Mini Horizontal boring mill build

[S_J_H]

Time for a dedicated thread as the machine is becoming a reality now.
Early threads with some discussion here- http://bbs.homeshopmachinist.net/showthread.php?t=29875&highlight=gilman
and here- http://bbs.homeshopmachinist.net/showthread.php?t=31008&highlight=building+machines

So basically I'm building a small horizontal boring mill/lathe.
The bed and base is a high end Gilman box way slide. .ooo5" accuracy over 3 feet. Meehanite iron base with hardened and ground rails. Scraped bearing surfaces and anti friction coating on the gibs.
The 2 columns are from a Sieg mini mill. The spindle is from a Sieg mini mill retrofitted with better bearings.
The z-axis for the horizontal spindle is 16tpi acme with a delrin nut. A gas strut will be used for counterbalance.
.2 pitch ball screws are used on the long and cross feed axis with dual preloaded nuts. 269oz steppers on each axis. The cross feed has been tested at a smooth reliable 200IPM and I have not yet fully tested the long axis as I just finished it today.
The cross feed table is mounted to a doweled sub plate so it can be easily removed for parts that might need to be mounted directly to the table.
The z axis is manual for now.
The spindle will be indexed with a proximity sensor and this info sent to mach 3. This will enable the machine to cut any pitch thread.
The spindle transmission is a 3 speed planetary drive with reductions of 72:1-40:1- and 13.5:1 and features a detent torque sensing clutch. A direct drive mode with slight reduction is also available by swapping the belts around.
Spindle speeds of around 20-3000+. A dc 5000 rpm motor and a Minarik DC drive will be used.
The boring bar in the pictures is there for scale. It is 1" diameter by 13" long.
The end support column can either be stationary and locked to the bed or towed with a strap by the main table.
The end column uses a rack and pinion for it's z-axis with fine feed. Heights will setup equally with a height gage.
The end column still needs to be finished.
A sliding support for the spindle will be built to give the headstock better rigidity.
I plan on adding another stepper to allow indexing the spindle and a small grinding/milling head to be used on the cross feed table.
Once finished I'll paint and pretty up the machine.
Steve
Main table-http://i109.photobucket.com/albums/n48/S_J_H/Horizontal%20boring%20mill/hbmprogress004.jpg
long axis ball screw with soft limit-
http://i109.photobucket.com/albums/n48/S_J_H/Horizontal%20boring%20mill/hbmprogress001.jpg
Stepper mount-
http://i109.photobucket.com/albums/n48/S_J_H/Horizontal%20boring%20mill/hbmprogress003.jpg
cross feed table-
http://i109.photobucket.com/albums/n48/S_J_H/Horizontal%20boring%20mill/hbmprogress005.jpg

[S_J_H]

another view of cross feed, it has 6.5" of travel so can be used for as a small gang slide in cnc lathe mode-
http://i109.photobucket.com/albums/n48/S_J_H/Horizontal%20boring%20mill/hbmprogress006.jpg
http://i109.photobucket.com/albums/n48/S_J_H/Horizontal%20boring%20mill/hbmprogress007.jpg
http://i109.photobucket.com/albums/n48/S_J_H/Horizontal%20boring%20mill/hbmprogress010.jpg
http://i109.photobucket.com/albums/n48/S_J_H/Horizontal%20boring%20mill/hbmprogress011.jpg

Steve

[Teenage_Machinist]

What happened to the bevel gear and crank drive?

[S_J_H]

What happened to the bevel gear and crank drive?
That setup went into the parts bin once I decided to cnc the machine with ballscrews. Originally this was to be a manual machine. But it just made sense to cnc it instead.

[John Stevenson]

Steve,
Very impressive, will there be any form of eccentric drive to the boring bar like the commercial ones or will it just be plain bar ?

[S_J_H]

Thanks John, Right now I'm thinking of just using plain bars. An auto facing head would be nice though. While many times I have wished for an easier way to line bore some of my projects I know that line boring is not something I'll be doing all that often. So it made sense to cnc this machine and also make it a cnc lathe. The adjustable spindle height axis (and once a stepper drive of some sort is added for position indexing with live tooling on the table), I think it should be pretty versatile.

