Author Topic: Mill/drill stand for Warco Major mill  (Read 1714 times)

Online philf

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Re: Mill/drill stand for Warco Major mill
« Reply #25 on: August 05, 2018, 04:29:55 PM »
......I was ready to replace the awful single phase vibrator that mascarades as a motor with a proper 3ph one ......
Bill,

We had a mill/drill at work and "single phase vibrator" sums up the motor nicely. It was well enough balanced in that when you let it run down from full speed to stop with no power there was no vibration. As soon as you applied power it was terrible, the belt guards rattled violently, and it was almost impossible to get a good finish! Swapping the motor out for a "decent" 3 phase motor with a VFD would be the first job I'd do on a mill/drill. Even a 1 ph motor from a good maker would be a huge improvement.

Phil.
Phil Fern
Location: Marple, Cheshire

Offline vtsteam

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Re: Mill/drill stand for Warco Major mill
« Reply #26 on: August 05, 2018, 05:12:19 PM »
The drill mill will do fine work ,  plenty of guys here do wonderful work on them

Now we agree.

Sorry about the bad motors mentioned, mine is fine, but it's an older Enco, and US electrical specs so again specifics, are important.
I love it when a Plan B comes together!
Steve
www.sredmond.com

Offline PekkaNF

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Re: Mill/drill stand for Warco Major mill
« Reply #27 on: August 06, 2018, 03:56:48 AM »
Single phase induction motor is bit like single cylinder four stroke I.C. you need an massive flywheel...problem is that this type of mill has splines between belt sheaves and spindle, you really need a 3p motor or secondary flywheel (or good fit with the spline).

RE: accuracy, rigidy, mass, stiffness and all that.....production environment is a completely different ball game. For hobbyist it pretty much tells what is the "absolute maximum rating" of the machine.

I know a person that "tested" the some machines with normal structural steels and end mills. His idea was to use same make end mill with recommended feeds/speeds and programs (on CNC) to produce commercial parts with commercial tolerances. Smallest machine (and the only manual machine) was Bridgeport. On this application bridgeport strugled on 12 mm or bigger endmill.  Can't remember how the real CNC:s were, but their productivity and and abbility to keep tolerances were magnitude better.

For most hobbyist the bridgeport (layout/size/weight/expence) is the goal or dream and we use way bigger than 12 mm endmills on them! It is just completely different ball game.

Yesterday I chucked 52 mm OD 2 mm wall pipe on milling vise and used 8 mm carbide endmill to notch it. I was using it probably 600 rpm (highest speed on my current mill) and feeds/speeds were fraction on nominal values. But I needed that radius and this was not production environment.

Anyway, I am bying cheap mill/drill that I'm paying way too much for what it is, but at this moment and on my situation it still looks like my best chance of getting something done... there are better and smaller (10x price), there are better and cheaper (5x weight/size, used), but this capacity/size/availability/price is just a compromize I had to make or I would not fit into my garage or would not move swarf.

Anyway, hope it get's shipped today and I get my hands on it and learn on next few something new....hopefully it is good enought and I don't need call it partial loss.

Pekka

Offline WeldingRod

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Re: Mill/drill stand for Warco Major mill
« Reply #28 on: August 06, 2018, 02:45:39 PM »
Another couple of stand thoughts: get it high enough, and make it so you can roll out the cabinet!
I jacked my Rockwell up about 6" to address my 6'4" height.  Its cabinet is useless, though.  I found some ikea drawer modules, about 4' tall as 12" so square with a whole bunch of shallow drawers.  I one on each side of the column.  Super handy! I wish they still made them!!
My Hardinge is jacked up about the same amount.

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Offline PekkaNF

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Re: Mill/drill stand for Warco Major mill
« Reply #29 on: August 14, 2018, 01:22:05 PM »
I thought they had lost the shipment, because last update on tracking info was 7.8 and contacted Warco Yesterday. Afetrnoon I got a call from Finnish depot that I can have it tomorow morning. Took surpricingly long time for them to process it. Hope I'll like it.

Offline PekkaNF

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Re: Mill/drill stand for Warco Major mill
« Reply #30 on: September 09, 2018, 07:34:59 AM »
Last night I cut some C-channel (80x45 mm and 65x40 mm). Four 740 mm pieces for legs (because that is the maximum size that fits into my flower pot that is filled with vinegar to remove rust and slag). And four 500/600 pieces for table apron and stretchers.

