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shedhappens
17th Sep 2018, 10:06 PM
G/day all, I have finally decided to give this mill a bit of TLC, it is 3hp, 40 taper, 1650 kgs.
I have had it for about 10 years and have had some fun with it throwing chips and coolant far and wide.

It always did have quite a rattle coming from the variable drive but I was always to busy to look at it and I spoze
that I am a bit slack about some things, you know the old saying "don't fix it if it ain't broke" :wink:
Anyway back in 2014 I fitted 3ph to 3ph Powtran vector drive VFD for speed control and fixed the variable drive into a position that it didn't rattle so much and kept using it.
Then a couple years ago I was boring a hole and when it got to the bottom of the hole I decided to to do spring cut
on the way back up, not thinking I didn't stop the the mill, I pulled out the the quill feed direction knob into reverse and straight away I could the hear mill starting to complain, I hit the stop button to no avail as I have 8 or 9 second hz ramp down, yup it sounded like a slow motion train wreck so I reckon it might be a good idea to put a brake resistor on it.
When I pulled the knob out it grabbed two gears at once and jammed up, but she was still goin so I kept on using it.

I have a bit more time now so I have now spread it's innards across the shed so here is some dodgy pictures of where I am up to at the mo.

I am fitting taper Loc pulleys, the 1st one that I stuck in the lathe had a .018" wobble and .012" run out, the second had about .003" both ways.

My plan is to fit an electric motor for the quill feed.

cheers, shed

shedhappens
17th Sep 2018, 10:23 PM
The 3 hp motor had a 17.85mm dia shaft so I put some meat on it.
I faced the end and put a centre in it with the aid of the fixed steady then supported it with the tailstock to turn it to size, 29.95mm
I used 1020 and miged it.

cheers, shed

caskwarrior
17th Sep 2018, 11:07 PM
Looking great, will you just get all your speed control from the VFD now and have a single speed in the head? The taper locks are so much better that almost any other way of taking drive they just dont wear out, did you buy fenner ones or something else off the shelf here?

Keep it up - Ralph

shedhappens
17th Sep 2018, 11:43 PM
G/day Ralph, it was single speed as I was using it for the past 4 yrs as I secured the variable pulleys from moving,
I did that to get a bit more life out of the splines as I had more pressing things to deal with.
It had no lack of power issues, it is a sensorless vector drive VFD and these have much more torque at low RPM/frequency than the standard VFD's, a problem that I did have is the VFD would go into a fault at about 75 hz, maybe I don't have something set right.
I have machined down a groove on each pulley to give the mill 2 belt speeds, 1 pulley will face up and the other will face down, this should give me plenty of power and speed.
The pulleys are off the shelf from here but I would say that they are made in china.

cheers, shed

shedhappens
22nd Sep 2018, 06:29 PM
I am going to piff the damaged gears into the bin and fit a variable speed dc motor to the quill feed.
I have replaced the original engagement arm with a pb bush and a needle roller thrust brg and have replaced
one of the gears with a bevel gear, the bevel gear will be driven by a dc electric motor through the gear
cover, I am still tossing over whether to make a new gear cover or mod the existing one to fit the motor.

cheers, shed

caskwarrior
22nd Sep 2018, 11:47 PM
Looks like that mating bevel gear is just sneaking in there. I think this is going to be a much superior feed, fully variable, look forward to seeing it come together.

shedhappens
25th Sep 2018, 05:57 PM
The 2 top bushes for this feed g/box had no way to lube them and I didn't want my shiny new thrust brg and bronze bush to
run dry sometime in the future.
I made a small reservoir with a check valve so that the grease gun wouldn't push the gasket out from under the reservoir and when the lube spurts out of the check valve you know it's lubed up.

The reservoir is secured by a stud on one side and the plate that is bolted to the rough underside of the casting supports a jacking bolt to press down on the other side and the fittings screw in also.

The grease fittings are screwed in with No 3 soft setting gasket cement and the bolts have a drop of 290 loctite.

