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The Sajo mill is here

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Bernd:
I see you've got machining down pretty good Trion.

Looks like you'll have a very nice looking mill when all done with the little fixes.

Bernd

Trion:
Thanks :)

Unfortunately, I didn't get a lot done on the machine this weekend, although I had all saturday. Most of it was spent on other projects, like mounting new shock absorbers on the daily driver, and chatting with friends. But chatting can be a good thing. By the looks of it, I might just have scored a monstrous machining vise. But I'm not celebrating until it stands on the milling table..

All that I have to report, is that i ground up a HSS tool as described in many threads around here. I also gave the part a quick pass, before I had to call it a day..

AdeV:
That's a nice mill, and I can only echo other's sentiments when I say - that's some fine repair/remedial work you're doing :)

The only comment I'd make about your swarf; that really blue stuff means you're running your cutter really hot; that's going to kill HSS off in no time, dunno about carbide, but I think the fact you've worn them out may be related? Anyway... certainly if you're using HSS bits, I think you should either slow the feed/speed down, or take lighter cuts, or use coolant - your edges should last longer then. But your swarf won't look quite so nice, mind...

Trion:
Thanks, It's a learn as I go along. I have a project update laying on the camera, will post it when I get home :wave:

I have made blue chips with HSS a few times, but not often. It allways ends with me swearing and heading for the grinder.. :bang:
Those chips that lay in the background are remains from last time, when I used carbide. The carbide inserts that I have, are very strange and not actually suited for use in the tool holder that I have. If you study them closely, you'll see that they have strange looking chip breakers that taper away from the cutting edge. The inserts are good for surfacing, but turning is a completely different story.. The shape of my tool holders are not contributing to that either. It seems that both my left and right hand carbide tool holders are made for surfacing when turning towards the chuck..
But you'r right, I was running the cutter too hot. I'm hoping to get hold of some coolant during the week, should help a bit with that matter.

On another note, the HSS tool shown on the picture didn't work too well. I was getting a lot of vibrations and quite wide cuts with the big nose radius. Still need to learn some more about grinding HSS, I guess ::)

Trion:
The promised update :)

Finished turning the handle mount


Test fitted it on the mill


Drilled a 7mm hole for a M8 set screw. Lacking a centre finder, I did it the flintstone way and just swung the drill back and forth (it can swing on the shaft it's standing on), slowly lowering the quill until it just touched.


Then I turned the part around and aligned it, to drill the hole for the handle. Again, flintstone..


But it seemed to work and both the holes got drilled :)


Then I tapped the set screw hole to M8 and the handle hole to M10, before I fitted it on the mill :D


If you look at the previous pictures you notice that its only a "pipe" with a through hole on which this is mounted to. To avoid the handle from spinning on the "pipe" i screwed the set screw into the pipe's through hole. But then there would be nothing to tighten the screw up against, so I inserted a suiting piece of round stock into the "pipe" and tightened the screw against it. Sort of.. ::)



Next up was beginning to make the handle, so I found some steel rod and started turning it's length to get a nice looking handle


But after several passes at various speeds and very low feed, the surface finish still was quite rough. My interpretation is that the material seems quite hard as the chips "crumble" of instead of spinning into a fine coil. Not sure if I'll get some other steel and make a new handle or try to salvage this one..


This was at about 700rpm, 0,1mm cut and the slowest feed possible..


I'm thinking of sanding down the handle, just for the looks of it, but it will be a bit of work before it's going to look ok..

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