Milling Machine with Digital Readout

Milling Machine with Removable Digital Readouts

Milling Machine with Removable Digital Readouts

Wished to have a Milling Machine that I could run as a manual mill for now … and also later have the ability to convert it to a CNC Milling Unit.

SolidWorks CAD Rendering of AccuRemote Digital Readouts

SolidWorks CAD Rendering of AccuRemote Digital Readouts

Also wished to mount AccuRemote 3-Axis Digital Readouts ( DRO ) on Mill.

Click Here for More Info about :  AccuRemote Digital Readouts

AccuRemote DRO Drawn in SolidWorks CAD Software to Create Mill Mounts

AccuRemote DRO Drawn in SolidWorks CAD Software to Create Mill Mounts

Decided to order a Charter Oak Automation Manual Bed Milling Machine.

Page 1 of the Milling Machine Specs

Page 1 of the Milling Machine Specs

Click on these images to see a larger view …

Page 2 of the Milling Machine Specs

Page 2 of the Milling Machine Specs

The people at Charter Oak Automation were great and answered all my questions and also suggested some upgrades.

Chose to add the additional Variable Frequency Drive (VFD) and also the Mach-1 Quick Change Tool System.

The Mach-1 Tool Changer is AMAZING and FAST!!

Milling Machine at Charter Oak Automation before Shipping

Milling Machine at Charter Oak Automation before Shipping

They sent me photos of the Crate before shipping so I knew what to expect.

The Milling Machine arrived in Las Vegas a Week Later … Fast Service!!

Photo of Milling Machine Crate before Shipping

Photo of Milling Machine Crate before Shipping

Didn’t know when I would be home so had it sent to a local shipping depot and then rented a U-Haul truck to bring it to my workshop.

Had some scrap wood so took an hour and made a ‘Cat-in-the-Hat’ style ramp to roll the Milling Machine Crate down to the shop floor by myself.

Sliding the Milling Machine Crate off the Rental Truck on my unusual ramp *grin*

Sliding the Milling Machine Crate off the Rental Truck on my unusual ramp *grin*

Needed my Pallet Jack for other projects so made a metal rolling unit …

Temporary Rolling Unit for Moving Packing Crates Around the Workshop

Temporary Rolling Unit for Moving Packing Crates Around the Workshop

Designed a Stand for the Milling Machine and welded it together … I will add shelves later after have used the Milling Machine for a few months and know what is needed for storage

Built a Stand for the New Charter Oak Automation Milling Machine

Built a Stand for the New Charter Oak Automation Milling Machine

Used some left-over metal to make a leveling lifting unit so I could control the lift because had to do it by myself.

Used the “Over the Jeep” Workshop Lift-Table/Gantry Hoist:
https://ctmprojectsblog.wordpress.com/2013/10/22/over-jeep-workshop-lift-table/

SolidWorks Concept of Milling Machine Stand and Lift

SolidWorks Concept of Milling Machine Stand and Lift

Once the Milling Machine was on the stand I really didn’t get to use it much because was needed on a different project… Once that was done the Lathe had arrived and I worked out where to put the new items in my small workshop area.

Then the hot desert summer weather arrived *sigh* … Needless to say… I am very excited that the cooler fall weather temperatures have arrived in the Las Vegas area.

Charter Oak Automation Milling Machine

Charter Oak Automation Milling Machine

I immediately started to drill holes and certainly voided the warranty, but that is OK because half the fun for  me is creating the modifications.

Moved some wiring to allow better access to Mill parts

Moved some wiring to allow better access to Mill parts

Raised the VFD Drive 1 inch to allow better clearance for wiring and DRO …

Front View of the Charter Oak Milling Machine

Front View of the Charter Oak Milling Machine

Drew the Milling machine into SolidWorks to make it easier to design and test out DRO (Digital Readout) Mount options.

In addition, will be using the SolidWorks Milling Machine CAD model while traveling to test out Milling Set-ups.

Drew a CAD Example of the Mill into SolidWorks

Drew a CAD Example of the Mill into SolidWorks

The next project was to install some inexpensive Digital Readouts that can be easily removed in the hot summer months when traveling.