Open to any and all suggestions!
Steve

[John Stevenson]

Any chance of a close up of the spindle nose.

[clutch]

Keep posting please. Too damn cold to play with my machines so I'm having to watch the work of others.

Nice work so far.

Clutch

[S_J_H]

John, the spindle is a mt3 tapered mini mill spindle. I have a ETM brand mt3 shank er32 collet chuck inserted in it which has excellent low run out.
I also have a mini lathe spindle with the flange for bolt on chucks I could use. But I thought the mill spindle without the flange would be better suited for this machine as I don't intend to do much chucking work. But I do plan on a making a mt3 shanked 3" 4 jaw chuck for occasional use. I also have mt3 collets.

What are your thoughts?
http://i109.photobucket.com/albums/n48/S_J_H/Horizontal%20boring%20mill/hbmprogress013.jpg

http://i109.photobucket.com/albums/n48/S_J_H/Horizontal%20boring%20mill/hbmprogress012.jpg


I figured for this machines size and hp that any tooling I use would be adequately held by the er32 chuck. I quasi line bored my SB9 headstock using this milling head and hardly any belt speed reduction from the motor and had excellent results.
http://i109.photobucket.com/albums/n48/S_J_H/lineboresetup003.jpg
http://i109.photobucket.com/albums/n48/S_J_H/lineboresouthbend014.jpg

Steve

[.RC.]

What spindle bearings does it use and how do you preload them.... :D


Great looking machine...I envy the skills of many on this board...

[John Stevenson]

What spindle bearings does it use and how do you preload them.... :D


Great looking machine...I envy the skills of many on this board...

Seconded, that is one class act and it's one that I'm dying to see the completion of.
Steve has proven in the past he can build them with his nice CNC lathe that unfortunately never got the exposure it deserved.

What I like about Steve's designs is their function and fit, some one once said if it looks right it is right and that does really apply.

Look back a few years to when countries designed their own products and before it went global.

If it looked like a square box with sharp corners it was designed in England, if it looked the same but with wings and flairs it was American, if it never had one straight line on it at all it was German, if it looked like a Mecanno set it was Canadian and if it looked exactly right it was Italian.

[ That should get Steve some exposure :D ]

.

[lazlo]

John, the spindle is a mt3 tapered mini mill spindle. I have a ETM brand mt3 shank er32 collet chuck inserted in it which has excellent low run out.

Beautiful job, as always Steve. I have that same ETM MT3 adapter for my lathe, and like you say, it's hardened and ground, and extremely accurate.

So what happened to the slick planetary gearbox you had made? That was very clever :)

On the Gillman gibs, are they coated with bronze? I always wondered why machine tool designers didn't use bronze gibs, since the coefficient of friction of cast iron on bronze is much lower than cast iron on cast iron. I always guessed that it was due to the lapping effect: the grit embeds in the softer material, and wears the harder material...

[S_J_H]

Awe shucks John, Thanks a ton for those words of encouragement!. But in the words of the great "Garth" of Waynes world fame, I'm not worthy!

Robert, from the SKF website here are the specs of the Gilman box way slide. They don't really say what the anti friction coating is. The gibs are coated on the side gibs and bottom plates.Even with a very slight oil film with tight gibs, movement is very smooth.
http://i109.photobucket.com/albums/n48/S_J_H/Horizontal%20boring%20mill/gilmanslide.jpg
http://i109.photobucket.com/albums/n48/S_J_H/Horizontal%20boring%20mill/gilmanfeatures.jpg

The planetary gearbox, which was the most complicated and time consuming unit to build on this machine is mounted on top of the spindle.
http://i109.photobucket.com/albums/n48/S_J_H/Horizontal%20boring%20mill/completeddrivesystem001.jpg
http://i109.photobucket.com/albums/n48/S_J_H/Horizontal%20boring%20mill/Stevesstuff.jpg

Steve

[lazlo]

They don't really say what the anti friction coating is. The gibs are coated on the side gibs and bottom plates.

