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Thread: small mill project.

  1. #1
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    Default 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.

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  2. #2
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    Default 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



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    Default 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. ..





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    Default Re: small mill project.

    The hacking has started...





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    Default Re: small mill project.

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



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





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    Default 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.





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    Default 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...







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    Default 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)




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    Default Re: small mill project.

    Front..


    Line-up grove...


    Top support


    Whole thing...


    Front




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    Default 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..







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    Default 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



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    Default 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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    Default Re: small mill project.

    Ran some oil through the saddle. Checking the flow. These are bijur flow regulators I got off eBay. I think they will work great. I slid the y axis on and it slides very easy on the film of oil.

    Sam

    (These are not made for 4mm tubing - but I found out the pressed in reducer removes easy. I just need to be careful that the tube doesn't protrude too far into the regulator - they don't flow then.. )

    - - - Updated - - -

    Things like this - the x axis stepper mount was getting in the way of the oil fittings.



    So - snip snip here and there...



    Getting things lined up pretty good. The really sucky thing is the table is slightly narrower than the saddle. (you can see the the ways and oil troughs) No one knows the story behind that goof. I plan on grafting an aluminum piece that bolts to the table to extend it over the ways. (mainly I want the oil to mostly stay under the table.)





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    Default Re: small mill project.

    Without going past the ways - it looks like travel will be 10" x 7-3/8" X 10-5/8" (XYZ)

    - - - Updated - - -

    1/2 done. Went suprisingly smooth...







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    Default Re: small mill project.

    This is going to work well to fix the table width/way issue.



    - - - Updated - - -

    Some quick tests...





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    Default Re: small mill project.

    sorry about the quality...





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    Default Re: small mill project.

    Looks like the nose of the spindle will be 3 inches above the table.. I think that will be just fine.

    Thank goodness for soft limits...





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    Default Re: small mill project.

    Going to re-use the z axis way cover. I needed to add a extention to the ways so the accordion wouldn't get caught.



    Another exciting video...


    some random videos of making the way extension...







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    Default Re: small mill project.

    The reason why I added the 5" Z spacer...





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    Default Re: small mill project.

    Lovely work, thank you for (1) remembering to document as you went - something I never remember to do until it's too late - and (2) sharing it with us.



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