Installing the Y Axis Extension Kit on the Taig® Mill

Transcription

Installing the Y Axis Extension Kit on the Taig® Mill
Congratulations on your purchase of the Y Axis Extension Kit for the Taig mill. This kit adds ¾´ of travel to
the Y axis, increasing the travel from 5.5´ to 6.25´. It also increases the distance from the spindle centerline to
the column from 5.50´ to 6.25´ (4.75´ to 5.00´ from spindle centerline to Z axis way).
Installation is straight forward, requires no machining and is easily reversed should the need arise.
Contents of kit (Figure 1)
2 ea - End Plate Spacer (A)
1 ea - Headstock Plate Spacer (B)
A
B
Note: Newer Taig Mills will have a
Headstock Spacer Plate with 8 holes
2 ea - 10-32 x 1½´ SHCS (C)
4 ea - 10-32 x 1¼´ SHCS (D)
(Note: SHCS = Socket Head Cap Screws)
The following items are not shown
2 ea - 8-32 x Ǫ´ Phillips Machine
Screws
2 ea - 8-32 KEP Nuts
4 ea - #8 Flat Washers
C
Tools Needed
5/32´ Allen Wrench (ball end preferred)
3/32´ Allen Wrench
9/64´ Allen Wrench (optional)
7/8´ Wrench (for column nut)
Tools Needed for Z Axis and Belt Pulleys
Alignment
D
Figure 1
A variety of tools can be used for the alignment of the Z axis and belt pulleys. The ones listed here are used
during these instructions. There are alternate methods of aligning the Z axis and belt pulleys. Use what ever
method works best for you with the tools you have at hand.
Copyright 2009-2010 by Wildhorse Innovations Ȃ All rights reserved. Reproduction in whole or part without written permission is prohibited.
http://www.wildhorse -innovations.com ± [email protected]
Page 1
Dial Indicator and Stand
-ORIndicol Style Indicator and Stand
(Magnetic stand preferred for either indicator)
Steel plate for mounting magnetic indicator to machine table
T-Nuts and clamps for mounting steel plate to machine table
4-5´ Angle Block
-OR123 Block
T-Nuts, bolts and hold down clamps for securing angle block or 123 block to machine table
Please refer to the parts explosion found at the bottom of http://www.taigtools.com/mmill.html for additional
information on the construction of the Taig mill.
DISCLAIMER
Application of this modification to your mill may result in voiding the manufacturer¶s warranty. In addition,
the techniques used by the installer of this modification are beyond the control of Wildhorse Innovations, LLC.
For these reasons, Wildhorse Innovations, LLC assumes no responsibility for the installation or performance of
this modification, or any damage to the customer¶s machine or the performance thereof. By proceeding with
the installation of this modification, the customer assumes full responsibility for the quality and performance of
this modification and any damage to the machine or the voiding of the manufacturer¶s warranty.
If you do not agree with these terms, your sole remedy is the return of the product, complete and in its original
form, to Wildhorse Innovations, LLC. Please obtain an RMA and instructions for the return of the product by
emailing [email protected] or by writing to Wildhorse Innovations, LLC at Attn: Returns,
PO Box 234, Plains, MT 59859. . Upon receipt of the product complete and in its original condition, Wildhorse
Innovations, LLC will refund the purchaser¶s full purchase price, less any shipping and handling fees. Products
returned without an RMA will be refused.
Extending the Y Axis Table Travel
The ¾´ extension of the Y axis table travel on the Taig mill is made possible by the fact that the lead screw on
the Y axis is longer than needed for the 5 ½´ stock Y axis travel. Additionally, the Y axis ways are long enough
to accommodate the additional travel. The saddle ways will overhang the fixed ways by a small amount when
the full 6 ¼´ travel is used. However, this is not a problem since the machine is designed to accommodate a
like amount of overhang at the rear of the ways when the saddle is at the rearmost (nearest the column) limit of
travel.
The extension of the Y axis travel can be accomplished without removing the saddle, lead screw, lead screw
handle or stepper motor.
Warning: When applying this modification to a CNC equipped machine, use caution when handling the
Y axis stepper motor and lead screw. The weight of the stepper motor should be supported with blocks
under the stepper motor or by another suitable method. NEVER allow the weight of the stepper motor
to be supported by the lead screw. Doing so can damage the threads or bend the lead screw.
Page 2
Step 1: Move the machine table to a position midway between the travel limits on the Y axis. Center the table
on the X axis. Position the Z axis about midway up the column.
Step 2: Remove power from the machine and, if the machine is CNC equipped, remove power from the
controller, computer and any other devices connected to the machine.