Those gibs are probably bronze coated. The Gillman spec says that it's 1/3 the coefficient of friction of cast iron on cast iron, which is bronze's CoF on cast iron.

It'd be interesting to braze some bronze onto a beat-up gib, lap it smooth, and see if it's better than a normal mild steel or cast iron gib.

[wierdscience]

That's looking great Steve,but where is mine?:confused: :)

[John Stevenson]

That's looking great Steve,but where is mine?:confused: :)

You are third in line :(

.

[Teenage_Machinist]

You pwn!


Now I need to get going on the Krase Tool and Cutter Grinder :eek:


It still won't be impressive as that!


Very nice job not buying any castings. I will not have such luck.

[JCHannum]

That is a very nicely thought and executed design. It looks like a machine, and I am sure will perform well. Steve's builds are impressive, and his interests from the Artisan lathe to the CNC builds should inspire us all.

No fuss, no muss or drama, just good workmanship.

The other thing about Steve's HBM and jackary's Stepperhead is that they show what can be done with CNC once the constraints of gears and the other mechanical necessities of conventional lathes and mills are forgotten. I see many CNC lathes and mills that, while interesting, are nothing more than conventional machines that have had electronics added.

[Peter Neill]

Absolutely superb.
I'm constantly amazed by the ingenuity and quality of the engineering projects that are presented on here, on what is essentially a parking spot for amateurs.

I don't think there are many people over on the PM forum for professional machinists that could conceive, design, and build the lathes, mills, and other equipment projects that are mooted in these threads.
I know it's a different ball game for them, but the skill is quite humbling none the less.

Peter

[Teenage_Machinist]

One thing I wonder is how the rigidity for this thing will be. Is it intended to be a really good lathe?


More! More! More homemadeness!

[aboard_epsilon]

nice job

sort of cnc'd murad bormilathe

http://www.lathes.co.uk/murad/page3.html

all the best.markj

[S_J_H]

Thanks for the kind words everybody. Really appreciate it.


One thing I wonder is how the rigidity for this thing will be. Is it intended to be a really good lathe?
Everything is relative. When used as a cnc lathe I think it's going to be pretty good for smaller diameter work.
There is quite a bit of iron in this machine. The carriage is very substantial and the box ways very rigid. This box way slide does have the accuracy of a good lathe with a 36" long bed. I think you would be in for sticker shock if you found out what one of these SKF/Gilman box way slides costs new.:eek:
The machine is well over 300lbs right now.
I began work on the headstock secondary brace today.
In comparing spindle deflection between this machine and my Sieg x3 mill with simple caveman methods of tugging/pulling/pushing the head/column and a indicator at the spindle to measure the deflection, I can say for certain it has less deflection at the spindle than my x3 mill does. So I think it should have the rigidity needed for it's size and intended use.

The Murad is a neat old machine! I read about it when I first started thinking about this project.
Steve

[Teenage_Machinist]

Interesting.. Now I think that this is not a "boring mill"
CNC lathe
or whatever,


You have made a HMC!

[lazlo]

Steve, how are you going to control the head axis in Mach 3?

Does Mach3 in lathe mode have an axillary axis?

Or you do plan to run it in mill mode with the headstock as a 4th axis?

[S_J_H]

Robert, I don't know yet.
Right now I'm not sure how many axis I want to cnc on this machine. I don't know if there is much use to cnc'ing the heads vertical travel? In lathe mode/boring mode I would think I would want it locked rigid.

For milling I can see it being useful but since I have a 4 axis cnc'd x3 mill right next to it I don't know that I'll need that function.So I may keep it manual unless I'm missing something?

