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madoverlord:robots-sherlinemillsetup [2016/05/14 19:42]
madoverlord
madoverlord:robots-sherlinemillsetup [2016/10/04 14:42]
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-=== Sherline 8-axis Mill Setup for Morons === 
- 
- 
- 
-(or, "How you can be a total mechanical neophyte and still get 
-it together without breaking it (too much)"​) 
- 
- 
- 
- 
- 
-<​html><​a href="​http://​media.madoverlord.com/​Lg/​DSC011/​DSC01115.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC011/​DSC01115.jpg"></​a></​html>​ 
- 
-This page documents my adventures in putting 
-together the [[http://​www.sherline.com/​|Sherline]] 8-Axis mini-mill. ​ Here you see all the parts, laid out in 
-their lubricated glory on what was (but is no longer) one of my wife's favorite 
-fluffy white towels. ​ I have already assembled the headstock and motor, as this is 
-relatively straightforward. ​ Also in the pic (click any image to see a larger 
-version) you can see the various tools and 
-measuring instruments needed to align the mill.  In particular, you will need a 
-precision machinist'​s square and a test indicator. 
- 
- 
- 
- 
-The Sherline instructions currently make some assumptions about the level 
-of knowledge of the poor sap (that would be me) putting it together. ​ As I am a 
-total mechanical moron (otherwise known as a software geek), this makes me an 
-interesting test case; if I can put it together, anyone can.  Also, I'll probably 
-make all the mistakes it is possible to make. 
- 
- 
- 
- 
-One assumption that I will make is that you have the 8-direction mill 
-assembly instructions;​ I won't replicate them here, just annotate them. 
- 
- 
-<​html><​a href="​http://​media.madoverlord.com/​Lg/​DSC011/​DSC01116.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC011/​DSC01116.jpg"></​a><​a href="​http://​media.madoverlord.com/​Lg/​DSC011/​DSC01117.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC011/​DSC01117.jpg"></​a><​a href="​http://​media.madoverlord.com/​Lg/​DSC011/​DSC01118.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC011/​DSC01118.jpg"></​a></​html>​ 
-<​html><​a href="​http://​media.madoverlord.com/​Lg/​DSC011/​DSC01119.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC011/​DSC01119.jpg"></​a><​a href="​http://​media.madoverlord.com/​Lg/​DSC011/​DSC01120.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC011/​DSC01120.jpg"></​a><​a href="​http://​media.madoverlord.com/​Lg/​DSC011/​DSC01121.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC011/​DSC01121.jpg"></​a></​html>​ 
- 
- 
-Attaching the round column 
-base (step 1) is pretty trivial, as is attaching the hold down bolt (step 2). 
- 
- 
- 
- 
- 
-<​html><​a href="​http://​media.madoverlord.com/​Lg/​DSC011/​DSC01122.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC011/​DSC01122.jpg"></​a><​a href="​http://​media.madoverlord.com/​Lg/​DSC011/​DSC01123.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC011/​DSC01123.jpg"></​a></​html>​ 
- 
-However, at this point, I made a mistake; 
-I added what I now know is the spacer block and extension post.  The instructions don't mention 
-them, but the drawing is a little ambiguous (and the exploded drawing shows them), so I 
-attached them.  This turns out to be a mistake, since you can't align the mill for the first 
-time with them on.  I was scratching my head about how those calibration marks were going to 
-work, because all the round elements except the base rotate; ​ this finally became clear much 
-later in the instructions when you're told to make a mark on the base to match the (aligned) 
-position to the column top (which has all the rule marks on it).  This mark that you make, 
-along with the two marks on the spacer block, let you line everything up when the spacer 
-block is in use.  Note that all the lines and marks are on the right side of the column as 
-seen from the front; the side with the left/right x-axis handwheel. 
