Datrons are badass machines. Very fast and some are built from granite plates for their beds....cool stuff. Anyone notice that their control is windows PC based apparently.... They appear to be able to setup four or five axis machines with robotic loading of parts and all sorts of cool stuff. I wonder if they are rigid enough to take light cuts in steels? they basically appear to be like monster CNC flatbed routers only extremely well made and engineered. peace

Pete

[kregan]

Cool Video.

Originally Posted by cornbinder23 Datron's use an Alcohol mist system, but it is only recommended for non ferrous metals (Ethanol) I used to work at a chocolate factory and we had 5 of these for making dies for injection molding the chocolate molds. Its a pretty intricate cooling system with it firing from both sides intermittently depending on the direction the axis is moving. DATRON CNC Machines - YouTube JTCUSTOMS

[kregan]

First cut video!

First Cuts On The New Mill - YouTube

This chews through aluminum way nicer then my smaller machine. The first cut is a 4 flute 3/8" at a DOC of .1 inch. The second cut is a 2 flute 1/2" at a DOC of .125 inch - 5500 RPM

This is huge for me.... I am used to cutting at depths of .02 - .05 on my smaller machine to keep the vibration down.

Anyway I am real happy with the machine even though it needs a lot more tweaking. Today I rerouted the air plumbing to both machines and ordered a new air switch. I decided NOT to get another foot pedal because I actually stepped on it by mistake last night while testing and it got me thinking.... if I did that while milling I would be hurting!!! I would rather have a lever style so that is what I ordered.

I also mixed up some of the BALLISTOL at 20:1 for a test. I used distilled water and it looks like milk when mixed with water. I am not sure I can deal with the smell, it is fairly strong, not bad, just potent. I put some on the mill table to see what it does when/if the water evaporates.

I also worked on the one shot oiler... Oil is not reaching all the ports so I think I have to hunt down some regulating valves for each tube.

[jid2]

That looks nice. Seems like you should be able to do deeper DOC. My typical DOC with my manual setup is .25" with a 1/2" 4 flute rougher, Ive even done .50" DOC when being lazy.

You should try some hoggin with a rougher.

[HimyKabibble]

Is that 2-flute HSS or carbide? If HSS, your RPM is about 2X what it should be, which will dull the tool very quickly. If carbide, then you need to up your feedrate. At 5500 RPM, you should be feeding about 2X that fast. Low feed will lead to a hot tool, and chip welding.

Regards,
Ray L.

[pete from TN]

Hey man congrats on the first cuts with the new mill. While I was watching that I was thinking quite the same as the other posters. That is really nothing compared to what it actually can do in aluminum. You should pick up some three flute cutters from whoever. I like these maritool carbide three fluters and they absolutely kick ass in 6061 or 7075. You could probably run that 1/2 inch at twice that feedrate easily at that DOC. If you get on IH's website and watch their videos of the machine cutting with a 3/4 inch three flute cutter it is most impressive so basically your machine should do that and more since you have a lot more available speed from your belt drive. I have a nice three flute 1/2 incher that is actually a finishing endmill from maritool but it cuts so damn fast in aluminum it is basically my rougher all the time for removing a lot of material. Then I will install my 3/8 or even my 1/8 for getting into the tighter stuff. Keep the tension on your drawbar as high as you can get it and follow Tormach's advice on how to properly lubricate and clean your collet mating surfaces as well as your drawbar tophat area. It makes a huge difference in holding power. Once you get that machine dialed in I think you will be very happy with it. Damn I wish I had those travels!! enjoy man...

Oh yeah I crashed the hell out of my daughter's heli the other day. Broke two of the blades and destroyed the tail rotor. Even broke the landing spar on one side. It still wants to fly tho so I think if I can get some new parts for it in here it will surely fly again. I cannot believe how durable that damn thing is. Most RC stuff I have owned once you crash it good a time or two it is basically done until you do some major surgery. This thing just keeps on ticking. I actually am getting really good at flying it but we are also getting into more complex flight paths thru the shop and over and under things so it gets more difficult. This time we were trying to land the heli on top of a ceiling mounted wood rack in the shop that is about ten inches from the ceiling. The target was a piece of 7 inch wide cedar plank with maybe nine inches of air above it. I ALMOST got it on there when I shut off the power but it kinda bounced a bit and then turned sideways and started to fall. Before I could get it powered back up and turned around it was already falling off the board and then down the nine and a half feet to the concrete floor. Still fun as hell tho.... The place where we bought this one sells a larger one that is supposed to be better in the wind but it is almost double the price. I may try to get one of those since this little one works so well... haha peace

Pete

[MrBean_pm]

Nice build, Kelly, and pointed here by Pete - between the 2 of you, I am going to be bankrupted - haha.

Luv your work, and will take a few tips wrt motor-sizing, as I am now seriously considering DMM as a supplier to my servo/controller needs - also might grab a few of those pretty nice proximities while I'm at it.

Good luck with your build, stellar job thus far, and looking forward to the final build.

Kind regards,
Phillip

[kregan]

Thanks guys I was nervous during that cut because I was testing all the systems together for the first time. I have a subscription to Gwizard but I need to rethink how I machine things now with this machine.

In the mean time I finished up the power drawbar plumbing with the new valve. Power Drawbar - YouTube

I also mixed up the Ballistol 20:1 and ran the flood coolant for the first time... What a mess! LOL but no leaks yet.

Here is a picture of the overall mill.

[rwskinner]

Thanks Ray!

Richard

Originally Posted by HimyKabibble Below is everything you need to know.... Regards, Ray L.