Position indexing of the spindle is a must though. I just ordered a LMS tool post grinder/milling head. I'll treat it as a kit and prep it so it's nice and accurate. I debated building one from scratch but I have enough on my plate right now.
I finished up the secondary brace for the headstock. Turned out pretty nice I think. It adds a lot of rigidity.
Try and get some pics of it tomorrow.
Steve

[S_J_H]

Just 2 pics of what I call the secondary support brace for the headstock. It cuts the spindle deflection in half. The spindle shows from .0005-.001" deflection when you tug/push on the columns. I think that's about as good as it'll get for this machine but it might improve a bit more once I fill the dovetail column and make a better retaining washer.
Now I'll begin work on the stepper indexing system for the spindle. It'll be similar to how Evan did his 4th axis/lathe head.
Steve
http://i109.photobucket.com/albums/n48/S_J_H/Horizontal%20boring%20mill/secondarybrace004.jpg
http://i109.photobucket.com/albums/n48/S_J_H/Horizontal%20boring%20mill/secondarybrace001.jpg

[aboard_epsilon]

Maybe a stupid question ..but how do you make sure the columns are dead on 90 degrees to the ways.

and when they deflect will they deflect more when under load from cutting.


all the best.markj

[S_J_H]

not a stupid question at all. Probably the most important issue I'll be dealing with soon. There is plenty of adjustablity in the column for horizontal/vertical alignment. I'll be setting it up just like you would adjust headstock alignment on a lathe.

Once that is done, then I'll bore the bushing hole in the end support column which will ensure both are on center for linebars. Height adjustments of each column when line boring etc will be set with a height gage off the table surfaces as they are both exactly the same height off the bedways.

Everything deflects under cutting loads. Nothing is perfectly rigid. But for the size of this machine it should be pretty good. I already stated this spindle has less deflection than my x3 mill does and I have no trouble doing some pretty precise work on that machine. It's a cnc machine, so finishing cuts are easily programmed in so deflection won't be an issue.

Steve

[Bruce Griffing]

I think you would get much less column deflection if you mounted a plate across the ways at the base of the column. This plate would mount both the column and the support on the other side. This would allow you to engage the full base of the minimill column, and would better couple the minimill column and the support. I think the fact that the minimill column has a small footprint is a weak point of the design.

[BadDog]

I'm sure you are aware that triangulation or a shear plane will be far more effective at controlling deflection that that parallelogram. Not sure how it would interfere with allowing the tilt feature obviously desired, but seems possible and should provide far greater rigidity. Am i missing something?

[S_J_H]

Bruce, I see what you are saying. As it is now, only 1" of the columns iron base is mounted against the bed. A plate across both ways gives me another .6" of supported base as well as ties both sides of the bed together. That should help, has to help. I think John advised me of this as well. I can still use the brace I made by welding the long side to the plates surface.
BadDog, Yes I know the brace is not the best.
I need a lot of room under the headstock still for the stepper /worm drive that will be mounted there. Not much room to fit bracing in between the motor either. I don't care about the tilt anymore. Just need a slight amount of tilt freedom to dial in the headstock straight. Let's see what the plate across the ways does to help.

Originally I only removed one side of the ground way on the bed with thoughts that it might come in handy on the other side. Now it serves no purpose so I may as get a better mounting surface for the column with a plate across both ways.

Steve

[aboard_epsilon]

Can you put a bar between the two columns with adjustable slots every say five inches in it ........then every push on one column will act on the two, hopefully making it a bit more rigid ...

all the best.markj

[S_J_H]

Yes, I do plan on a support to tie in both columns. The columns are offset to each other so the brace will need to be spaced out on one of the columns.
I don't know how much this brace will help but it can't hurt.
A pair of round bars rigidly mounted to the headstock column with clamping bearing sleeves mounted to the end column might work and look good.

Steve

[Bruce Griffing]

BTW, when I said the minimill base was a weak design, I meant on the part of Seig - not you!!!!

[S_J_H]

Finished up the new column mounting plate.
Had to cut off a section of the hardened way on the opposite side and then drilled/tapped for four 3/8" grade 8 bolts. The ways on this slide are VERY HARD. My abrasive chop saw had a rough time cutting it.
Redid the secondary brace and welded a plate on the bottom.So now it is held with 2 bolts on the top and 1 on the side.
Measured the spindle deflection and I am pleased with the results. It was worth the effort to do this.
Much less deflection and .001" is about the max the spindle will deflect before the entire machine is lifted.
I'll probably make a new secondary brace in the future, all welded and triangulated. But for now this one works very good. I'll also make a new mounting plate as right now I am using 2 pieces of 3" wide 1/2" thick 6061 as that was all I had. In the future I will use 1/2" steel plate.
But for now I can move on and begin the stepper indexing setup for the spindle.
Steve
http://i109.photobucket.com/albums/n48/S_J_H/Horizontal%20boring%20mill/newmount002.jpg
http://i109.photobucket.com/albums/n48/S_J_H/Horizontal%20boring%20mill/newmount003.jpg

[rubes]

Hey...some of that material looks familiar..LOL. Lookin good Steve..

