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Metalworking (rec.crafts.metalworking) Discuss various aspects of working with metal, such as machining, welding, metal joining, screwing, casting, hardening/tempering, blacksmithing/forging, spinning and hammer work, sheet metal work. |
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#1
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Mills and Drills
Can anyone elaborate on the differences between a Drill and a Mill as
far as the relative size, placement, and materials when it comes to the chuck, spindle, quill, arbor, collet, bearings, gears, ect.? In other words, it's obvious that a mill can move the tooling along more than a single axis, unlike the drill press, but I am attempting to get a handle on the *physical* reasons why so many here say that a drill press shouldn't be adapted to mill use. If these physical reasons can be solved with only small manufacturing changes in drill presses to allow them to become more suited for milling, then does the conventional drill presses unsuitability have to do with the bottom line of the manufacturers or lack of consumer interest responsible for a lack suitable adapers/tooling, or perhaps there are other logistical issues involved? I've heard about the specific forces that the bearings and so forth would have to take as being a reason for a drill presses unsuitability for milling operations, but it seems to me that a suitable gearing adapter would negate much of these "lopsided" forces.(Probably at the expense of a lot of power). Also, I figure that since so many of you have been machining for so many years, is there a possibilty that any bad drill press milling experiences are at least in part a result of a lack of availability of suitable adapters and tooling for this? Anyway, in the meantime I will of course still take the advice of not using a drill press for milling purposes, but only when it comes to metals, because there shouldn't be as much of a problem with plastics like Nylon or Delrin.(But I'll listen to opinions either way). :-) Thanks a lot. Darren Harris Staten Island, New York. |
#2
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Mills and Drills
wrote in message oups.com... Can anyone elaborate on the differences between a Drill and a Mill as far as the relative size, placement, and materials when it comes to the chuck, spindle, quill, arbor, collet, bearings, gears, ect.? In other words, it's obvious that a mill can move the tooling along more than a single axis, unlike the drill press, but I am attempting to get a handle on the *physical* reasons why so many here say that a drill press shouldn't be adapted to mill use. If these physical reasons can be solved with only small manufacturing changes in drill presses to allow them to become more suited for milling, then does the conventional drill presses unsuitability have to do with the bottom line of the manufacturers or lack of consumer interest responsible for a lack suitable adapers/tooling, or perhaps there are other logistical issues involved? I've heard about the specific forces that the bearings and so forth would have to take as being a reason for a drill presses unsuitability for milling operations, but it seems to me that a suitable gearing adapter would negate much of these "lopsided" forces.(Probably at the expense of a lot of power). Also, I figure that since so many of you have been machining for so many years, is there a possibilty that any bad drill press milling experiences are at least in part a result of a lack of availability of suitable adapters and tooling for this? Anyway, in the meantime I will of course still take the advice of not using a drill press for milling purposes, but only when it comes to metals, because there shouldn't be as much of a problem with plastics like Nylon or Delrin.(But I'll listen to opinions either way). :-) Thanks a lot. Darren Harris Staten Island, New York. Drill presses built for side forces are called mill/drills. I don't know what kind of adapter you are imagining that would turn a drill press into a milling machine. |
#3
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Mills and Drills
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#4
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Mills and Drills
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#5
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Mills and Drills
According to :
Can anyone elaborate on the differences between a Drill and a Mill as far as the relative size, placement, and materials when it comes to the chuck, spindle, quill, arbor, collet, bearings, gears, ect.? In other words, it's obvious that a mill can move the tooling along more than a single axis, unlike the drill press, but I am attempting to get a handle on the *physical* reasons why so many here say that a drill press shouldn't be adapted to mill use. Start with the lack of rigidity of the drill press's frame. It is designed only to support the workpiece against the axial forces of drilling. A milling machine has a *lot* more metal in the head, a more rigid column (the best ones don't have round columns, and actually move the *table* up and down with a leadscrew. Even those with round columns have a larger column diameter, to minimize the twist under cutting loads. The quill (which moves the spindle up and down for drilling type operations) is larger in diameter, and a more