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  • pensioner
    replied
    Great, I enjoyed watching your work Bruno, thanks!
    Ivan.

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  • Bruno Mueller
    replied
    Click image for larger version

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ID:	1897532 The part still got the correct color design.

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  • Bruno Mueller
    replied
    Click image for larger version

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ID:	1897525 The cross slide is finished.

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ID:	1897526 Original and replica.

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ID:	1897528 Assembled on the lathe.

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  • Bruno Mueller
    replied
    The connecting element between cross slide and top slide consists of two parts.
    A tension bolt with conical bore and a screw-in bolt with a corresponding taper.
    The screw-in bolt is made of tool steel 115CrV3.The M10x 1 thread was cut on the lathe with the leading spindle.
    The 6mm hexagon socket was broached.
    Afterwards the screw-in bolt was hardened and tempered.
    The guide surfaces were then ground.
    The tension bolt was not hardened.

    Klicke auf die Grafik für eine vergrößerte Ansicht  Name: 016.jpg Ansichten: 187 Größe: 494,1 KB ID: 1897521 Click image for larger version

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    Klicke auf die Grafik für eine vergrößerte Ansicht  Name: DSCN2122.JPG Ansichten: 178 Größe: 1,27 MB ID: 1897522
    Last edited by Bruno Mueller; 09-09-2020, 07:06 AM. Reason: Add a drawing.

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  • Bruno Mueller
    replied
    The cross slide was pre-milled and left to rest overnight to relieve internal stresses.
    After the cross slide carrier was finished, the dovetail could also be milled and adjusted in the slide.
    Klicke auf die Grafik für eine vergrößerte Ansicht  Name: DSCN2091.JPG Ansichten: 0 Größe: 1,22 MB ID: 1897515Klicke auf die Grafik für eine vergrößerte Ansicht  Name: DSCN2095.JPG Ansichten: 0 Größe: 1,28 MB ID: 1897516
    Pre-milled cross slide.
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    Sliding plate and spindle for the cross slide.
    From scale line to scale line the graduation corresponds to a diameter deviation of 0.1mm.

    Klicke auf die Grafik für eine vergrößerte Ansicht  Name: DSCN2114.JPG Ansichten: 0 Größe: 1,19 MB ID: 1897518 Complete cross slide
    Klicke auf die Grafik für eine vergrößerte Ansicht  Name: DSCN2119.JPG Ansichten: 0 Größe: 1,19 MB ID: 1897519
    The connecting part between plan and top slide is still missing.
    Last edited by Bruno Mueller; 09-09-2020, 07:02 AM.

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  • Bruno Mueller
    replied
    Click image for larger version

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ID:	1897511Click image for larger version

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ID:	1897512 Test assembly and angle control on the lathe.

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  • Bruno Mueller
    replied
    The cross slide carrier .
    From a grey cast iron block of 80 x 80 x 120mm I first milled the dovetail and the groove for the thrust spindle. The contours of the beam were drawn and cut to size on the band saw. Then the dovetail guide was milled. With grey cast iron, there is no need to fear any winding.

    The weekend passed and the chips were made. I clamped the cross slide carrier on the cross slide of the lathe and predrilled the hole for the guide column.
    The cross slide carrier remains on the cross slide of the lathe until the final machining with a reamer.


    I was still waiting for a 30mm reamer, so I cannot continue to work on the facing support beam.

    Instead I have pre-milled the plansupport.

    For the dovetail to fit I need the plansupport carrier.But it is clamped on the lathe.
    Click image for larger version

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ID:	1897507The cross slide carrier when using the reamer on the lathe .
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    Finished machining.

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  • Bruno Mueller
    replied
    Click image for larger version

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  • Bruno Mueller
    replied
    Click image for larger version

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    Attached Files

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  • Bruno Mueller
    replied
    Now I would like to show you more drawings. Here are the feed spindles of the cross-slide.


    Steel S355JO+C (St.52-3) 12mm was the starting material. Clamped in the collet chuck on the lathe and planned and centered on both sides.

    The paragraph 8mm- 19 long and 6mm -11 long was turned and the thread M3 12mm deep was cut.

    Change the collet chuck to 8mm and clamp it on the turned 8mm spigot. On the other side, hold the roller punch against it.

    Turn the threaded part with Lynette support to 8mm and cut the undercut for the thread run-out to 6.5mm,

    The thread M8 was cut almost finished on the lathe with the lead screw and thread steel. I supported the spindle with the rolling lynette and cut the remaining 1/10mm with the die. The tips were honed with fine emery.

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  • Bruno Mueller
    replied
    Originally posted by Alan Smith View Post
    Great work Bruno. Also good job on the drawings. You say you used pencil, did you ink them afterwards? I ask because they have reproduced on the computer screen very well.
    I scanned the drawings and then improved them with an editing program. I reduced the brightness a bit and set the contrast to the highest level.

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  • Alan Smith
    replied
    Great work Bruno. Also good job on the drawings. You say you used pencil, did you ink them afterwards? I ask because they have reproduced on the computer screen very well.

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  • Bruno Mueller
    replied
    I have milled the top slide before. Over night the inner tensions can be released. Afterwards the dovetail was milled with undersize.

    After another night the finishing is done.
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  • Bruno Mueller
    replied
    The top slide carrier was pre-milled.

    First my band saw had cut a piece of the 70mm x 20mm material. Afterwards the part was machined on the milling machine.

    The steps for the dovetail were pre-roughened. Thereby I left about 1mm material allowance. Afterwards the groove for the spindle was milled. The part was turned and the backside was removed with the flying cutter about 0.5 mm.

    The part had to rest overnight, the inner tensions could be worked off and the next morning the part could be machined further. Klicke auf die Grafik für eine vergrößerte Ansicht  Name: DSCN2052.JPG Ansichten: 0 Größe: 1,16 MB ID: 1897474Klicke auf die Grafik für eine vergrößerte Ansicht  Name: DSCN2051.JPG Ansichten: 0 Größe: 1,20 MB ID: 1897475

    The next day the top slide carrier was finished.
    Klicke auf die Grafik für eine vergrößerte Ansicht  Name: DSCN2056.JPG Ansichten: 0 Größe: 1,30 MB ID: 1897476Klicke auf die Grafik für eine vergrößerte Ansicht  Name: DSCN2057.JPG Ansichten: 0 Größe: 1,30 MB ID: 1897477
    Attached Files

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  • Bruno Mueller
    replied


    With Auto-CAD and Co. I am on a war footing. My drawings are created on a drawing board and are drawn with pencil.

    For the assembly I made copies of the single part drawings, cut them out and put them together overlapping.

    The drawings do not correspond to the DIN standard, but they will be sufficient for a reproduction.


    First I intended to create the basic body as a welded construction. But I do not trust my welding skills. I have learned this once, but I lack the practice.

    The sleds themselves I will make from steel S235JR+C (St 37).

    For the basic body (cross slide carrier) I have planned a grey cast iron block made of EN-GJL-250 (GG25).

    The original holder has only one central screw to fix it to the guide column. But since grey cast iron does not have the strength of white tempered iron cast, I added two clamping screws to this part. So the load for a single screw is not too high and the force is better distributed.


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    You can follow the complete documentation of the refurbishment on my homepage

    http://www.bosch-combi.de/ersatzteile.html
    Last edited by Bruno Mueller; 09-06-2020, 05:53 AM.

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