[S_J_H]

Rubes!!! :D How the heck you doing? Yep, I used most of the steel plate I got from you already.

I might need to drop by the warehouse for some raw materials.:D

Steve

[rubes]

Rubes!!! :D How the heck you doing? Yep, I used most of the steel plate I got from you already.

I might need to drop by the warehouse for some raw materials.:D

Steve
I'm OK Steve, thanx. Yeah, come on by anytime, or just let me know what you need and I'll even deliver it so I can see this beauty.

[oil mac]

Exemplary, You will end up with a most usefull machine I admire your dedication
I am going back to lurk in my workshop!

[Teenage_Machinist]

I suggest that you keep that 3jaw chuck or face plate option open, and also make it so the head stock can still swivel, just not being able to use the brace. Surely the Metal Gods will elevate you to sainthood:D

A pair of pairs of calipers would make aligning the head and tail stocks much easier. Then you would just need to indicate.

I suggest also CNCifying the Y axis for the head stock, you have an overarm, right?


Then you could just put a giant angle plate on the table and have a vertical mill, or use it horizontal, or what ever you want.

[S_J_H]

TM,
I'll definitely make adapters for a 3" 3 and 4 jaw chuck.
No overarm. Just no room for one with the planetary transmission above the spindle. Instead arbors will be supported by the end column via center or bushing.

Without the brace, the headstock can still tilt which might come in handy some day.
I really don't see the need to cnc the vertical axis of the headstock right now. I do have a cnc'd x3 mill that can do all that type of work.

What this machine is to be used for is-
CNC LATHE
Line boring machine
indexed milling of parts held in the spindle with live tooling on the cross feed table.
Some horizontal light milling / saw cutting.
Digital scales will be added to the headstock and end columns.
Steve

[Teenage_Machinist]

Truly, this is the most awesome build the world has ever known.

[S_J_H]

Alright T.M. , let's not get carried away!!

[S_J_H]

I finished building the spindle indexing system today and tested it out.
It works fantastic. As for now I have a strong 425oz motor on it so i can run pretty tight backlash.

A external gear was added to the drive system. A Iron block with a precision bore is mounted to the headstock. Inside the bore is fitted an eccentric shaft keyed which itself is bored to accept the worm gear. and provides the bearing surface.
To engage the drive you grab the stepper and rotate it 180 degrees and because of the eccentric the worm meshes with the ring gear.It locks into place with a ball detent inside the iron block. To disenage the drive just turn the stepper 180' opposite. No tools needed, no belts to remove nothing. Works perfectly.
This was the last major hurdle. I'm now ready to begin final assembly, alignment and then bore the end column support bushings.

overview-
http://i109.photobucket.com/albums/n48/S_J_H/Horizontal%20boring%20mill/spindleindexer004.jpg
another view-
http://i109.photobucket.com/albums/n48/S_J_H/Horizontal%20boring%20mill/spindleindexer001.jpg
worm engaged-
http://i109.photobucket.com/albums/n48/S_J_H/Horizontal%20boring%20mill/spindleindexer006.jpg
worm disengaged by simply rotating the stepper.
http://i109.photobucket.com/albums/n48/S_J_H/Horizontal%20boring%20mill/spindleindexer005.jpg

Steve

[djc]

To engage the drive you grab the stepper and rotate it 180 degrees... To disenage the drive just turn the stepper 180 opposite.

Looks fantastic.

Do you have to disconnect anything in the direct-drive system in order to use the spindle in indexing mode?