Step 3: Fold the Y Axis Front Way Cover back
over the table. Optionally the Front W ay Cover
can be removed using the 9/64´ Allen wrench
to remove the two 8-32 x ½´ SHCS¶s which
secure the way cover to the Saddle. This may
be a good time to remove both way covers and
clean them using hot water, dish washing soap
and a stiff brush. The 8-32 x ½´ machine
screws and matching washers and nuts are
provided as replacements for the screws
securing the W ay Cover Stiffeners and way
covers at the center hole in the assembly.
2A
2B
(Obscured by
motor mount in
this photo.)
Step 4: (Reference Figure 2) Using a 5/32´
Allen wrench, loosen and remove the two 1032 x ¾´ SHCS¶s which secure the Y Axis End
Plate to the Saddle (2A and 2B). If this is a
CNC machine, be sure to support the weight of
the stepper motor with scraps of wood or any
other suitable support.
Figure 2
Step 5: (Reference Figure 3) Carefully slide the
entire Saddle, Y Axis Lead Screw, End Plate
and Lead Screw Handle (or stepper motor, if
CNC equipped) outwards, opening a gap of
about 1´ between the End Plate and Machine
Base. Be sure to maintain support of the
stepper motor on CNC equipped machines.
Instructions continue on page 4
1´ gap
Figure 3
Page 3
Step 6: (Reference Figures 4 & 5) Insert the 2 End Plate
Spacers (4A) between the Y Axis End Plate and the
Machine Base. Hold the spacers in position using the
two 10-32 x 1½´ SHCS (5A and 5B).
Step 7: (Reference Figure 6) carefully slide the entire
Saddle, Y Axis Lead Screw, End Plate and Lead Screw
Handle (or stepper motor, if CNC equipped) inwards,
closing the gap between the End Plate, Spacers and
Machine Base. Be sure to support the stepper motor on
CNC equipped machines. Tighten the two 10-32 x 1½´
SHCS securely.
4A
This completes the installation of the Y Axis Travel
Extension Kit. Test the installation by moving the table
through the full range of movement on the Y axis.
Assure that the Lead Screw is parallel to the travel path
of the Table. The close tolerances held during the
manufacture of the Spacers should eliminate the need
for any adjustment. However, should you find that the
alignment of the Lead Screw needs adjustment, there is
a small amount of adjustment available by loosing the
two 10-32 x 1½´ SHCS¶s and repositioning the End
Plate.
If you have limit or home switches mounted on the Y
axis they may need to be adjusted to compensate for the
extended travel. Switches which are activated by the
rearward movement of the Y axis should not need
adjustment as we have not made any changes to the rear
limit of the table movement. Switches at the forward
limit of travel of the Y axis will most likely need
adjustment to accommodate the additional ¾´ of travel.
Figure 4
5B
5A
Figure 5
The two 8-32 x ½´ screws are provided to replace the
center screws on the way cover mounts. I have seen
several machines with the nuts missing because no lock
washer was used in the initial installation. Use them as
you see fit.
Figure 6
Page 4
Installing the Z Axis Headstock Plate Spacer
With the installation of the Y Axis Extension Kit, you have extended the range of movement of the Y axis by
¾´. However, the spindle to column distance must be increased in order to take advantage of this increase in
the range of movement. Installation of the Headstock Plate Spacer increases the spindle to column distance by
¾´.
NOTE: Newer Taig mills have Headstock Mounting Plates with 8 holes instead of 6. Your kit will include
a Headstock Plate Spacer with 6 or 8 holes, depending upon which model you ordered. The number of
holes in no way alters the following instructions.
A cautionary note here: Although the installation of the spacer is straightforward, the process of installing the
spacer will invariably result in the Spindle Headstock being out of alignment. Realignment of the Spindle
Headstock is straightforward, but requires precision tools. The results of the alignment will only be as good as
the accuracy of the tools used and the care taken by the installer. It is our objective that the instructions given
here are detailed and complete enough to allow a person with little or no knowledge of these alignment
procedures to successfully setup the mill for accurate operation.
In addition to the step by step instructions and illustrations provided, the reasoning behind our procedures is
outlined.
Most of the pictures and illustrations in these instructions show the Spindle M otor, and in some cases, the Mill
Table, removed. The table need not be
removed during the process of installing the
Headstock Plate Spacer. The removal of the
motor is optional, as will be explained in the
7A
first section of the instructions.
Step 8: Remove the Spindle M otor. Although
it is possible to install the Headstock Plate
Spacer and perform the subsequent alignment
procedures without removing the motor,
because the motor is quite heavy and the
weight of the motor is off-center in relation to
the Spindle Block, the process is made
considerably more difficult with the motor
installed. Therefore it is highly recommended
that the motor be removed.