- 
- 
- 
- 
- 
-<​html><​a href="​http://​media.madoverlord.com/​Lg/​DSC011/​DSC01124.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC011/​DSC01124.jpg"></​a><​a href="​http://​media.madoverlord.com/​Lg/​DSC011/​DSC01125.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC011/​DSC01125.jpg"></​a><​a href="​http://​media.madoverlord.com/​Lg/​DSC011/​DSC01126.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC011/​DSC01126.jpg"></​a><​a href="​http://​media.madoverlord.com/​Lg/​DSC011/​DSC01127.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC011/​DSC01127.jpg"></​a></​html>​ 
-<​html><​a href="​http://​media.madoverlord.com/​Lg/​DSC011/​DSC01128.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC011/​DSC01128.jpg"></​a><​a href="​http://​media.madoverlord.com/​Lg/​DSC011/​DSC01129.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC011/​DSC01129.jpg"></​a><​a href="​http://​media.madoverlord.com/​Lg/​DSC011/​DSC01130.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC011/​DSC01130.jpg"></​a></​html>​ 
- 
-In the next step, you loosen up the 
-flange bolt (the big bolt on the side) that lets the elbow of the bed & swing arm rotate, open it to about 90 degrees, 
-and tighten it up again. ​ Then you attach it to the column. 
- 
- 
- 
- 
- 
-<​html><​a href="​http://​media.madoverlord.com/​Lg/​DSC011/​DSC01131.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC011/​DSC01131.jpg"></​a><​a href="​http://​media.madoverlord.com/​Lg/​DSC011/​DSC01132.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC011/​DSC01132.jpg"></​a><​a href="​http://​media.madoverlord.com/​Lg/​DSC011/​DSC01133.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC011/​DSC01133.jpg"></​a><​a href="​http://​media.madoverlord.com/​Lg/​DSC011/​DSC01135.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC011/​DSC01135.jpg"></​a></​html>​ 
- 
-Next, put 
-on the column adjustment 
-block. ​ This locks the column so that it cannot tilt front/back, and lets you make a fine 
-adjustment to its orientation. ​ You'll also want to use the 4 outer hex bolts to tighten up the 
-column rotation axis so the whole thing doesn'​t flop around, and the 4 inner bolts to lock the 
-vertical column bed to the rotary column (the big red dial). 
- 
- 
- 
- 
- 
-Finally, assemble the 
-motor mount onto the saddle (that rides on the column bed).  This is actually kind of a waste of time, because if you 
-read the instructions on how to square up the column, you'll realize you have got to take 
-it off again... 
- 
- 
- 
- 
-<​html><​a href="​http://​media.madoverlord.com/​Lg/​DSC011/​DSC01136.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC011/​DSC01136.jpg"></​a><​a href="​http://​media.madoverlord.com/​Lg/​DSC011/​DSC01137.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC011/​DSC01137.jpg"></​a><​a href="​http://​media.madoverlord.com/​Lg/​DSC011/​DSC01138.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC011/​DSC01138.jpg"></​a><​a href="​http://​media.madoverlord.com/​Lg/​DSC011/​DSC01139.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC011/​DSC01139.jpg"></​a><​a href="​http://​media.madoverlord.com/​Lg/​DSC011/​DSC01140.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC011/​DSC01140.jpg"></​a></​html>​ 
- 
- 
- 
- 
- 
- 
- 
- 
- 
-=== Aligning the Mill === 
- 
- 
- 
-<​html><​IMG SRC="​http://​media.madoverlord.com/​Lg/​rollpi/​rollpitchyaw.gif"​ BORDER=0 WIDTH=229 HEIGHT=240 ALIGN=TOP></​html>​ 
- 
-Before 
-we begin, let's define names for some of the parts. ​ Given that I am a pilot, I'm familiar with 
-aviation descriptions for the various axes.  If you imagine the mill as being an airplane, with 
-the nose at the front and the tail at the rear, then the big red **rotary column** dial at the front 
-of the mill (locked with the 4 bolts on its faceplate) is used to set our position on the roll axis (axis 
-8 in sherline'​s figure 1), 
-the **knuckle** right behind it (locked with the flange bolt on the right [as seen from 
-the front] and fine adjusted with the center bolt of the column adjustment block sets the pitch (axis 
-7), and the big flange nut at the back of the mill (that locks down the round column) locks both 
-the yaw (axis 6) and the forward/​backward "​thrust"​ (axis 5). 
-The first step is to get the roll and pitch (axes 8 and 7) axes roughly aligned using a machinist'​s square. ​ You 
-will note that at this point, I (a) hadn't realized I still had the extension post in, and 
-(b) missed the instruction on removing the headstock & motor. ​ Using the square against the 
-front of the column bed, you can see if it's aligned correctly (a strong light shining from behind 
-helps). ​ Then you loosen the knuckle'​s flange bolt, adjust the central bolt in the column adjustment 
-block to get it nice and straight, and tighten the flange bolt again. ​ This sets the pitch. 