Do you have (or maybe do you want or see any need of) any way of repeatably indexing the spindle when switching between the modes?

In an earlier post you mentioned you have the ability to 'tow' the tailstock with the carriage. For the benefit of my lack of imagination, could you briefly outline an application for this facility as I can't think how it might be used.

On cnccookbook there are some ideas posted concerning how to switch between 'free rotating' and 'indexing' spindles should you wish to pursue that route.

[S_J_H]

generally a part would be turned in lathe mode. Maybe a gear blank,timing pulley etc. Then you would engage the indexer and with live tooling on the crossfeed table cut the grooves, or gear teeth. Of course many other uses could be done with this setup such as drilling, tapping, key ways, grinding .
'Towing the end table wich supports the end of a line boring bar could be towed under powerfeed to keep the bar well supported. Also large parts can extend to sit on both tables with the crossfeed system removed.

Nothing has to be disconected to engage the stepper index mode. The drive motor of course must not be turned on!
Steve

[S_J_H]

Update, for those following this build. Final assembly and alignment is underway. I disassembled the entire machine, cleaned, repainted with blue Hammer finish and gave it a better fit and finish so it looks a little nicer.
The headstock and main column are aligned. I spent a good 3 hours dialing it in. Started off with a .0005" DI and once it was close switched to my new Bestest with .00005" increments. I used a precision ground bar. The vertical alignment was fairly simple as the column is on a pivot. The Horizontal alignment was time consuming as this machine has no "ways" to locate the headstock. So careful trial and error tapping while sneaking up on the accuracy was the method used.
Vertical error 8" out from the chuck is around .0001". Horizontal error is about .00025" 8" out, with the error in the direction to aid against deflection.
I know the machine probably won't hold tolerance to these specs though it's nice to know it's accurately aligned.
The end column support for line boring bars and long arbors is next and then this baby is ready to make it's first test chips. But still a lot of little details like the proximity sensor for the spindle and limit switches etc, so plenty of work still ahead.
Steve
http://i109.photobucket.com/albums/n48/S_J_H/Horizontal%20boring%20mill/hbmfinalprep001.jpg
http://i109.photobucket.com/albums/n48/S_J_H/Horizontal%20boring%20mill/hbmfinalprep002.jpg
http://i109.photobucket.com/albums/n48/S_J_H/Horizontal%20boring%20mill/hbmfinalprep003.jpg

[S_J_H]

All this time an unbelievable error in the construction was overlooked by me!
I just could not understand why the spindle seemed to have more deflection than I thought it should. Unless everything was super tight, gibs the brace it just had a lot of deflection.
Well all of a sudden I saw my error today!.
All this time the headstock carriage flats were never riding on the outside dovetail flats! The inside flat of the carriage was riding on the flats that protrude from the center of the column. This is a weak area compared to the outside flats which give a much wider and more stable contact.
So off came the column, milled .075" off the flats in the center of the column for about 15" in length. Now the headstock carriage rides properly on the outside flats and dovetails.
Deflection is now very good. A max of .0005" unless you really try and flex the machine. That is about twice as good as my x3 mills spindle which will deflect around .001" with the same force applied.
Very happy now. Had to realign everything all over again.
Now I have a lot of confidence the machine is rigid enough to do very good work.
Steve

[topct]

A 21st century rose engine.

[Teenage_Machinist]

I cannot wait to see it all done and with video.


To use the spindle indexing best however a CNC on the head column is in order. Not needed on the tail.

[rubes]

Stopped by to do some horse trading with Steve today and got to see this thing in person. My guess is that the med's he was on must have helped some in the design of this thing...LOL. Always nice to see some original ideas and to learn from Steve. Thanx again pal...enjoy.

[S_J_H]

The end column support system is finished.
The end column's function is to support the outboard end of line boring bars, long arbors and it can also be used to support the end of a work piece being turned or milled.
It uses the mini mill rack and pinion with the geared fine feed drive system for the z-axis which works real well.

