Metalwork - Lathe and Mill topics: May 2020

Friday, 29 May 2020

Re: [Amateur-repairs] Test Message

On Thu, 28 May 2020 18:02:40 -0700, "Richard Knoppow"
<1oldlens1@ix.netcom.com> wrote:

> Thanks, I think the returns and probably other messages were
>being delayed for some reason.

It could be your mail server. That is the most likely culprit reported
in the group manager's forum here.

Donald -- AD8DY

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Thursday, 28 May 2020

Re: [Amateur-repairs] Test Message

Thanks, I think the returns and probably other messages were
being delayed for some reason.

On 5/28/2020 5:00 PM, Lou Everett, Sr. wrote:
> We are seeing them.
>
> Lou WA5LOU
>
> On Thu, May 28, 2020 at 4:47 PM Richard Knoppow
> <1oldlens1@ix.netcom.com <mailto:1oldlens1@ix.netcom.com>> wrote:
>
> I am not seeing my messages in the list so this is a test.
>
> --
> Richard Knoppow
> 1oldlens1@ix.netcom.com <mailto:1oldlens1@ix.netcom.com>
> WB6KBL
>
>
>
>
> --
> Lou WA5LOU
>
> **
>

--
Richard Knoppow
1oldlens1@ix.netcom.com
WB6KBL

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Re: [Amateur-repairs] Test Message

Got this and a couple of others that seem to have been
delayed. I wondered if I was being moderated but maybe things are
just slow.

On 5/28/2020 2:47 PM, Richard Knoppow wrote:
> I am not seeing my messages in the list so this is a test.
>

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Re: [Amateur-repairs] Test Message

I didn't know there was going to be a test

On May 28, 2020, at 20:01, Lou Everett, Sr. <loueverettsr@gmail.com> wrote:

We are seeing them.

Lou WA5LOU

On Thu, May 28, 2020 at 4:47 PM Richard Knoppow <1oldlens1@ix.netcom.com> wrote:
I am not seeing my messages in the list so this is a test.

--
Richard Knoppow
1oldlens1@ix.netcom.com
WB6KBL

--
Lou WA5LOU

Re: [Amateur-repairs] Test Message

We are seeing them.

Lou WA5LOU

On Thu, May 28, 2020 at 4:47 PM Richard Knoppow <1oldlens1@ix.netcom.com> wrote:

I am not seeing my messages in the list so this is a test.

--
Richard Knoppow
1oldlens1@ix.netcom.com
WB6KBL

Lou WA5LOU

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[Amateur-repairs] Test Message

I am not seeing my messages in the list so this is a test.

--
Richard Knoppow
1oldlens1@ix.netcom.com
WB6KBL

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Sunday, 24 May 2020

Re: [clausing-lathe-and-mill] Clausing 5914 "Chatter Test" - .125" DOC / 5" Stick Out (VIDEO)

Seeing you are capable of over-driving the motor to 120hz you could use the backgear to reach from stock 280 rpm to 330 rpm and even reach 360 with a few more hertz. Then you have full power to the spindle...

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Saturday, 23 May 2020

Re: [clausing-lathe-and-mill] Clausing 5914 "Chatter Test" - .125" DOC / 5" Stick Out (VIDEO)

Ryan- Good thought, going with an inverter duty motor, as well as going up to a larger HP. Costs a bit more, but it's going to handle the heat from running at 20 Hz much better than a standard motor.

-Dan

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Friday, 22 May 2020

Re: [clausing-lathe-and-mill] Clausing 5914 "Chatter Test" - .125" DOC / 5" Stick Out (VIDEO)

Great video! Would you mind listing the parts you used (pulleys etc)? And post some pictures of the way you set things up?

On May 22, 2020, at 6:24 PM, Ryan K <grizzlybagworks@gmail.com> wrote:

It took me almost 2 years to finish but I think I'm pretty much done with the 5914 teardown/rebuild. Overall I really love the machine but the Reeves drive+timing belt drive, even when properly rebuilt, was simply too loud for my liking. Shame because I spent a lot of time/money rebuilding the countershaft and the rest of the components.