- 
- 
- 
- 
-<​html><​a href="​http://​media.madoverlord.com/​Lg/​DSC011/​DSC01141.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC011/​DSC01141.jpg"></​a><​a href="​http://​media.madoverlord.com/​Lg/​DSC011/​DSC01142.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC011/​DSC01142.jpg"></​a><​a href="​http://​media.madoverlord.com/​Lg/​DSC011/​DSC01143.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC011/​DSC01143.jpg"></​a><​a href="​http://​media.madoverlord.com/​Lg/​DSC011/​DSC01144.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC011/​DSC01144.jpg"></​a><​a href="​http://​media.madoverlord.com/​Lg/​DSC011/​DSC01145.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC011/​DSC01145.jpg"></​a></​html>​ 
-<​html><​a href="​http://​media.madoverlord.com/​Lg/​DSC011/​DSC01147.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC011/​DSC01147.jpg"></​a><​a href="​http://​media.madoverlord.com/​Lg/​DSC011/​DSC01148.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC011/​DSC01148.jpg"></​a><​a href="​http://​media.madoverlord.com/​Lg/​DSC011/​DSC01149.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC011/​DSC01149.jpg"></​a></​html>​ 
- 
-In a similar way, you adjust the rotary column. ​ I aligned against the sharp edge of the column bed, as it was hard to see if things 
-were correct any other place (but, see below). ​ To adjust, you loosen the 4 outer bolts on the front plate, 
-and rotate to things line up.  I found it easiest to actually do it by feel, using the 
-machinist'​s square to hold the column bed in the right orientation while I tightened the 
-bolts down. 
- 
- 
- 
- 
- 
-<​html><​a href="​http://​media.madoverlord.com/​Lg/​DSC011/​DSC01151.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC011/​DSC01151.jpg"></​a></​html>​ 
- 
- 
-It was at this point that I realized that I should have taken the motor off, as well as the 
-extension block. ​ After I did this, I had to align against the saddle, not the column bed, because my 
-square was too big to do otherwise; I couldn'​t raise the saddle high enough to get out of the way. 
- 
- 
- 
- 
- 
-<​html><​a href="​http://​media.madoverlord.com/​Lg/​DSC012/​DSC01204.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC012/​DSC01204.jpg"></​a><​a href="​http://​media.madoverlord.com/​Lg/​DSC012/​DSC01205.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC012/​DSC01205.jpg"></​a><​a href="​http://​media.madoverlord.com/​Lg/​DSC012/​DSC01206.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC012/​DSC01206.jpg"></​a></​html>​ 
- 
-The next step is to measure the built-in error of the 
-y-axis. ​ Frustratingly,​ Sherline doesn'​t explain why this is done, or how to use the results, 
-but here is how to do it.  You will need a dial indicator, which allows you to measure differences 
-in position in units of 1/10,000th of an inch or less.  Mount it in the spindle of the mill using 
-a chuck. ​ Move the little measuring tip (you can reposition it by hand) until it is at a 45 degree 
-angle to vertical, then lower it onto the back of the saddle until the reading changes (I moved it 
-until I got a full dial's rotation, which was 80/10000ths of an inch, as far as I can tell. 
- 
- 
- 
- 
-Then, using the Y axis knob at the front of the mill, move the saddle towards the back until 
-the dial indicator tip is almost at the front of the saddle, and record the variation in the 
-readiing. ​ I got a reading of +16 at the center of the saddle and +10 (1/1000th of an inch) at 
-the front, as compared to the back.  This is at the low end of the range Sherline mentions. 
- 
- 
- 
- 
- 
-<​html><​a href="​http://​media.madoverlord.com/​Lg/​DSC012/​DSC01207.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC012/​DSC01207.jpg"></​a><​a href="​http://​media.madoverlord.com/​Lg/​DSC012/​DSC01208.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC012/​DSC01208.jpg"></​a></​html>​ 
- 
-The next step is to square up the ram (the yaw axis (axis 6) 
-and the thrust (axis 5)).  Both of these are clamped down by the big flange bolt on the round 
-column at the back.  You set the thrust to where you want it (usually, so the center point of 
-the spindle is about in the middle of the Y axis travel), mount the test indicator in the vice 
-(tip: move the Y axis so that the bed is roughly centered under the spindle, mount the vice, 
-mount the test indicator so that it's as close as possible to the vertical column, and do the 
-fine adjustment to get the test indicator to touch; as you'll see, after you finish this 
-alignment, you should NOT move the Y axis wheel at all), 
-and move it left and right on the vertical column. ​ You want to get identical readings on each 
-side of the column; that means the column is square. ​ If one side shows a higher reading (and 
-thus is closer to the front than the other side), a gentle tap on the horizontal swing arm on 
-the opposite side will rotate the entire assembly a bit in the correct direction. ​ Tap, measure, 
-repeat until you've got them as close to perfect as possible, then clamp down the flange bolt. 
