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Thread: Churchill Cylindrical Grinder
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28th Aug 2019, 10:08 PM #16Most Valued Member
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- Apr 2012
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Generator
Hi fella's, the 110 volt DC generator that powers the electrical circuit for the hydraulics for the grinding dwell control is a goer.
If anyone is interested in the timer control board you can see it here https://metalworkforums.com/f309/t20...estions-please
Ok.... firstly don't be lazy, like me, don't use a CCMT insert to cut copper.
Yeah it works sorta but not as good as HSS, as can be seen in the photo below it cut pretty rough and smudged into the gap between the segments. No biggie as I needed to undercut the commutator anyway.
After undercutting I finished with wd40 and 400 wet and dry on a lathe file.
I made a rotary grinding tool to dress the damaged/worn brushes, with the emery glued on it was pretty close to the same diameter as the commutator, as you can see it clogged the emery but still did the job.
So now I need to make some pulley's, with the generator spinning at 1150 rpm it puts out 110 volts so I will need to make the ratio to suit that. The oil pump drive motor also drives the generator and has a double row sprocket on the shaft for the generator and nothing on the generator shaft, I will remove the sprocket and fit a pulley's and a belt.
Both the oil pump drive motor and the generator have virtually no adjustment, maybe half a bolt diameter of adjustment, so I think that it will end up with a spring loaded idler pulley.
cheers, shed
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24th Sep 2019, 07:16 PM #17Most Valued Member
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- Apr 2012
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generator drive
I found some pulley's to drive the generator, I made a drive pulley out of an old howard bantam pulley and bored it to suit the shaft on the test motor pictured in the previous post.
I then cleaned up an old alloy pulley to about the size i needed and fitted it on the generator and fitted a belt, i adjusted the motor rpm with the vfd to exactly the same rpm that the drive motor on the grinder runs at and measured the generator voltage.
I removed and machined the pulley 3 or 4 times until the generator was running at the speed required and putting out 110 volts.
Then rebored the cast pulley to suit the motor on the grinder and gave it a keyway.
I put the gen back on the machine and made a idler pulley bracket and tidied up another pulley, bored it and fitted a couple of brgs.
Test runLast edited by shedhappens; 24th Sep 2019 at 07:37 PM. Reason: editing
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24th Sep 2019, 07:34 PM #18Most Valued Member
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- Apr 2012
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- Healesville
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Grinding wheel balance weights
I noticed that when the grinding wheel was running that I could see the work head vibrating, it wasn't much of a vibration tho and it felt only slight...... but...
There was no weights in the bucket of rust that came with the machine nor was there any in the spare wheel flange, i guess the pics should tell the story here, both of the wheel flange dovetails needed re machining and as you will see the balance weights are not quite finished but well on the way.
cheers, shed
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28th Sep 2019, 12:14 AM #19
Hi John,
How are the weights secured, or are they loose like those on CD drives ?Best Regards:
Baron J.
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28th Sep 2019, 07:25 PM #20Most Valued Member
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Hi John, there will be a grub screw at the centre line of the 2 halfs.
With a bit of luck i will get the threaded holes done in the next day or so..... actually... it might be a little longer because i am thinking that i would like all the threaded holes to have the threads start at the same point so that all the weights (inner and outer) are interchangeable with each other, if that makes sense
cheers, shed
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28th Sep 2019, 08:17 PM #21
Hi John,
Yes that makes perfect sense.
I must admit I did struggle to try and work out how you would secure them where you needed them. Very nice work making them as well.
Thanks for the explanation.Best Regards:
Baron J.
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29th Sep 2019, 03:11 AM #22Most Valued Member
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- Aug 2011
- Location
- Melbourne
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- 4,779
That's a nice job with the balancing weights shed.
My surface grinder uses similar weights as well.
Simon
Sent from my SM-G970F using TapatalkGirl, I don't wanna know about your mild-mannered alter ego or anything like that." I mean, you tell me you're, uh, super-mega-ultra-lightning babe? That's all right with me. I'm good. I'm good.
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1st Oct 2019, 05:35 PM #23Most Valued Member
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- Healesville
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Finished the wheel weights
Here are the finished weights, the longer weight is a spare, when i say spare i mean that if it is needed it gives me the option of using it as is or cutting it in half and having 2 smaller weights.