What I ended up going with is a direct drive system using an 8 rib poly-v belt. I chose a 2hp Marathon Black Max Inverter Duty/TENV motor paired with a Hitachi WJ200 VFD+47ohm 500w braking resistor. Speeds are same as stock with a 1:1.75 pulley ratio. Machine runs 20hz to 120hz. Machine stops faster than the stock clutch/brake and starts faster as well. I have dynamic braking setup but haven't set up DC injection braking yet.

My main concern was that 2hp wasn't going to be enough power going direct drive. At 20hz you're looking at .66hp at the spindle. DOC and Feedrate are linearly proportional to HP so the idea of drop my DOC by 1/3 didn't thrill me.

I decided to chuck up some material and run some tests. The results have put my concern to rest. Being able to move between carbide and HSS tooling I'll be able to stay in the machines "powerband". But even on the outskirts of that power band the performance is more than acceptable for me. At 20hz in 1.25" 4140 I'm able to peel a .150" DOC (.300" diameter) at .015" feed rate. A cutting force calculator would tell you that you need ~2hp spindle to do this, hence original my concern. (https://www.kennametal.com/us/en/resources/engineering-calculators/turning-calculators/cutting-forces.html).

Here's a video of the machine in action performing Clausing's "Chatter Test". This is actually a more strenuous test that the original as I'm taking an additional .025" DOC and the material is 1/4" smaller in diameter. At 1.25" diameter the stick out should have been around 4.16".

I just thought I'd share for those of you that may be struggling with the Reeves drive and want to do something simpler, smoother and quieter. I'm willing to trade off less power for that 5% of the time I may need it for a dramatically quieter and smoother machine for the other 95%.

Here's the specs on the cut:
.150" Depth of Cut (.300" Diameter) (Original Test Called for .125")
.0026"/rev feed rate 360 Rpm (HSS) 1.25" hot rolled 4140 (annealed) (Original Test Called for 1.5") 5" stick out, Unsupported

https://youtu.be/EFmI_R3GHSU

[clausing-lathe-and-mill] Clausing 5914 "Chatter Test" - .125" DOC / 5" Stick Out (VIDEO)

It took me almost 2 years to finish but I think I'm pretty much done with the 5914 teardown/rebuild. Overall I really love the machine but the Reeves drive+timing belt drive, even when properly rebuilt, was simply too loud for my liking. Shame because I spent a lot of time/money rebuilding the countershaft and the rest of the components.

What I ended up going with is a direct drive system using an 8 rib poly-v belt. I chose a 2hp Marathon Black Max Inverter Duty/TENV motor paired with a Hitachi WJ200 VFD+47ohm 500w braking resistor. Speeds are same as stock with a 1:1.75 pulley ratio. Machine runs 20hz to 120hz. Machine stops faster than the stock clutch/brake and starts faster as well. I have dynamic braking setup but haven't set up DC injection braking yet.

My main concern was that 2hp wasn't going to be enough power going direct drive. At 20hz you're looking at .66hp at the spindle. DOC and Feedrate are linearly proportional to HP so the idea of drop my DOC by 1/3 didn't thrill me.

I decided to chuck up some material and run some tests. The results have put my concern to rest. Being able to move between carbide and HSS tooling I'll be able to stay in the machines "powerband". But even on the outskirts of that power band the performance is more than acceptable for me. At 20hz in 1.25" 4140 I'm able to peel a .150" DOC (.300" diameter) at .015" feed rate. A cutting force calculator would tell you that you need ~2hp spindle to do this, hence original my concern. (https://www.kennametal.com/us/en/resources/engineering-calculators/turning-calculators/cutting-forces.html).

Here's a video of the machine in action performing Clausing's "Chatter Test". This is actually a more strenuous test that the original as I'm taking an additional .025" DOC and the material is 1/4" smaller in diameter. At 1.25" diameter the stick out should have been around 4.16".

I just thought I'd share for those of you that may be struggling with the Reeves drive and want to do something simpler, smoother and quieter. I'm willing to trade off less power for that 5% of the time I may need it for a dramatically quieter and smoother machine for the other 95%.

Here's the specs on the cut:
.150" Depth of Cut (.300" Diameter) (Original Test Called for .125")
.0026"/rev feed rate 360 Rpm (HSS) 1.25" hot rolled 4140 (annealed) (Original Test Called for 1.5") 5" stick out, Unsupported

https://youtu.be/EFmI_R3GHSU

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