The master bronze bushing which is shown in the pics is 1.25" ID. So that would be the largest bar or arbor end it could support in a pass through system. I plan on making a variety of reducer sleeves for different sized bars, arbors and also live center to fit the master sleeve.
The next update will include video of it making chips!
Now I just need to come up with a catchy name for this little beast of a machine.:rolleyes:
Steve
http://i109.photobucket.com/albums/n48/S_J_H/Horizontal%20boring%20mill/HBMendcolumn002.jpg
http://i109.photobucket.com/albums/n48/S_J_H/Horizontal%20boring%20mill/HBMendcolumn003.jpg
http://i109.photobucket.com/albums/n48/S_J_H/Horizontal%20boring%20mill/HBMendcolumn004.jpg

[S_J_H]

I hooked up the spindle sensor and now have the true rpm readings for each gear ratio.
The highest ratio is 65:1 with a range of 0- 75 rpm
2nd gear is 40:1 with a speed range of 0-125rpm
3rd gear is 12:5 with a speed range of 0 400rpm
4th gear which bypasses the planetary transmisson is 1.7:1 and a max speed of 2900 rpm.
It's a pretty good broad rpm range.

I tested the machine for several hours today. The first impression you get is that it is very quiet , just a high pitch from the motor. The planetary transmission adds almost no extra noise compared to direct belt drive.The heavy duty aluminum housing and bronze bearings plus ball bearings for the shafts makes this unit one of the best working things I have ever built IMO.
It operated without fault or getting hot for a good 4 hours non stop almost in all 3 gears. It is sealed and runs in heavy oil.
The detent clutch works fantastic and saved my ass several times today during testing. There is enough torque at low speed that without the clutch to save it, this machine would BREAK something.
The little mini lathe dc motor powering the spindle through the planetary transmission has plenty of power. The machine has no problem taking a .050" DOC in 303 stainless and easily takes a .1" DOC in 6061.
I have a even more powerful motor I may add though.

I'll be testing out it's horizontal cutting action with a boring bar and arbor type cutter next.
So here is a video of it making it's very frst chips in some 303 stainless and 6061 aluminum.
This is just a clip of it doing a few lathe ops and it's poor quality, but you can at least see and hear the machine at work.
http://i109.photobucket.com/albums/n48/S_J_H/Horizontal%20boring%20mill/th_hbmfirsttests.jpg (http://s109.photobucket.com/albums/n48/S_J_H/Horizontal%20boring%20mill/?action=view&current=hbmfirsttests.flv)

Steve

[BillH]

Steve, amazing work as usual. Good job

[abn]

Really really nice versatile looking machine. Superb work.

[wierdscience]

Nice,well if your not going to build one for John and I,could you at least send the plans over to Sieg?:)

[S_J_H]

Thanks guys! I'm going to fiddle with it some more today.:D I was pretty impressed with the smoothness of it yesterday operating as a chucking lathe.
So I want to try out a line boring bar today and utilize the end column. Hopefully take a vid while doing it.

You know, Seig could make this machine. The planetary transmission would be replaced with a lesser drive I'm sure. I'm not sure what they would come up with for the main bed. Probably a dovetail bed. The seig off the shelf parts list I am using is
2 mini mill column assemblies, part #1766
1 mini mill mt3 headstock with (upgraded SKF bearings)-part #1906
1 mini mill spindle housing mount ,part #1498 ,plus all the parts needed for the fine feed for this mount.
1 mini mill saddle,part # 1479
1 mini mill table, part # 1470
1 mini lathe motor and a variable speed control, part # 1311 and #3061

Now, all the Sieg parts were in some way modified for this machine. Some very heavily modifed!! But it was easier and cheaper starting with good existing castings and parts rather than start with barstock.

This machine is far from a 100% scratch built bar stock project. It's more like a monster garage construction. Starting out with the Gilman box way slide was like being half way done. I never would have taken on this build had I not come accross the slide.
Steve

[John Stevenson]

Starting out with the Gilman box way slide was like being half way done. I never would have taken on this build had I not come accross the slide.
Steve

You could always have used a builders plank :p

[Teenage_Machinist]

This is a pretty good machine. It looks like one could have a "vertical mill" by putting a gigantic angle plate on the table.


