Posted by Robin Woodward on 17/07/2011 09:54:37:
Hi All,
The mill described here with a 48mm Quill is the Emco “Mentor Mill”, it has 4 speeds as opposed to the 6 speeds of the FB2.
Surface finish on these machines can be a problem, single phase motors do not run that smooth, and gear transmissions do not help the case. That is why on the FB2 the gears are shaved for high precision and Emco fitted a flywheel on the motor spindle to damp out cyclic variation. The FB2 also has a pumped oil lubrication as opposed to grease on the Mentor Mill
The tapered bore is undoubtedly due to the single sided clamp, this will have “Sprung” out wards when the slit was put in. Being single sided and with enormous cross-section it would be very difficult to lock up, that is why the FB2 has the slit all across as Dusty suggests.
One thing Emco recommend is that all elements of the machines that are not being moved should be locked for maximum rigidity.
If you are hell bent on rectifying a fault that does exist from new, I know I had one new, then please the route to go is oversize quill in a slightly oversize bore. Sleeving in auto mobile engines is only done once all the oversize pistons have been used up
Rob
Robin
With the quill clamped I get an excellent surface finish probably because of the modifications I have made.
My 4 speed Mentor came fitted with a motor flywheel although I find it hard to see how it can reduce cyclic speed variations at the spindle nose especially as the flywheel is not rigidly coupled to the motor shaft. As you probably know the standard motor is wound for three phase so I have ditched the capacitor and run mine off a VFD.
I think the improvment in surface finish is because I have made a new spindle that uses taper roller races, The original bottom bearing (regardless of how good a condition it is) must have some sideways movement. As JS aptly described it earlier, its a rubbish design!
Using a 50mm radius flycutter with a (very sharp tipped cutter) the surface finish on aluminium is excellent with no evidence of any gearing related effects so I’m happy.
The oversize bore in my case is not caused by the casting opening up. The original slot looks to have been cut with a 3mm cutter and with the bolt loose, a 3mm thick feeler is gripped nicely. The bottom end of the bore has nearly 0.1mm of wear but there is also quite a lot of play further up the bore, harder to measure but its about 0.05mm. (0.003″ & 0.0025″) The body of the quill has very minimal wear and is also quite parallel so I dont want to make a new oversize one.
My plan is to sleeve the lower portion of the bore, (the section that always contains the quill) that way the upper, less worn part of the bore is retained as a reference for aligning the casting when setting it up. In any event if I get a good fit after sleeving the quill wont even come into contact with that part of the bore.
The only hold up at the moment is sourcing a suitable bit of seamless tubing to make the sleeve out of.