I drilled the first hole a bit south of where i was planning, i wanted all the weights to be interchangeable with each other so i went
with that hole placement for all of them.
To get all the threads to start in the same place i drilled through the fixture with the 5.5mm tapping drill then put a 1/4" drill through the back of that hole and leaving about 12mm of the 5.5mm hole, then came in from the back and tapped the remaining 12mm of the 5.5mm hole to 1/4 unf.
With the weights clamped into the fixture i then tapped them from the back using the thread in the fixture as a thread starting and following guide.
For a grub screw effectiveness test i fitted all the weights into one of the flanges and set that up in the lathe and faced the weights,
none moved so i called that job done
Next up is a balancing gizmo, bit of a problem is there is no through hole in the outer wheel flange for a shaft to pass through.
cheers, shed
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21st Oct 2019, 04:31 PM #24Most Valued Member
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- Apr 2012
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- Healesville
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balancing gizmo
I still have a couple of other things to do to the grinder so i have not tried it yet.
The spindle parts are pressed together and turned to within a beez from the finished size then ground to size and i skimmed the flange
front and back while it was in the t&c grinder.
The spindle tube is an aftermarket m/c fork slider with a slug pressed into each end and turned for the brg's.
The brgs are ceramic brgs bought off ebay, they seemed a little gritty when i got them so i washed and blew them out and they are
much better. The shaft spins very freely and i think it should work ok for balancing this size grinding wheel.
I knocked up a frame and SHEZZZAM there is a wheel balancer on the bench
cheers, shed
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21st Oct 2019, 06:16 PM #25
Hi John,
Thats a lovely jobBest Regards:
Baron J.
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23rd Oct 2019, 05:46 PM #26Most Valued Member
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balancing
I weighed the 8 flange and mounting bolts, they were up to 1 gram different in weight, i took a bit off the ends with a flap disc
to get them all the same. Then i dressed the wheel before putting it on the gizmo.
The ceramic brgs did not work that fantastic, i washed the oil out of them and they might of worked a bit better.
So with a bit of guestamation and nearly falling off the chair a few times from getting dizzy watching that rock spinning around i think that i got it fairly close to balanced, i will soon know when i grind something.
The vibration that i could previously feel on the workhead has gone so that is promising, just for entertainment i did the 2 bob trick with all 4 motors running.
cheers, shed
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27th Oct 2019, 02:48 PM #27Most Valued Member
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- Apr 2012
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- Healesville
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replaced missing tailstock boot
Another little job ticked off the list.
I took some measurements and I found a suitable CV boot in a specials box that I had seen at an auto shop.
It works like a little beauty
cheers, shed
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29th Oct 2019, 06:36 PM #28Most Valued Member
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- Apr 2012
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- Healesville
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Coolant stuff
As you would expect the coolant tank was a swamp, or maybe it was a black lagoon.
I shoveled it out and cleaned it with hot water and degreaser, cleaned the all the pipe fittings ect and fitted new clear pipe.
I poured in 88 ltrs of water and 4 1/2 ltrs of coolant, I reckon it probably wants about 100 ltrs all up
One problem that needed attention was the wheel cover, the cover bowed out at the bottom and the coolant poured out of the crack
and straight into the coolant reservoir and by taking this shortcut it avoided the settlement tank.
So I made a poor copy of the existing cover clamp and fitted some grinder guard sealing strip.
Sparks soooon......
cheers, shed
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29th Oct 2019, 08:06 PM #29Most Valued Member
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- May 2011
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- Murray Bridge S Aust.
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Do you think the grinder guard sealing will hold up for any length of time???
KrynTo grow old is mandatory, growing up is optional.
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29th Oct 2019, 08:23 PM #30Most Valued Member
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- Apr 2012
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- Healesville
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Hi Kryn, "will it hold up"....... i pondered that very question myself, I thought about all the foam air cleaners and precleaners that i have cleaned and oiled over the years..... and given that it was in my hand and i didn't have to go for an hrs drive to find something else the answer to the qwestion "will it hold up" was .....suck it and see man...
cheers, shed
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