This is the grease that I will use for the quill feed gearbox https://www.penriteoil.com.au/products/semi-fluid-grease

cheers, shed

shedhappens
9th Oct 2018, 03:48 PM
A bit more progress on this, I have made a new cover and have moved the gearshift shaft over 6mm to give a bit more room to get a drive shaft through, the gears change very smoothly with this offset from the centreline of the gear.... I was a little worried about that before I started.
I don't know what the material is, I thought that it was duraflex, it was horrid to get a good surface finish on.
I installed dowel pins to ensure that the bevel gear mesh is retained and so that the cover will not move from side to side after years of use.
There are a few more holes needed in the cover and they will be decided on when I make the shaft and motor mounting.
cheers, shed

caskwarrior
9th Oct 2018, 06:58 PM
What was the dovetail cutter being used for in photo 3?

shedhappens
9th Oct 2018, 08:27 PM
G/day Ralph, I was having trouble with surface finish and I used the dovetail cutter to improve that, it was sharp new and multi-toothed and I used it to fluff cut the surface.
The little Centec suffers from rigidity and age related problems and so I needed to reduce load and vibration, so the problem was the mill not the material as it seemed to turn well enough in the lathe.

cheers, shed

shedhappens
21st Oct 2018, 08:19 PM
A few more pics of the progress here.

The mounting was turned from a bar of 75mm 4140 (because thats what I had).

The shaft I tried unsuccessfully to machine in the lathe but the surface finish was unacceptable no matter what I tried, I dont know what the material is but it is quite hard, it does file and a magnet sticks to it.
So I ground it in the T&C grinder.

The bushes I hope are PB,

It seems to have plenty of power but I noticed a bit of slip from (most likely) the motor coupling when I grab the hand wheel tightly, it took quite a bit holding though.
So I will add grub screws to the coupling.


cheers, shed

BaronJ
21st Oct 2018, 09:08 PM
Hi Shed,

Brilliant job ! I wish I could work to your standards :(

Just a note on the wiper motor. It is designed to drive the large gear anti clockwise, the worm pushing against the ball at the end. Not normally a problem, but some of these motors don't have anything at the other end of the shaft to push against other than a flat washer.

You have basically done the same as I did to the wiper motor when I made my mill table drive using one.

shedhappens
21st Oct 2018, 09:28 PM
Hi Baron, yeah it is the same as a wiper motor but no not a wiper motor, I hope this link still works https://www.ebay.com.au/itm/JCF63R-DC-12V-80W-High-Torque-Reversible-Electric-Gear-Motor-160RPM-/391820467808?hash=item5b3a51de60

simonl
22nd Oct 2018, 05:59 PM
Hey Shed,

The work on your mill looks bloody amazing. I like the method you used to align the hole and bush for the shaft. Nice work, very practical.

Do you use a PWM power supply on that DC motor?

Edit: I was pretty happy with my standard 3 speed quill feed feature on my mill..... that is until I saw your mod!

Simon

Simon

shedhappens
22nd Oct 2018, 08:30 PM
Do you use a PWM power supply on that DC motor?

Simon

Simon

I have a PWM and a power supply that I will use when I get a bit further on, yesterday I used a battery charger to run it, tried it on both 6v and 12v and it had plenty of power on 6v, so I guess that when using the PWM it should have plenty enough grunt at low speeds.

cheers, shed

simonl
23rd Oct 2018, 08:42 PM
The beauty of using PWM to control DC motor speed is that regardless of the speed setting, the motor still sees the full voltage, so torque is not compromised.

Simon

shedhappens
24th Dec 2018, 02:12 PM
I didn't want to hack a hole in the side of the mill so I devised a way to change belt speeds from the front, it goes like this.
1st loosen belt, lift flap and insert right hand in hole to move belt from one groove to the other while also turning the pulley and your left hand operates the lever
that guides the belt up or down on the rear pulley.

I made a temporary pulley support bracket to test my theory while making the bits and pieces.

shedhappens
24th Dec 2018, 02:37 PM
The top of the mill is alloy so i cut out and fitted 10 mm plate for the motor mounting plate to slide back and forth on and I had .0075" runout at the top of the input shaft.
I had been looking forward to checking that as when I set the shaft up to grind the spline off the top brg mounting surface was an oval shape, so .0075" wasn't to bad l guess.
I decided to fit an outer support brg for this shaft as it is hollow and I had removed a bit of its meat and it has a bit of runout, so I used a brg with a larger ID and made a bush and bored it .0075" off centre.
I installed a dowel pin either side of the input shaft and threaded holes in the cover for jacking bolts to remove the cover.

The shaft support bush and the motor mount pivot bolt are made out of EN36A

shedhappens
24th Dec 2018, 02:47 PM
some more pics

shedhappens
30th Dec 2018, 04:34 PM
Thought i would do a look n' see if it worked ok..... https://www.youtube.com/watch?v=0zEVYv5iTyI :D

caskwarrior
30th Dec 2018, 06:45 PM
That's very impressive, really quiet even at the high speed.

simonl
2nd Jan 2019, 03:59 PM
I like it!

Simon

azzrock
22nd Jul 2020, 08:52 PM
hi shed
you do great work mate. good on ya