- 
- 
- 
- 
-I found it helpful to tighten the flange bolt 1/8 turn at a time, then remeasure to make 
-sure I hadn't disturbed things, and noticed that if I used a 1/8 turn, wait a few seconds, 1/8 turn, 
-wait a few seconds, sequence, I wouldn'​t disturb the setting at all -- but if I just tightened it 
-quickly as one would usually tighten a bolt, things would get thrown off. 
- 
- 
- 
- 
-The final step is to scribe a vertical line below the zero mark on the lower part of 
-the round column (at the back-right of the mill) as a rough guide should you need to realign 
-the mill later. 
- 
- 
- 
- 
- 
-<​html><​a href="​http://​media.madoverlord.com/​Lg/​DSC012/​DSC01209.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC012/​DSC01209.jpg"></​a><​a href="​http://​media.madoverlord.com/​Lg/​DSC012/​DSC01210.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC012/​DSC01210.jpg"></​a></​html>​ 
-<​html><​a href="​http://​media.madoverlord.com/​Lg/​DSC012/​DSC01211.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC012/​DSC01211.jpg"></​a><​a href="​http://​media.madoverlord.com/​Lg/​DSC012/​DSC01212.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC012/​DSC01212.jpg"></​a></​html>​ 
- 
-What Sherline calls "​Squaring the column with the X-axis"​ 
-is more precisely "​setting the roll axis", and what you are adjusting is the rotary column. 
-Confusingly,​ Sherline states "​Because the axis that allows you to tilt the column in and out 
-hasn't been squared yet, you should only read the indicator at the same Y-axis location on 
-the worktable that you used before." ​ But they don't say which previous operation they are 
-talking about, why you need to do this, or mention in the previous step you shouldn'​t move the 
-Y-axis. ​ My guess is they'​re talking about the previous step, thus my tip before. 
- 
- 
- 
- 
-I won't go into as much detail about this operation (you should be getting the idea), 
-but here are some tips: 
- 
- 
- 
- 
-  * The only measurements that count are those on the extreme left and right as you turn the spindle. ​ As long as they are equal, you're OK. 
-  * If your test indicator doesn'​t have a swivel mount (like mine!), the Sherline boring tool can be used to offset the indicator. 
-  * To get the clamping bolts to the proper tension for adjustment, loosen each one, then tighten it gently until you feel just a little resistance. 
-  * When you've got things set, gently tighten each bolt just a bit, remeasure, tighten a bit more, etc.  Gently does it. 
- 
- 
- 
- 
- 
- 
-<​html><​a href="​http://​media.madoverlord.com/​Lg/​DSC012/​DSC01213.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC012/​DSC01213.jpg"></​a><​a href="​http://​media.madoverlord.com/​Lg/​DSC012/​DSC01215.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC012/​DSC01215.jpg"></​a><​a href="​http://​media.madoverlord.com/​Lg/​DSC012/​DSC01216.JPG"​ target="​_blank"><​img src="​http:/​wiki.animeigo.com/​MO/​Sm/​DSC012/​DSC01216.jpg"></​a></​html>​ 
- 
-Next we'll adjust the pitch axis, 
-freeing the knuckle by 
-loosening the flange bolt behind the rotary column dial, and doing fine adjustment with that 
-central bolt.  Read the instructions carefully, and realize that because the front and back 
-points you are measuring are both in front of the pivot, their positions will change in the 
-same direction but different amounts. ​ All you care about is getting them to the same value, so: 
- 
- 
- 
- 
- 
-  * If the front reading is greater than the back reading, you need to tilt the column back, by tightening the bolt. 
-  * If the front reading is lower than the back reading, you need to tilt the colum forward, by loosening the bolt. 
-  * Because of the funky way the numbers will change, make small adjustments,​ and then even smaller ones as you get closer. 
-  * It helps to reposition the test indicator vertically between measurements to get full benefit of its range. 
- 
-