Tom Senior E milling Machine

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Tom Senior E milling Machine

This topic has 7 replies, 4 voices, and was last updated 10 February 2013 at 18:06 by Dave Shield.

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6 February 2013 at 19:49 #111145
Peter Hodkinson
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@peterhodkinson30460
I'm thinking of purchasing a Tom Senior E to replace my Dore Westbury MK1 which works well but is limited in metal removal. The Tom Senior fits the space I have available and would live in an unheated garage/workshop. I would like to know as a ref what a 16mm cutter mounted in a 2MT ER25 collet chuck could be expected to remove in unleaded mild steel. The electronics of the ready availble alternative worries me with the wide change in temp and humidity in my workshop. Any help or comment would be appreciated even warnings

Phody

Edited By Peter Hodkinson on 06/02/2013 19:51:08
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6 February 2013 at 19:49 #12078
Peter Hodkinson
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@peterhodkinson30460
Dose anybody have one
6 February 2013 at 20:55 #111160
Sub Mandrel
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@submandrel
If it helps for comparison my X2 mill will comfortably cope with a 80 thou (~2mm) deep cut using a 13mm slot drill using an ER25 collet in an MT3 holder, as long as the cutter is well sharpened. Plenty of blue chips. I'd guess the Tom Senior has greater cutting ability.

Neil
7 February 2013 at 09:10 #111216
Lambton
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@lambton
Peter,

I have owned a Tom Senior E type mill for many years and it has always proved to be a capable and sound machine. The round column is fitted with a substantial key that guarantees alignment even when the column is raised or lowered. Mine is a metric 3 phase machine fitted with an inverter drive. The graduations on the X & Y index dials takes some getting used to as I guess TS used the same dials with 100 total divisions on both imperial and metric machines. I have made new ones that are more suitable for a metric machine.

Your question about its suitability for the use of a 16 mm cutter depends on several factors not necessarily connected to any particular type of small mill. e.g.
- At what rate would you like to remove metal/?
- What type of cutter ripper, standard, end mill, slot drill?
- Is the cutter really sharp?
- Are you going to use cutting fluid?
- Is the machine in good order with properly adjusted slides?
- You need to lock the slides that are not being used to traverse the cut.
- Etc.
I think if all the above points are considered and applied you should generally have no difficulty in taking reasonable cuts with a 16 mm cutter.
7 February 2013 at 13:32 #111259
Peter Hodkinson
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@peterhodkinson30460
Thanks for the replies.

My DW MK1 is in pretty good condition. and slide ways are well adjusted. I have recently overhauled the machine which made a great improvement. For general face cutting I use SOMTA fine rippers and then I replace the cutter with a standard DORMER end mill. With 1mm of end cut 'full width' vibration and deflection appear abnormal. I have wondered if the column is not stiff enough. The head bearing are adjusted correctly and lubricated using a medium gear oil. As regards the proverbial spline issues I have fitted an adjustable gib to the bronze drive section which again has made improvements to the DW. I tend not to use cutting emulsion but do use a Lubrisil neat cutting oil. I'm glad to hear the the Tom Senior E is more rigid. I have read odd notes with regard to not exceed 1/3 the cutter dia with and no more the 25% of the dia in depth. This I would be happy with at 16mm dia. Cutter range 6mm to 16mm speed 300 to 700 nominal

Am I expecting too much?

Thanks for all your help.

Edited By Peter Hodkinson on 07/02/2013 13:34:33
7 February 2013 at 17:26 #111276
Lambton
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@lambton
Peter,

It is best not to use the full width of the cutter for reducing the thickness of a work piece – keep the cut just less than the radius of the cutter. Make sure you are not "climb" milling as this is not good practise on a lightly built mill – OK on a Bridgeport.

I do not have any of the problems you describe with my Tom Senior when using sharp cutters. Make sure the corners of your cutters are really sharp.

I always use the spindle speed that the machine is "happy" with and tend to ignore cutting speeds and feed quoted in various tables as they only apply to heavy duty industrial machines on production work not of small, light machines.

I use 3 flute 5% cobalt cutters wherever possible for milling and slotting applications.

Are you holding the work piece very firmly in a proper milling vise? Light drill press vises are not suitable for milling.

I hope this is of help.
10 February 2013 at 15:45 #111591
Peter Hodkinson
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@peterhodkinson30460
Thanks for all your help.

My next task is the aquire a Tom Senior E metric. This is because my ML10 and Cowell 90ME are metric and I have generally set my stall out to go with the flow. for those who have Dore Westbury MK1 machines I have now list on improvment or things to look out for. The most devious was the lower quill bearing. The bearing I believe should have been a press fit and or bearing lock adhesive. When I dismantled the quill to remove grease the bearing pushed out with nothing more than a light tap. Having recently re adjusted the bearing using the two large nuts I used Delta bearing lock and a noticable improvement was made.

Thanks again
10 February 2013 at 18:06 #111621
Dave Shield
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@daveshield21426
I have a Tom Senior M1 not the same as the one you want, I also have a Dore Westbury that I built years ago. Go with a Tom Senior you will be amazed at the difference. I looked at some imports but was not impressed, its just a shame they are not built any more.All the stories what has to be done to the imports to make them into something decent Both my Myfords worked straight from the box as did the second hand Tom Senior.
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