Decided to try building a leveling system for my wire EDM tooling that uses a ball & socket instead of jack screws. I spent a couple of days thinking about how to go about this. Below is how it looked on paper.
http://img.photobucket.com/albums/v30/j ... tment3.jpg
http://img.photobucket.com/albums/v30/j ... tment4.jpg
The parts for my ball adjuster, all 304 SS; I bought some 3/4 and 1" stainless steel balls on Ebay.
I made the ball socket with a 1" ball endmill in my Series I CNC Bridgeport.
Roughed out the socket using a 31/32 drill point then a 3/4 ballnose endmill for depth. Finished with the 1" ballnose endmill. I used the knee crank to do the down feed (or up feed). It worked very well. I check the fit between the ball and socket. The ball turned easily without noticeable side play.
http://img.photobucket.com/albums/v30/j ... ndmill.jpg
The 1" stainless steel ball is screwed to the bottom base plate. The ball has a small flat where the 1/4-20 tapped hole is for stability. The spacer is .090 thick to keep the two plates separated by about 1/32 for adjusting.
http://img.photobucket.com/albums/v30/j ... deview.jpg
The top cap clamps the ball in place. Each socket cavity was milled to about .495 deep to be certain the two ball cavities would clamp on the ball.
http://img.photobucket.com/albums/v30/j ... andcap.jpg
Final assembly:
http://img.photobucket.com/albums/v30/j ... seassy.jpg
Hope this was of interest,
Jim
Latest Project: Ball leveling system
-
- Posts: 2281
- Joined: Sat Jan 04, 2003 8:33 pm
- Location: 40 Miles West of Chicago/near DeKalb
- Contact:
Latest Project: Ball leveling system
Tool & Die Maker/Electrician, Retired 2007
So much to learn and so little time.
www.outbackmachineshop.com
So much to learn and so little time.
www.outbackmachineshop.com
Re: Latest Project: Ball leveling system
Jim,
Very nice!
Can you do this thick headed guy a favor? Tell me how the ball is used to advantage. I've never seen a setup like that before.
Thanks,
Harold
Very nice!
Can you do this thick headed guy a favor? Tell me how the ball is used to advantage. I've never seen a setup like that before.
Thanks,
Harold
Wise people talk because they have something to say. Fools talk because they have to say something.
-
- Posts: 2281
- Joined: Sat Jan 04, 2003 8:33 pm
- Location: 40 Miles West of Chicago/near DeKalb
- Contact:
Re: Latest Project: Ball leveling system
Wire EDMs are a different animal compared to the traditional shop machines. Keep in mind I have yet to actually operate a wire EDM so I'm just winging it for now. But the guys that do operate wire EDMs say work holding devices need leveling systems.
The first thing that must be done to a wire EDM is adjust the wire guides so the wire (or cutting tool) is perpendicular to the machine table. Just like squaring the head of a vertical milling machine.
Next, when setting up the workpiece in the wire EDM machine. Keep in mind the wire guides need to be as close as possible to the workpiece, kinda like bandsaw guides. For this reason workholding devices need to have a low profile. When holding a workpiece in a milling machine vise we can square the piece (left to right) with a small combination square. We have all done that. But what if the workpiece is not perpendicular front to back when held in the vise jaws?
This is where the leveling system comes in. The workholding device itself is adjusted to hold the workpiece verticle relative to the EDM wire (or tool). Most of the time adjustments are subtle so a large adjustment range is not required.
Remember, in EDM there are no cutting forces like milling, drilling or turning. The work holding devices do not need to be rock solid. In wire EDM de-ionized water is used for flushing and cooling so tooling needs to be made of stainless steel.
I'm not certain I'll even need this work holding vise mounted to a ball leveling system. But I had a blast building it.
Now I need to get the wire EDM machine running. Maybe this weekend.
Jim
The first thing that must be done to a wire EDM is adjust the wire guides so the wire (or cutting tool) is perpendicular to the machine table. Just like squaring the head of a vertical milling machine.
Next, when setting up the workpiece in the wire EDM machine. Keep in mind the wire guides need to be as close as possible to the workpiece, kinda like bandsaw guides. For this reason workholding devices need to have a low profile. When holding a workpiece in a milling machine vise we can square the piece (left to right) with a small combination square. We have all done that. But what if the workpiece is not perpendicular front to back when held in the vise jaws?
This is where the leveling system comes in. The workholding device itself is adjusted to hold the workpiece verticle relative to the EDM wire (or tool). Most of the time adjustments are subtle so a large adjustment range is not required.
Remember, in EDM there are no cutting forces like milling, drilling or turning. The work holding devices do not need to be rock solid. In wire EDM de-ionized water is used for flushing and cooling so tooling needs to be made of stainless steel.
I'm not certain I'll even need this work holding vise mounted to a ball leveling system. But I had a blast building it.
Now I need to get the wire EDM machine running. Maybe this weekend.
Jim
Tool & Die Maker/Electrician, Retired 2007
So much to learn and so little time.
www.outbackmachineshop.com
So much to learn and so little time.
www.outbackmachineshop.com
Re: Latest Project: Ball leveling system
Pretty much as I envisioned, but, like you, I'm not the least bit familiar with the operation of EDM's of any description. The closest I've been to one is the Elox that was used to remove broken taps, and that was many years ago.
Thanks for the input, Jim. From your comments, I gather that the adjustments are made, then the ball is locked with the screw. Everything rides on the locked ball---which is adequate because there is no cutting load.
Harold
Thanks for the input, Jim. From your comments, I gather that the adjustments are made, then the ball is locked with the screw. Everything rides on the locked ball---which is adequate because there is no cutting load.
Harold
Wise people talk because they have something to say. Fools talk because they have to say something.