Hobbing machine repair

[bsaint]

We have this old hobbing machine that is orphaned. I think it's from the 60s. We had a part go bad it cracked in a bad spot near a gusset. The stock bar is so far out for this I decided to make a weldment. I made two weldments and let them mellow. Then I machined some reference features and mates them. Did the final weldment today. It's mellowing out in the enclave now for rough machining tomorrow. Once more in the oven then final machining.

 

[bsaint]

Here's an update. The weldment was close enough. Now I gotta weld a pinch tab, furnace it, do the final bore, cut it down an inch in height, and then slit it.

 

[rsanter]

Nice work

 

[cruzer75]

Pretty cool, more about the process and material please. Why the cool down in the oven? Did you preheat as well?

 

[cmandp]

Pretty cool, more about the process and material please. Why the cool down in the oven? Did you preheat as well?

I assume he normalized it. Which is just getting rid of stresses present from all the welding he had to do. So the part doesn't move all over the place as he machines it out.

 

[wasfast]

Great workaround for the broken part by fabbing it. Did you consider brazing the broken cast one?

 

[bsaint]

I assume he normalized it. Which is just getting rid of stresses present from all the welding he had to do. So the part doesn't move all over the place as he machines it out.

Exactly.

So we didn't wanna braze it because the piece flexes to clamp and there's a gusset right where it broke so we thought it would be a bad repair.

I machined out the part that's going to clamp, welded it on and it's in the oven tonight for the last phase. I got a haimer today which is going to aid in finishing it. I found the center of the bore and installed a hardened pin so I can transfer the center of the bore to the perpendicular plane for the slot I have to put in.

 

[bsaint]

Pretty cool, more about the process and material please. Why the cool down in the oven? Did you preheat as well?

I think its all 1018. I took it off the Misc materials rack. Before I came on board things weren't not nicely labeled. I made a program to make adapters and the material I found I could go crazy. Cut like 12L. Found some more and put it in. Tool steel. My end mill did not survive the first pass lol

 

[bsaint]

Well I didn't like the little errors that were adding up then I broke a tap and so I scrapped the part. The blank of steel came in so this is after about a half a day of roughing plus making adjustments. I have to take it easy our mill is not very strong. Left it to finish overnight. Tomorrow I'll do my finish passes.

 

[bsaint]

Almost done with this setup. Just double checking the dimensions to put in the last hole. This little mill definitely did not like the 3" loc

 

[bsaint]

Setup 1 is done!

 

[catalytic]

WOW WOW WOW
I have restored a few tons of machinery over the years and am super compulsive about doing things right---this is probably the first time I've ever seen anyone machine a cast iron part out of steel where they matched the form perfectly to the original casting. Beautiful work. I personally would have sent it to CatTail foundry and had it recast in cast iron, but only because I have limited access to a CNC mill. This new part will last forever.

Let's see more of your work and machines!

 

[bsaint]

WOW WOW WOW
I have restored a few tons of machinery over the years and am super compulsive about doing things right---this is probably the first time I've ever seen anyone machine a cast iron part out of steel where they matched the form perfectly to the original casting. Beautiful work. I personally would have sent it to CatTail foundry and had it recast in cast iron, but only because I have limited access to a CNC mill. This new part will last forever.

Let's see more of your work and machines!

Thanks man! It's my first go at something more complicated than a bracket or adapter.

My mill is just a small Haas Super Mini Mill. This part is probably the most it can do lol. I couldn't even use the tool changer for long holders because it would hit the part. Unless I G53 x to a certain spot. The long DOC features took a toll on the end mill from vibration.

 

[Graham08]

That is some very nice work to program and machine that! The fabricated version was looking good, too. Sorry to hear all that work went down the drain with a broken tap.

 

[bsaint]

Cutting the slit

 

[bsaint]

In production. The press fit on the pin was a little loose so the maintenance dept tacked it

 

[laser3kw]

that's showing an old machine some love!
looks like it turned out perfect. I'd hate to pay someone for that much time, but those old machines are some times worth it.

 

[dutchgray]

Nice work keeping an old machine running. With it being a CNC job the next time you need to make one it should be easier as long as the file can be found.

 

[RPH]

Sweet work and an excellent repair.

 

[Nealcrenshaw]

very nice