Step 8a: (Reference Figure 7) Disconnect the
Motor Power Cable at the On/Off Switch (7A).
Figure 7
Instructions continue on next page.
Page 5
Step 8b: (Reference Figure 8) Using a 5/32´ Allen
wrench, loosen the two 10-32 x ¾´ Motor Mounting
Screws (8A & 8B). Remove the Spindle Belt. While
supporting the motor, remove the screws and washers.
(A long shaft, minimum 9´, T-handle Allen wrench is
very useful for this procedure.) Set aside the motor,
screws and washers. These are two of the few screws
on this machine that use washers and the replacement
of the washers is critical. As you remove the M otor
Mounting Plate, carefully inspect for any shims
between it and the Motor Mounting Block (10B), note
their position and set them aside with the motor (most
machines will not have shims.)
8A
8B
Figure 8
Step 9: (Reference Figure 9) Using a 5/32´ Allen
wrench, loosen the Spindle Headstock Mounting
Clamp (9A) about ½ turn. It is not necessary to
remove this screw entirely. Be sure to support the
Spindle Headstock while loosening the screw as it may
slide off of the Headstock Mounting Plate once the
clamping screw is loosened.
9A
Figure 9
Step 10: (Reference Figure 10) Slide the Spindle
Headstock (10A) off of the Headstock Mounting Plate
(10C). The headstock can be slide either up or down
to remove it. If the headstock does not slide easily,
loosen the mounting clamp screw (9A) another ¼ to
½´ turn until the headstock removes easily.
10B
10C
Note that the Spindle Motor Mounting Block (10B)
will remain attached to the headstock.
10A
Figure 10
Page 6
Step 11: (Reference Figure 11) Using a 5/32´ Allen
wrench, loosen and remove the four 10-32 x ½´
SHCS¶s (11A, 11B, 11C & 11D). This will allow the
Headstock Mounting Plate to be removed. Notice that
there are six holes in the mounting plate and 8 threaded
holes in the Z Axis Main Body. Make a note of the
position and the mounting plate and which holes are
being used on your machine. As a side note, the
variety of holes allows not only the vertical adjustment
of the spindle position, but by rotating the mounting
plate 90 degrees the spindle may be used in the
horizontal position.
11B
11A
11C
11D
Figure 11
Step 12: (Reference Figure 12)) Using the four 10-32
x 1¼´ SHCS¶s, reattach the Headstock Mounting Plate
(12A) to the Z Axis Main Body (12B), inserting the
Headstock Plate Spacer (12C) between the two. Be
sure to use the same mounting holes that were used
when the Headstock Mounting Plate was removed.
12A
12B
12C
Figure 12
Page 7
Alignment of Column and Spindle to the Table
The ultimate objective of aligning the Spindle to the Table is to not only have the Spindle axially aligned at
right angles to the table surface, but also to have the VERTICAL MOVEMENT of the Spindle at right angle to
the table surface. Many instructions and tutorials on the Taig Mill will focus on a method known as
³Tramming´ to accomplish this alignment. However, tramming alone does not take into consideration that the
Taig Mill has several points of potential misalignment that are not found on a conventional mill. This makes
the alignment of the Taig Mill somewhat more involved than the alignment of a conventional mill. However,
this alignment can be performed with a few simple precision tools which should be present in any machinist¶s
toolbox.
Figure 13
Figure 13 illustrates the possible misalignment that can occur when only tramming has been used. The
misalignment is exaggerated for illustrative purposes. In this illustration, the spindle is shown to be aligned
perpendicular to the table surface (The actual spindle is removed here for purposes of clarity. The spindle
alignment is represented by the Z-Axis Headstock Mounting Plate.) However, because the Z-Axis Headstock
Mounting Plate is mounted to the Z-Axis Column and Main Body with 4 screws WITHOUT ANY
ALIGNMENT PINS or other mechanism to assure alignment, it is possible, and likely, that the Z-Axis
Headstock Mounting Plate and Z-Axis Column and Main Body will not be in alignment with each other. This
results in the condition illustrated in Figure 13 where the spindle is in alignment with the table but the Column
is not perpendicular to the table. Many procedures for aligning the column call for the use of a machinist¶s
square to align the column. This is adequate for rough alignment of the column, but for maximum accuracy,
more refined procedures are required. Our procedures for this process follow in this document.
Page 8
Note: In order to avoid confusion with step
numbering in these instructions, the step numbers
will continue in sequence from the previous
installation sections.
