Upgrade Your Mill with Quick Change Mill Tooling (Mark 2)

Table of Contents

1. Introduction
2. Switching to Quick Change Tooling
3. Improving the Tooling Swap Process
4. Addressing Run Out Issues
5. Grinding the Taper for Better Results
6. Replacing the ER20 Collets
7. Exploring Alternative Tool Holders
8. Cutting Down the Tool Holders
9. Using Copper Soft Jaws on the Lathe
10. Comparing Old Tool Holders to Off-the-Shelf Options
11. Testing the New Tool Holders
12. Results and Conclusion

Introduction

In this article, we will discuss the benefits of using quick change tooling for the milling process. We will explore the process of switching to quick change tooling and the advantages it offers over traditional methods. Additionally, we will address common issues such as run out and provide solutions to improve the overall tooling experience. By the end of this article, You will have a clear understanding of how quick change tooling can enhance efficiency and effectiveness in the milling process.

Switching to Quick Change Tooling

When I decided to switch to quick change tooling for my mill, I wanted to improve the process of swapping tooling in and out of the ER collet chuck. The traditional method I was using worked fine, but it was quite slow. To enhance the efficiency and speed of the process, I purchased a Morse taper collet for the mill and several ER20 collets. I also turned down tool holders on the lathe that would accept the ER collets and fit into the Morse taper collet. This new setup proved to be a quick and effective way of swapping tooling.

Improving the Tooling Swap Process

While I was impressed with the results of the quick change tooling setup, there were some issues that needed addressing. One of the main concerns was run out. Some of the tool holders I had created had run out issues, affecting the precision and accuracy of the milling process. To address this, I decided to try grinding the taper to achieve better results. However, I must admit that my grinding setup was not the best, and I was pushing the limits of my lathe. Although the run out slightly improved after grinding, I was hoping for better results.

Addressing Run Out Issues

In addition to dealing with run out, I also suspected that the inexpensive ER20 collets I had been using were contributing to the run out problems. Upon inspection, I found that some of the collets had rust, pitting, and other visible issues. To alleviate this problem, I replaced all of the ER20 collets with high-quality ones. This ensured better performance and reduced run out during the milling process.

Grinding the Taper for Better Results

Grinding the taper provided some improvement in run out, but it was not as significant as I had hoped. With the limitations of my grinding setup, I realized that achieving perfect results might be challenging. Nevertheless, the slight improvement in run out was a step in the right direction. It is worth noting that grinding the taper requires careful precision and expertise, and not everyone may have the necessary equipment or skills to achieve optimal results.

Replacing the ER20 Collets

Based on my observation of rust, pitting, and other issues with the inexpensive ER20 collets, I made the decision to replace them with high-quality ones. The new collets were free from any visible defects and offered better performance and reliability. This replacement was crucial in reducing run out and ensuring consistent results during the milling process.

Exploring Alternative Tool Holders

Instead of machining tool holders from scratch as I had done previously, I decided to explore alternative options available in the market. During my search, I came across ER collet tool holders that were readily available on platforms like eBay and AliExpress. These tool holders were priced at around twelve dollars each and were designed to fit various sizes of ER collets. My initial impressions of these tool holders were positive, as they were advertised as being made of heat-treated carbon steel and had well-ground surfaces. Comparing them to the ones I had previously made, these tool holders seemed to have a better tapered fitting, making them more promising for improved performance.

Cutting Down the Tool Holders

Since the new tool holders were 20 millimeters in diameter, I had to purchase a new Morse taper collet that could accommodate this size. Unfortunately, this meant that all of my existing tooling, which was designed to fit the old collet, would need to be remade. Despite this inconvenience, I decided to proceed with the new tool holders and cut them down to the required size. This process involved carefully cutting the shank of the tool holders to a length that would fit the collet chuck effectively.

Using Copper Soft Jaws on the Lathe

In order to hold the tool holders securely without causing damage to the Threads, I used copper soft jaws on the lathe. These soft jaws provided a gentle yet secure grip on the tool holders, ensuring that they remained stable during the cutting process. This step was crucial in preventing any potential damage to the tool holders and maintaining their overall integrity.