It is unusual for a machine to work so well as a lathe and a mill and then yet retain another function, that of line borer.



Here is what I see: It would have a 3-speed gearbox and vari speed drive. THe spindle would be threaded. I am thinking of a manual machine.

With the headstock at the bottom, a gear would mesh with a threading train. Otherwise, no power feed. Half nuts and bevel gears like you had at the beginning.


There would be a big angle plate to go on the table. Not too rigid but increases functionality. It would be able to mount on tail stock saddle for better rigidity.

[S_J_H]

T.M, I say go for it!! Sounds like you have some good ideas.

I made a Delrin reducer sleeve for the end support to fit a old line boring bar I had made a while ago. Delrin is a good material for this use. It fits good and tight and is retained with a threaded collar on the tail end.
Then mounted a vise on the table. Lightly clamped a piece about 3.5" long of some 6061 pipe. The machine line bored it beautifully with a very good finish.
The boring bar with the end support is very rigid.
So far so good. Nothing major going wrong so far and it's working according to plan. Knock on wood...
http://i109.photobucket.com/albums/n48/S_J_H/Horizontal%20boring%20mill/HBMfirstlineboringtests003.jpg
http://i109.photobucket.com/albums/n48/S_J_H/Horizontal%20boring%20mill/HBMfirstlineboringtests004.jpg
And a short video of it doing some boring line boring :D
http://i109.photobucket.com/albums/n48/S_J_H/Horizontal%20boring%20mill/th_HBMfirstlineboringtests007.jpg (http://s109.photobucket.com/albums/n48/S_J_H/Horizontal%20boring%20mill/?action=view&current=HBMfirstlineboringtests007.flv)

[S_J_H]

This machine is going to require many accessories and tooling to be fully utilized.
I am going to begin building the portable milling/drilling head tomorrow.
I will begin with the housing and quill from a old drill press.
I will make a complete new ER 32 spindle for it.
Power from a DC mini lathe motor and timing belt drive.

Pics to come.:D
Steve

[3t-]

S J H

Fantastic work. I am really enjoying watching your machine come together!
You have a talent for neat, clean precise work, a real inspiration.

You may have mentioned this but if not can I ask where you are purchasing all of your mini-mill parts. Motors, columns, etc.

[S_J_H]

Thank you 3t.

Well I started off in the this hobby with a mini lathe and mini mill. Eventually after having tons of fun and even cnc'ing the mini mill, things wore out and the machines slowly went into my parts bin.

I always knew one day I would I would reuse the parts from those machines in another project. So I had a lot of the parts needed in my parts bin when I started this project. All recently purchased Sieg made parts for this machine were bought through www.littlemachineshop.com

They carry every possible part for the Sieg machines at a good price with great service.
Steve

[greener121]

Steve,

The machine looks fantastic, hope to see it in action sometime soon.

Brian

[S_J_H]

Thanks Brian.

The machine now has a mill/drill accessory for the table. Since it's not really a cnc project I posted it in the general forum here - http://bbs.homeshopmachinist.net/showthread.php?t=33582
Here's a pic of the milling unit. It operates very smoothly and has a quill for quick drilling ops. I also swapped in a stronger motor for the machine.
http://i109.photobucket.com/albums/n48/S_J_H/Horizontal%20boring%20mill/portablemilldrill001.jpg

[S_J_H]

I tried out the spindle indexing setup and the table mounted milling head. I'm making a small model rocket for my 9 year old daughters school project.

The rocket body is 303 stainless. I needed to cut 4 slots for the fins.
I made a spud to fit end of the rocket and the end column bushing for support.
Very happy with the how well it worked. Used a 2 flute 1/8" endmill and plunged into the stainless with the manual quill. Locked the quill and then used cnc feed to make the 1.5" long slots.
No chatter at all and the milling head was very rigid and easily cut the slots about .2" deep.
Steve
http://i109.photobucket.com/albums/n48/S_J_H/Horizontal%20boring%20mill/misc009.jpg
http://i109.photobucket.com/albums/n48/S_J_H/Horizontal%20boring%20mill/misc011.jpg