Accu-Remote Single Axis Digital Readout

Accu-Remote Single Axis Digital Readout

Used the SolidWorks CAD model to test out DRO mounting options …

Uploaded the AccuRemote Digital Readout CAD files to:  GrabCAD.com

SolidWorks CAD Model of the Milling Machine

SolidWorks CAD Model of the Milling Machine

Nice thing about SolidWorks is one can hide items on the screen to make it easier to see the items you are working on …

SolidWorks DRO Mounting Concept

SolidWorks DRO Mounting Concept

It was somewhat the Chicken before the Egg … or the Egg before the Chicken situation because wished to have the DRO accuracy to make the DRO mounts

Hand-Made first X-Axis DRO Mount for Milling Bed

Hand-Made first X-Axis DRO Mount for Milling Bed

Decide to hand-make the 1st X-Axis DRO mount and will machine a replacement out of Aluminum later this winter

X-Axis DRO Mount before being covered with Aluminum Guard

X-Axis DRO Mount before being covered with Aluminum Guard

Next decided to use the 3D-Printer to make several DRO mount parts out of ABS plastic … and they turned out to be very strong and stable

Z-Axis DRO 3D-Printed Parts in SolidWorks

Z-Axis DRO 3D-Printed Parts in SolidWorks

Used a chrome plated shaft that came off an old copying machine to create an inner Z-Axis DRO slider …

Mill Front Cover Plate Removed

Mill Front Cover Plate Removed

3D-Printed the inner slider bushings and Z-Axis mounts …

3D-Printed DRO Mounts and Bushings out of ABS Plastic

3D-Printed DRO Mounts and Bushings out of ABS Plastic

It is starting to become part of my design process to 1st 3D-Print out test fitup parts and then later machine the actual items out of Aluminum or Steel

Using the AFINIA 3D-Printer to make the Z-Axis Mounts

Using the AFINIA 3D-Printer to make the Z-Axis Mounts

The Digital Readouts are mounted creating a ‘Poor Man’s’ DRO Unit. *smile*

Milling Machine with Removable DRO Readouts

Milling Machine with Removable DRO Readouts

It only takes about 30 seconds to unplug and remove the upper digital readouts and take them in the house when I am traveling during hot weather.

During the summer with the sun on the roof the workshop can get above 115 F.

Closer View the Milling Machine's 3-Axis Digital Readouts

Closer View the Milling Machine’s 3-Axis Digital Readouts

Can still use the Quick inch markings on the front of the Milling Machine because the bottom edge of the Z-Axis DRO lines up with the Zero Mark.

Inch Markings Start at the Bottom of the DRO Body

Inch Markings Start at the Bottom of the DRO Body

Paul at Charter Oak Automation was nice enough to send me a conversion chart

Frequency to RPM using the different gear options and the VFD

Variable Frequiency Drive (VFD to RPM) Conversion Chart

Variable Frequency Drive (VFD to RPM) Conversion Chart

Below is a High-Resolution image of the ‘VFD to RPM’ chart if you have a similar Charter Oak Automation machine with the DC Motor VFD option.

High-Resolution Copy of the VFD to RPM Conversion Chart

High-Resolution Copy of the VFD to RPM Conversion Chart

As previously mentioned … Now use the SolidWorks Milling Machine CAD model to test how to mount specific parts on the milling machine.

Very helpful when traveling and stuck waiting in the airports because when get home know exactly what items I need and how the stock metal needs to be clamped down to the milling machine.

Using SolidWorks to Test Milling Set-Ups

Using SolidWorks to Test Milling Set-Ups

Purchased 2 of these Step-Block Clamping Kits and drew  into SolidWorks …
https://www.grizzly.com/products/Clamping-Kit-for-5-8-T-slots-58-pc-/G1076

Clamp Kit Drawn into SolidWorks

Clamp Kit Drawn into SolidWorks

If you would like CAD files for this clamping kit ~  I uploaded it to GrabCAD
https://grabcad.com/library/clamp-kit-for-milling-machine-1

SolidWorks Rendering of the Clamp Kit

SolidWorks Rendering of the Clamp Kit

Also uploaded to GrabCAD this Parallel Set …
https://grabcad.com/library/machinist-s-parallel-set-for-milling-machine-1

Parallel Set Drawn into SolidWorks

Parallel Set Drawn into SolidWorks

Added some tooling bins and an additional shelf under the Milling Machine …

Added Two Shelves Under the Milling Machine

Added Two Shelves Under the Milling Machine

Also mounted the mill hold-down items on the side of the stand …

Easy access to the Mill's Hold-Down Clamp items

Easy access to the Mill’s Hold-Down Clamp items

Now it’s time to make a few projects with this Milling Machine!!

— CHEERS …

UPDATE ~

Added a ( DRO ) Digital Readout to the Milling Machine  CLICK HERE

Close-Up of the Tablet Displaying the TouchDRO App Digital Readouts

Close-Up of the Tablet Displaying the TouchDRO App Digital Readouts

.   .   .

 

Advertisements

Leave a comment

Filed under 3D-Printing, PROJECTS, WORKSHOP

Leave a Reply

Fill in your details below or click an icon to log in:

WordPress.com Logo

You are commenting using your WordPress.com account. Log Out / Change )

Twitter picture

You are commenting using your Twitter account. Log Out / Change )

Facebook photo

You are commenting using your Facebook account. Log Out / Change )

Google+ photo

You are commenting using your Google+ account. Log Out / Change )

Connecting to %s