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Evolution of a tool. "me"

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Evolution of a tool. "me"

Postby phill05 » 26 Dec 2021, 13:29

A few years ago I built a manual dividing head for the milling machine and hoped that I could make similar for the lathe, In the middle of working on this I found an old cnc machine and rebuilt it to use to make parts then a year or two ago I designed and built an electronic indexing unit that could be moved between machines I found electronic parts online and started building the controller box to power a stepper motor, I needed 240v supply in and 12v - 24v - 68v out in one box that could be taken with the control box to where ever I needed to use it. So the power box was made.

Then I started on the control box I found a board ( made by Steve Ward) that would give Jog: Divide: Degree: or Constant: working around that I used a plastic box to hold a Stepper driver, the card, a fan and a keyboard, one input 24v and 68v then a step down to 12v, on the opposite side power out to motor, I designed and cut the keys/pad with the cnc the window for the screen and the cut outs for the fan at the back of the box, I connected a motor all works as it should.

controller.JPG
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conected.jpg
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I then moved on to the indexer, plain aluminium frame to hold a ER32 collets plain bored shaft and the stepper motor with 3 to 1 reduction for holding position.

ER 32.jpg
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Once complete put power to box - box to stepper indexer in now working as it should be with a complete range of collets, then started thinking what if it had a 4 jaw chuck on it, so made two back plates to fit the nose thread of the ER32, one for a 125mm 4 jaw and one for a 80mm 3 jaw this now gives me many options.
Chuck fittings.jpg
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Next I made a tailstock to suite.
Tailstock.jpg
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I have used it in making/repairing old clock wheels and parts and in the future I want to use it to finish building a Turret clock that I started but could not take it any further at the time do to ill health.
A few months ago I came across a post on here by Dr Al that gave me the inspiration of another tool I was missing a slow rpm diamond grinding/honing plate, I had been looking online at different machines for doing it, but mostly based on a std grinder to me that was too fast, then Dr Al hit me, not in a bad way, I read his online website of the different tools he has made and I emailed him and out of the information I gleaned this was what I wanted to add to my indexer as I could have low speed.
So thanks to Dr Al this is where I started the honing plate, the disk is the same design as Al's (thank you Al) but fixed the disk to a 20mm back plate to fit in ER32 collet.

20mm fitting.jpg
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Mags fitted.jpg
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I was given two diamond disks 400 grit and a 2000 grit from a friend but both had different mounting holes, made a reversible centre plate that has different sized spigots this is now done and it works really well.

WIP:

I now have to decide how I want the table to be.
To be continued:

Phill
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Re: Evolution of a tool. "me"

Postby Dr.Al » 26 Dec 2021, 14:58

Wow, that indexing set-up looks awesome and the idea to add your flat plate onto that is great. I've got a DivisionMaster and a small and not-very-good-quality rotary table/dividing head thing, which I modified to add a stepper motor, but yours looks in a different league.

:text-bravo:
My projects website: https://www.cgtk.co.uk
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Re: Evolution of a tool. "me"

Postby 9fingers » 26 Dec 2021, 15:02

Excellent work!

Bob
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Re: Evolution of a tool. "me"

Postby DaveL » 26 Dec 2021, 15:41

Yes, very nice.
Regards,
Dave
My tool kit is almost complete, only a few more to get.
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Re: Evolution of a tool. "me"

Postby 9fingers » 26 Dec 2021, 15:52

Do you find that your dividing head had sufficient holding power to resist machining forces between indexing points?
Especially if your are using micro-stepping to interpolate between the 200(?) steps on the motor.
Never having tried anything like this, it has been one of the doubts in the back of my mind.

Bob
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Re: Evolution of a tool. "me"

Postby phill05 » 26 Dec 2021, 16:28

Hello Bob,
Yes the stepper holding torque of 3Nm and a 3: to 1: reduction has not been a problem I have cut metal and wood rotary and divisional and so far no problems.

Edit: forgot to say I did pick up an electronic brake that fits on the motor shaft at the rear but I never got round to fitting it I just started using it

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Re: Evolution of a tool. "me"

Postby Peri » 26 Dec 2021, 16:56

That's brilliant.

I wish my electronics knowledge extended further than "push switch up, machine goes".
Two thirds of people don't have a clue about fractions - and the other half aren't much better.
Good decisions are based on experience. Unfortunately experience is built on bad decisions.
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Re: Evolution of a tool. "me"

Postby 9fingers » 26 Dec 2021, 17:33

phill05 wrote:Hello Bob,
Yes the stepper holding torque of 3Nm and a 3: to 1: reduction has not been a problem I have cut metal and wood rotary and divisional and so far no problems.

Edit: forgot to say I did pick up an electronic brake that fits on the motor shaft at the rear but I never got round to fitting it I just started using it

Phill


Thanks Phill. Very useful that not only is holding torque adequate but also that a supplementary brake is not needed.

Bob
Information on induction motors here
https://drive.google.com/file/d/1dBTVXx ... sp=sharing
Email:motors@minchin.org.uk
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Re: Evolution of a tool. "me"

Postby TrimTheKing » 09 Jan 2022, 17:02

Brilliant! We’ll beyond my current spree of knowledge, but I can tell it’s good!
Cheers
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Re: Evolution of a tool. "me"

Postby Woodster » 09 Jan 2022, 23:16

Nice job Phil. I don’t know if it helps, it has me, but you can get oversize collets in ER32 up to 1”. Not cheap at £20 each but I’ve found them very handy. I have a 1” a 23mm and a 22mm. Have a look on the auction site for “Gloster ER32 collet” if it’s of interest. ;)
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Re: Evolution of a tool. "me"

Postby phill05 » 10 Jan 2022, 09:57

Thanks everyone It takes me a while now to make the parts but at least it keeps the old grey matter working, good call on the ER32 collets I could find a use for the 22mm and 1" will be sure to get them.

Been thinking on the table design and I am going with this for the brackets:

image_2022-01-10_084752.png
(5.61 KiB)


This will have a form of slotted table so you can say hold down a plane blade or chisel and could also be used to machine angles on the miller if needs be.

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