precise fit in the headstock, so it will not move sideways under cutting loads. The mounting of the cutter to the spindle of a milling machine is *not* via a drill chuck. A drill chuck is normally mounted via a taper -- a mount not designed for side loads, as the drill chuck will pop lose and start bouncing around the shop, spinning rapidly, and carrying a sharp cutter with it. And -- a normal drill chuck is not designed to grip the hardened surface of an end mill shank. (An exception is the diamond grit jaws on one of the more expensive Albrecht drill chucks -- designed for use in a milling machine, and made with a standard milling machine taper (e.g. #40 MTMB, or R8 collet format) shank -- *not* a taper such is used for normal drill chucks. The bearings in a drill press are designed to handle only the axial (thrust) loads, not side loads. If these physical reasons can be solved with only small manufacturing changes in drill presses to allow them to become more suited for milling, then does the conventional drill presses unsuitability have to do with the bottom line of the manufacturers or lack of consumer interest responsible for a lack suitable adapers/tooling, or perhaps there are other logistical issues involved? I've heard about the specific forces that the bearings and so forth would have to take as being a reason for a drill presses unsuitability for milling operations, but it seems to me that a suitable gearing adapter would negate much of these "lopsided" forces.(Probably at the expense of a lot of power). Gear drives can increase the torque at the expense of speed. So can belt drives. This is *not* the major weakness of a drill press when used for milling. Milling machines have a *lot* more steel and cast iron which go into their makeup. There are cheap small tabletop drill presses which can be easily lifted with one hand. The weight of a tabletop milling machine of similar size will probably require a two-hand lift. Also, I figure that since so many of you have been machining for so many years, is there a possibilty that any bad drill press milling experiences are at least in part a result of a lack of availability of suitable adapters and tooling for this? A lack of suitable design for the purpose. A *first* requirement for a drill press which is going to be used for milling is a hollow spindle, so a drawbar can lock the end mill holder or collet into the spindle -- to protect against popping the tool holder out from side loads. And *nobody* is going to make a drill press with such a spindle, as it would cost more, and the machine's frame would still be inadequate for the lateral and twisting loads which milling would apply to it. Making a drill press with such a spindle would simply be leaving them open to lawsuits, which all manufacturers would rather avoid at all costs. Note that a radial arm drill press *might* be solid enough in some features so you could get away with it -- but none of these weigh less than a minimal floor-standing milling machine, and there is no way that you could get it up to your apartment. Anyway, in the meantime I will of course still take the advice of not using a drill press for milling purposes, but only when it comes to metals, because there shouldn't be as much of a problem with plastics like Nylon or Delrin.(But I'll listen to opinions either way). :-) Of course there are problems using it for Nylon or Delrin. You have done nothing to deal with the tendency of the chuck to pop off the taper when subjected to side loads. And there is still the tendency for the frame to wind up under cutting loads, causing a deeper cut than you intended, and thus increasing the chance that the chuck will pop off. Yes -- it is *possible* to redesign and manufacture a drill press for use as a milling machine -- and this is exactly what you will get if you purchase a "mill drill". And -- it will be to heavy to get up your stairs. (And -- it will still not have the workpiece size ability of a milling machine so designed from scratch. Good Luck, DoN. -- Email: | Voice (all times): (703) 938-4564 (too) near Washington D.C. | http://www.d-and-d.com/dnichols/DoN.html --- Black Holes are where God is dividing by zero --- |
#6
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Mills and Drills
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#7
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Mills and Drills
According to Don Foreman :
On Sun, 15 Jan 2006 00:21:37 +0000, (DoN. Nichols) wrote: Yes -- it is *possible* to redesign and manufacture a drill press for use as a milling machine -- and this is exactly what you will get if you purchase a "mill drill". And -- it will be to heavy to get up your stairs. (And -- it will still not have the workpiece size ability of a milling machine so designed from scratch. A small mill-drill would be no problem to disassemble and move up a residential staircase. No part of those is as bulky or heavy as, say, a refrigerator. But he has multiple floors of narrow staircases, and he has suggested that an appliance dolly will not be practical on those stairs. But -- he has also said that he has managed to move some pinball games up those stairs, so I don't really know. A really small mill drill, like a Sherline or Taig, could be carried up intact by one person. Sure -- but I would consider those to be miniature milling machines, not small mill drills. Same for the little mills which Harbour Freight (among others) seems to offer. But since he wants to do a lot of work with stainless steels, I'm not at all sure that any of these would prove satisfactory. I really think that he needs a place at ground floor level for his machines -- perhaps one of the garages which can be rented. A small mill would at least let him get some experience, which would enable him to make a somewhat better choice next time around. Perhaps even to choose to find somewhere else to live which would adapt to the machine tools which he really needs. (But then again -- living in New York (Staten Island) is a different kind of life -- and one not well fitted to hobby metalworking. Enjoy, DoN. -- Email: | Voice (all times): (703) 938-4564 (too) near Washington D.C. | http://www.d-and-d.com/dnichols/DoN.html --- Black Holes are where God is dividing by zero --- |
#8
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Mills and Drills
DoN. Nichols wrote: According to Don Foreman : On Sun, 15 Jan 2006 00:21:37 +0000, (DoN. Nichols) wrote: Yes -- it is *possible* to redesign and manufacture a drill press for use as a milling machine -- and this is exactly what you will get if you purchase a "mill drill". And -- it will be to heavy to get up your stairs. (And -- it will still not have the workpiece size ability of a milling machine so designed from scratch. A small mill-drill would be no problem to disassemble and move up a residential staircase. No part of those is as bulky or heavy as, say, a refrigerator. But he has multiple floors of narrow staircases, and he has suggested that an appliance dolly will not be practical on those stairs. But -- he has also said that he has managed to move some pinball games up those stairs, so I don't really know. A really small mill drill, like a Sherline or Taig, could be carried up intact by one person. Sure -- but I would consider those to be miniature milling machines, not small mill drills. Same for the little mills which Harbour Freight (among others) seems to offer. But since he wants to do a lot of work with stainless steels, I'm not at all sure that any of these would prove satisfactory. I really think that he needs a place at ground floor level for his machines -- perhaps one of the garages which can be rented. A small mill would at least let him get some experience, which would enable him to make a somewhat better choice next time around. Perhaps even to choose to find somewhere else to live which would adapt to the machine tools which he really needs. (But then again -- living in New York (Staten Island) is a different kind of life -- and one not well fitted to hobby metalworking. I was going to pick up a hand truck, but realized that it would add to the dimensional size of the video games I wanted to get up the stairs and around the corners. These machines are as wide as 25 inches, as deep as 34 inches, and over 6 feet tall and 350lbs.(These are maximum numbers). Ok, so perhaps what I need is a universal base that would perhaps amount to three 100-150lbs sections before being bolted together, and an attachable/detacheable dovetail column which may add another 150lbs. To this would be added the swappable heavy duty "Mill head"(motor housing and all containments). All this would ad up to attain the needed ridgidity.(I can dream, can't I?). I guess you're right about me getting a small mill for now. The most extreme thing that I will have to do that would be beyond the capability of the Rotabroach I just won on eBay is carve out a 4" diameter hole that is 1/16" deep in stainless steel.(Not all the way through). If I can establish that I could get that done with something like a Micro-Mark Mini-Mill, then I'd be set for now.(I'd of course need to also get a machine for straight cutting 1/4" thick S.S.). *** BTW, as far as a drill presses short-comings as a mill, if we apply what was said to a lathe instead of a drill press? Would most of the same issues apply? Thanks a lot. Darren Harris Staten Island, New York. |
#9
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Mills and Drills
According to :
[ ... ] I guess you're right about me getting a small mill for now. The most extreme thing that I will have to do that would be beyond the capability of the Rotabroach I just won on eBay is carve out a 4" diameter hole that is 1/16" deep in stainless steel.(Not all the way through). If I can establish that I could get that done with something like a Micro-Mark Mini-Mill, then I'd be set for now.(I'd of course need to also get a machine for straight cutting 1/4" thick S.S.). Hmm ... the 4" diameter will probably call for slower spindle speeds that the Micro-Mark can provide -- and more torque. Especially so because you insist that stainless is your material of choice. I really suggest that you experiment with something like 12L14 steel, and compare how easy that is to machine to what is needed with stainless. I'd be a *lot* happier if you were not insisting on stainless. And I'm not sure *why* you insist on stainless. If it is inside what you are making, it can be lightly coated with oil, and you will have no problems with rust. If it has to be out where people can handle it, then you might want stainless. The Micro-Mark probably could make a 4" x 4" *square* pocket fairly easily. Though you might have to make two or three passes with Stainless to get 1/16" deep. To make a round one on a small machine, you would be better off with a rotary table -- *if* the overall size of the workpiece is small enough so the corners will clear the column as it is being rotated. *** BTW, as far as a drill presses short-comings as a mill, if we apply what was said to a lathe instead of a drill press? Would most of the same issues apply? A lathe is a *lot* better as a mill than a drill press is. The setup is awkward, and the travel is less than you would probably like, but since the spindle is hollow, you can fit a drawbar to hold the endmill in a collet (or in an endmill holder) in place. The lathe is designed for lateral loads. Mostly, the problems are with the orientation of the milling cutter to the work, and the added stuff needed to give a vertical axis -- which is usually not as good as the rest of the lathe. That said -- model makers, in particular in England, do some amazing milling in a lathe. Enjoy, DoN. -- Email: | Voice (all times): (703) 938-4564 (too) near Washington D.C. | http://www.d-and-d.com/dnichols/DoN.html --- Black Holes are where God is dividing by zero --- |
#10
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Mills and Drills
DoN. Nichols wrote: According to : Can anyone elaborate on the differences between a Drill and a Mill as far as the relative size, placement, and materials when it comes to the chuck, spindle, quill, arbor, collet, bearings, gears, ect.? In other words, it's obvious that a mill can move the tooling along more than a single axis, unlike the drill press, but I am attempting to get a handle on the *physical* reasons why so many here say that a drill press shouldn't be adapted to mill use. Start with the lack of rigidity of the drill press's frame. It is designed only to support the workpiece against the axial forces of drilling. A milling machine has a *lot* more metal in the head, a more rigid column (the best ones don't have round columns, and actually move the *table* up and down with a leadscrew. Even those with round columns have a larger column diameter, to minimize the twist under cutting loads. The quill (which moves the spindle up and down for drilling type operations) is larger in diameter, and a more precise fit in the headstock, so it will not move sideways under cutting loads. The mounting of the cutter to the spindle of a milling machine is *not* via a drill chuck. A drill chuck is normally mounted via a taper -- a mount not designed for side loads, as the drill chuck will pop lose and start bouncing around the shop, spinning rapidly, and carrying a sharp cutter with it. And -- a normal drill chuck is not designed to grip the hardened surface of an end mill shank. (An exception is the diamond grit jaws on one of the more expensive Albrecht drill chucks -- designed for use in a milling machine, and made with a standard milling machine taper (e.g. #40 MTMB, or R8 collet format) shank -- *not* a taper such is used for normal drill chucks. The bearings in a drill press are designed to handle only the axial (thrust) loads, not side loads. If these physical reasons can be solved with only small manufacturing changes in drill presses to allow them to become more suited for milling, then does the conventional drill presses unsuitability have to do with the bottom line of the manufacturers or lack of consumer interest responsible for a lack suitable adapers/tooling, or perhaps there are other logistical issues involved? I've heard about the specific forces that the bearings and so forth would have to take as being a reason for a drill presses unsuitability for milling operations, but it seems to me that a suitable gearing adapter would negate much of these "lopsided" forces.(Probably at the expense of a lot of power). Gear drives can increase the torque at the expense of speed. So can belt drives. This is *not* the major weakness of a drill press when used for milling. Milling machines have a *lot* more steel and cast iron which go into their makeup. There are cheap small tabletop drill presses which can be easily lifted with one hand. The weight of a tabletop milling machine of similar size will probably require a two-hand lift. Also, I figure that since so many of you have been machining for so many years, is there a possibilty that any bad drill press milling experiences are at least in part a result of a lack of availability of suitable adapters and tooling for this? A lack of suitable design for the purpose. A *first* requirement for a drill press which is going to be used for milling is a hollow spindle, so a drawbar can lock the end mill holder or collet into the spindle -- to protect against popping the tool holder out from side loads. And *nobody* is going to make a drill press with such a spindle, as it would cost more, and the machine's frame would still be inadequate for the lateral and twisting loads which milling would apply to it. Making a drill press with such a spindle would simply be leaving them open to lawsuits, which all manufacturers would rather avoid at all costs. Note that a radial arm drill press *might* be solid enough in some features so you could get away with it -- but none of these weigh less than a minimal floor-standing milling machine, and there is no way that you could get it up to your apartment. Anyway, in the meantime I will of course still take the advice of not using a drill press for milling purposes, but only when it comes to metals, because there shouldn't be as much of a problem with plastics like Nylon or Delrin.