Flower pots are perfect size, almost 750 mm internal lengt, but still about 10 liter volume. Drawbacks are missing lid (opening means streching new clingafilm) and material should be thicker all over.

Not cruicial on this one, but sometimes it would be really nice how to weld together pipe/plate/channel to to produce strogest joint. I know some priciples, but there is more. Wonder if there is a siple guide to layman?

Pekka

Offline PekkaNF

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Re: Mill/drill stand for Warco Major mill
« Reply #31 on: September 15, 2018, 05:29:06 PM »
Draw bar.

First I was thinkking if differential screw. It needs certain ration and at the taper end is tandard, that leaves tail end to play with. Hole trough the spindle is pretty good for M16x2 thread and was easy to tap. Therefore I made alternative design.

Drilled 8,5 mm hole trough  M16 20 mm long screw.

M8 thread at tail end of draw bar and long nut to fit.

Greased the rotaing parts and used bearing retainer glue to glue M8 long nut into draw bar. Left it upright for glue to harden and prevent it running to wrong places.

Pekka

Pekka

Offline PekkaNF

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Re: Mill/drill stand for Warco Major mill
« Reply #32 on: October 14, 2018, 02:45:27 AM »
I have been bussy lately, but put hour now and then to this.

Decided to  make it minimum size (base size for the drill mill and a little extra to put the mount holes iddle of the C_channels results in outer size of base is 400x600 mm. Height 750 mm.

Welding and paintin was easy. Came out pretty heavy.

Used best part of the day putting the lifting eye on the roof joist. Build it from two 2x4" upright atop of roof joists. Spend some time questimating would that bee good enough. It was. Used M16 8.8 all thread and lifting eye, big washer upper end trough hole on one 2x4" laying flat.

I bought cheap chanin block and I am not sure if the markings are right on the box. Promise is for one metric ton, but maybe for them metric and imperial ton is the same. It was a little sticky with 1/3 of metric ton.

Got it lifted, put in the tray and proceeded to shim (my day off).

Pekka

Offline PekkaNF

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Re: Mill/drill stand for Warco Major mill
« Reply #33 on: October 14, 2018, 05:54:13 AM »
uhuh

Shimming it straight was not easy (nor completely over) :Doh:

I think that not only the floor is skewed but the welded fame has a set and something flexes on 0,1 mm /m scale when bolts are tightened.

The big idea was to nip the frame reasonably straight and true on mill base (it is ribbed cast iron frame with some rigidy) and then shim it level and relaxed on the floor. That did not give consistent results.

Plan "B" now it is reasonably level, but not completely straight. I bolted it down, let it settle and if it has big issues I shim again the base. If it stays on level, I will shim the mill straight betwen mill plinth and table frame.

Next time I'll design adjustment on the floor pads.

After I bolted the frame on the ground i cut the bilical cord - took away the hoisting equipment. Now it has to stand on it's own.

Offline tom osselton

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Re: Mill/drill stand for Warco Major mill
« Reply #34 on: October 14, 2018, 07:36:16 PM »
Looks good but Iíd be worried a little the machine base is bigger than the stand and once the table is moved to the end of travel supporting any weight the leverage just might tip it! I see itís bolted down Iím just saying!

Offline PekkaNF

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Re: Mill/drill stand for Warco Major mill
« Reply #35 on: October 15, 2018, 03:05:39 AM »
Pretty convinced that M10 achor bolts will keep it tied properly on floor.

I was first considering buidling a frame over a toolbox. I could not find a tool cart of proper size (I actually bought one). But with wheels and/or table support frame it would have brought the many mill controls too high and I would have left behind it 100% empty space - they are not that deep and this mill is about one metre deep. The tool cart will be repurposed to it's original function as a tool cart to store some measurement tools and such

Then I checked smallet tool chests and boxes and I felt that I would be designing in a unnecessary complication with a very little gain. All resulted in wasted space and reduced flexibility. Therefore I decided to build funcional frame and later fit in few selves or drawers and maybe mount something on the frame.

This is build way too thick materials (6-8 mm wall thickness) but that is what I had in hand. And It won't break. I was considering a 3 mm sheet metal shell and putting three drawers in. Would have looked more professional, but harder to build anything in after mounting the milling machine.

Pekka

Offline vtsteam

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Re: Mill/drill stand for Warco Major mill
« Reply #36 on: October 15, 2018, 02:23:35 PM »
Good to see it on the stand, Pekka! :beer:
I love it when a Plan B comes together!
Steve
www.sredmond.com