Comparing Old Tool Holders to Off-the-Shelf Options

At first glance, the newly purchased ER collet tool holders resembled the off-the-shelf ER20 collet holders that were available in the market. The main AdVantage of the off-the-shelf options was that they were already designed to the correct Shape and length, eliminating the need for additional cutting or modifications. However, I opted to go with the tool holders I had purchased due to the size difference. The off-the-shelf options had shanks that were three-quarter inch in size, while the more stable collets I found were designed for an imperial drawbar. Since my chucks and Morse taper adapters used metric threads, it made more Sense for me to cut down the 100 millimeter shanks to the required size instead of going for the off-the-shelf options.

Testing the New Tool Holders

Once the tool holders were prepared and fitted into the collet chuck, it was time to test their performance. From the initial fit, it was evident that the new tool holders aligned well and had a smooth connection, indicating a promising result. Upon closer inspection, there was no visible run out, which was a significant improvement compared to the previous setup. Using a test indicator, the run-out measurement was around 0.01 millimeters, which is impressive considering the multiple potential sources of run out in the setup. Overall, the new tool holders exceeded expectations and delivered exceptional performance with minimal run out.

Results and Conclusion

The new quick change tooling setup proved to be a success, addressing the issues of run out and improving the efficiency of the overall tooling swap process. The ability to quickly and seamlessly change tooling, coupled with minimal run out, provided significant advantages in terms of productivity and precision. With only 10 microns of run out and the capability to handle heavy cuts with ease, this setup exceeded my initial expectations. While there are still other tooling options I would like to explore, such as world and shank side-locking holders or shrink-fit tooling for carbide end mills, these will be endeavors for another day. Nevertheless, the Current quick change tooling system provides all the necessary features and benefits for an enhanced milling experience.

Highlights:

1. Quick change tooling improves the efficiency of the milling process.
2. Addressing run out and replacing low-quality collets is crucial for optimal performance.
3. Alternative tool holders can offer cost-effective solutions with improved performance.
4. Cutting down tool holders allows for compatibility with new collets.
5. Copper soft jaws protect threads when holding tool holders during machining.
6. Testing the new tool holders shows significant improvement in run out and cutting capabilities.

FAQ

Q: What is quick change tooling?

A: Quick change tooling is a system that allows for faster and more convenient swapping of tooling in a machining process. It eliminates the need for manual adjustment and offers improved efficiency.

Q: Why is run out an issue in tooling?

A: Run out refers to the deviation of a rotating tool or component from its desired path or axis. It can impact the precision and accuracy of machining operations, leading to subpar results.

Q: How can I address run out issues in my tooling setup?

A: Some possible solutions include grinding the taper for better fitting, replacing low-quality collets, and using high-precision tool holders. It's also important to ensure proper maintenance and cleaning of the tooling components.

Q: What are the benefits of using high-quality collets?

A: High-quality collets offer better precision, durability, and performance compared to low-cost alternatives. They are less likely to develop rust, pitting, or other issues that can negatively impact machining operations.

Q: How can I determine the compatibility of off-the-shelf tool holders with my existing tooling setup?

A: It's essential to consider the size, shape, and threads of the tool holders and the chuck or collet system they will be used with. Make sure to check if the Dimensions and specifications match your specific requirements.

Q: What are the advantages of quick change tooling over traditional methods?

A: Quick change tooling allows for faster tool changes, reducing downtime and increasing productivity. It also offers improved accuracy and precision, resulting in better machining outcomes.

Q: Can quick change tooling handle heavy cuts?

A: Depending on the specific setup and tooling used, quick change tooling can handle heavy cuts with ease. However, it's important to ensure the tool holders, collets, and cutting tools are properly chosen and maintained for optimal performance.

Q: Can I use quick change tooling for different types of milling processes?

A: Yes, quick change tooling can be used for various milling processes, including face milling, end milling, and slotting. The compatibility of the tooling system with your specific milling machine should be assessed before implementation.

Q: Is quick change tooling compatible with other machining operations, such as turning or drilling?

A: Quick change tooling is primarily designed for milling processes, but it may have applications in other machining operations as well. The compatibility and suitability for different operations should be evaluated based on the specific requirements and equipment involved.

Q: Are there any drawbacks to using quick change tooling?

A: While quick change tooling offers numerous benefits, there may be some limitations or challenges depending on the specific setup and requirements. It's important to assess the feasibility and compatibility of the system with your existing equipment and processes before making the switch.