(But I'll listen to opinions either way). :-) Of course there are problems using it for Nylon or Delrin. You have done nothing to deal with the tendency of the chuck to pop off the taper when subjected to side loads. And there is still the tendency for the frame to wind up under cutting loads, causing a deeper cut than you intended, and thus increasing the chance that the chuck will pop off. Yes -- it is *possible* to redesign and manufacture a drill press for use as a milling machine -- and this is exactly what you will get if you purchase a "mill drill". And -- it will be to heavy to get up your stairs. (And -- it will still not have the workpiece size ability of a milling machine so designed from scratch. To clarify what I said about the specific(radial) forces not friendly to the conventional drill press, I was addressing the possibility of a "gearbox" placed *after* the chuck that would negate these negative forces to an extent.(That is why I said that it would result in the loss of a lot of power, by virtue of being inefficient). This gearbox would of course have to be made to "fit" the housing in the chuck area. This would have the effect of distributing out the radial loads that account for all the negative things you mentioned. But of course there is still the ridgidity issue. P.S: I haven't been able to find detailed plans on the internet, so if anyone is aware of any illustrated info concerning the parts and dimensions of these machines, and in particular the work tables(rotary and otherwise), I'd appreciated it. Thanks a lot. Darren Harris Staten Island, New York. |
#11
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Mills and Drills
snip
but I am attempting to get a handle on the *physical* reasons why so many here say that a drill press shouldn't be adapted to mill use. snip 2 major problems: (1) you have side load and interrupted cut on an end mill which a drill press is not designed to take. At best the quill bearings will get beaten out quickly. At worst, the end mill will slip in the chuck, the chuck will come off the arbor, the arbor will com out of the quill, generally at high speed. (2) The lateral location of the drill press head is not rigid. I.e. most drill presses are made so the drill press head and table clamp to the column. Again, not a problem in drilling, and in fact it may even be helpful to allow the drill to seek center. Milling side loads will cause the head/table to shift resulting in part/machine damage and possible operator injury. If you are bound to try this, or have economic constraints, be sure to keep everything as tight as possible, re tighten the chuck frequently, use slow speeds and don't force anything. In my not so humble opinion, it takes *MORE* skill and experience to successfully mill with a drill press than a milling machine. Of course, by the time you have acquired the necessary skill, you wouldn't do it. It still beats a file. Uncle George |
#12
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Mills and Drills
Uncle George sez:
" It still beats a file." Perhaps someone should have expounded on the method of "milling" whereby one chain drills an outline of the desired part and then does final shaping with files. I'd be a lot safer than trying to mill on a drill press. Supposedly there is a gun factory in one of the "Stans" (packy I think) where they produce modern-type firearms with only files. It must be a real bitch to bore and then cut rifling. Those stanny dudes are very innovative, though. Bob Swinney "F. George McDuffee" wrote in message ... snip but I am attempting to get a handle on the *physical* reasons why so many here say that a drill press shouldn't be adapted to mill use. snip 2 major problems: (1) you have side load and interrupted cut on an end mill which a drill press is not designed to take. At best the quill bearings will get beaten out quickly. At worst, the end mill will slip in the chuck, the chuck will come off the arbor, the arbor will com out of the quill, generally at high speed. (2) The lateral location of the drill press head is not rigid. I.e. most drill presses are made so the drill press head and table clamp to the column. Again, not a problem in drilling, and in fact it may even be helpful to allow the drill to seek center. Milling side loads will cause the head/table to shift resulting in part/machine damage and possible operator injury. If you are bound to try this, or have economic constraints, be sure to keep everything as tight as possible, re tighten the chuck frequently, use slow speeds and don't force anything. In my not so humble opinion, it takes *MORE* skill and experience to successfully mill with a drill press than a milling machine. Of course, by the time you have acquired the necessary skill, you wouldn't do it. Uncle George |
#13
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Mills and Drills
On 14 Jan 2006 14:46:06 -0800, wrote:
Can anyone elaborate on the differences between a Drill and a Mill as About 5,000 pounds Gerry :-)} London, Canada |
#14
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Mills and Drills
Gerald Miller wrote:
On 14 Jan 2006 14:46:06 -0800, wrote: Can anyone elaborate on the differences between a Drill and a Mill as About 5,000 pounds Gerry :-)} London, Canada Er, how about one of the HF/Sherline/Taig mills (they are real mills, just small) vs. most any radial drill? Pete C. |
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