Step 13: (Reference Figures 14 & 15) Reinstall the
Spindle Headstock by mating the V ways on the
headstock with the V ways in the Headstock
Mounting Plate, sliding the headstock into place and
tightening the Spindle Headstock Mounting Clamp
(15A)
Figure 14
15A
Figure 15
Page 9
Indicator
Indicator Base
clamped to
Headstock
Vertical
Surface
Angle Plate
-or123 Block
Figure 16
Step 14: (Reference Figure 16) Using Figure 16 as a reference, set up an indicator and angle plate (or 123
block) as shown (angle place mounted to table, indicator mounted on the Spindle Headstock). The Spindle
Headstock is made of aluminum so a magnetic mount will not adhere to it and must be mounted using a clamp.
In Figure 16 the base is secured to the headstock using a C-Clamp.
The longer the length of the vertical surface the more accurately you can set the column¶s perpendicularity.
Using whatever movement controls you have available (handles on manual mill or jogging on CNC mill), move
the Z axis so that the indicator moves up and down along the full length of the vertical surface.
Page 10
A
Figure 17
If alignment of the column is needed, loosen the mounting nut at the bottom rear of the column (reference
Figure 17, item A). Use a soft mallet or block of wood to lightly tap the column near the top to achieve proper
alignment. Re-tighten the column mounting nut and recheck alignment.
Page 11
Figure 18
Step 15: (Reference Figures 18 & 19) We have now aligned the column side to side. Although there is no
³Official´ adjustment for front to back alignment, now is a good time to check it. Reposition the angle (or 123)
block 90 degrees so the face is parallel to the X axis of the mill. Move the Z axis up and down noting any
movement in the reading on the indicator. There is no adjustment for misalignment in the front to back tilt of
the column, if the column is leaning in this direction, you can loosen the column mounting nut and fabricate
shims to place between the two faces of the column mounting ³disks´ (Reference Figure 19). Not much
shimming should be needed. A 0.001´ shim will result in an approximently 0.010´ alignment change over the
full travel of the Z axis.
Page 12
Insert shims
between these
surfaces to align
front to back tilt
of the column.
Figure 19
If changes are made to this alignment you will need to repeat Step 14 above.
Page 13
Narrow flat
on this edge.
Figure 20
Step 16: (Reference Figure 20) Now that the column is perpendicular to the table in all directions we will align
the Spindle Head so that it is vertical in relation to the table surface. First remove the Spindle Headstock then
using your indicator and indicator mount, duplicate the setup shown in Figure 20. Since the Taig table is nonmagnetic, I clamped a steel plate to the table so that my magnetic indicator stand will work. Be sure to have
your indicator resting on the Headstock Mounting Plate and not on the Headstock Plate Spacer.
Note: The Headstock Mounting Plate has a dovetail to which the Spindle Headstock is mounted. This dovetail
has a very narrow flat edge on which to rest the indicator point. Do not rest the indicator point on the angled
portion of the dovetail or on the Headstock Plate Spacer.
Move the Z-Axis up and down, noting any variation in the indicator reading. If adjustment is needed, loosen the
four 10-32 x 1¼´ SHCS just enough to adjust the position of the Headstock Mounting Plate. When the
Headstock Mounting Plate is aligned perpendicular to the table surface, remove the indicator. Be sure to retighten the four 10-32 x 1¼´ SHCS. You are now ready to re-install the Spindle Headstock.
Page 14
Once the Spindle Headstock is re-installed your mill should be in near perfect alignment. You can use
tramming to verify alignment or to realign if the column is tilted for milling or drilling at an angle. But always
be sure the column is properly aligned, demonstrated by the procedures contained in this document,
before using tramming.
Step 17: Re-install the motor by reversing the procedure used to remove it. Since the Spindle Headstock has
been removed and re-installed, the motor and spindle pulleys are almost certainly misaligned. Realign the
pulleys using whatever method you prefer. Remember that misalignment of these pulleys will result in
shortened belt life.
Visit our website:
http://www.widhorse-innovations.com
For more machine shop supplies and tools.
Wildhorse Innovations is the exclusive US Distributor for the Wildhorse Innovations DRO-350 DRO in both kit and
assembled form. Your receipt from this purchase entitles you to a 10% discount on your next order of $50.00 or more from
our website.
Page 15
Taig Mill Y Axis Extension Kit ± Packing List
________
2 ea - End Plate Spacer
________
1 ea - Headstock Plate Spacer (6 or 8 hole)
________
2 ea - 10-32 x 1½´ SHCS
________
4 ea - 10-32 x 1¼´ SHCS
________
2 ea - 8-32 x Ǫ´ Phillips Machine Screws
________
2 ea - 8-32 KEP Nuts
________
4 ea - #8 Flat Washers
________
1 ea ± Instructions Set
Page 16

Installing the Y Axis Extension Kit on the Taig® Mill

Transcription

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