I'm working on rebuilding a K&T model 2HL horizontal mill SN 10-3676 and encountered a strange (to me) wear pattern I want to repair. The wear is on the end of item 97 (Spindle drive bevel gear 2HL-D97) where it contacts item 22 (Feed drive sleeve gear 2HL-E22). The parts catalog is too large to attach, but here is a link to identify these parts. Kearney & Trecker Co. - Publication Reprints - Model 1H-2HL Knee Type Milling Macine - Parts Manual | VintageMachinery.org They mesh together when the machine is assembled and 2HL-E22 drives 2HL-D97 when the spindle clutch is engaged.
Picture "wear 2HL-D97.jpg" shows the worn area of 2HL-D97. The shiny region is one of three cavities removed from the spline where 2HL-E22 makes contact. Picture "wear 2HL-E22.jpg" shows the mating region of 2HL-E22 with very little wear.
I'm thinking to build up the worn areas with silicon bronze using TIG and then hand filing back to the original spline contour. Does anyone have comments on this approach or want to recommend a different way?
I've also been looking for possible misalignment that might have caused this wear. When I removed the spindle speed gear box, I found that a 0.012 inch shim had been added at the rear face of item 85 (speed box 2HL-D885), the main gear box casting. This displaced the mating end of 2HL-D97 rearward and also changed the mating angle. I suspect the shims were not put there by the factory because the edges of the shims where they were cut for bolt holes are very ragged.
I've been looking for possible misalignment that the shims might have been installed to correct but have not found any so far. The machined faces on the column where the speed box 2HL-D885 and the pulley bracket 2HL-E17 attach measure 10.625 +/- 0.0005 inch apart and are parallel. I've trammed between the Pulley 2HL-E12 and Pulley bracket 2HL-E17 and there is 0.0015 inch variation. The setup is in Picture "tram 2HL-E17.jpg".
So far, I have not found anything that would justify adding the 0.012 shim. I'm thinking that the wear was caused by misalignment introduced by the shim. Does anyone have alternative ideas I should consider or thoughts about how to check other areas for misalignment?
Walter
Picture "wear 2HL-D97.jpg" shows the worn area of 2HL-D97. The shiny region is one of three cavities removed from the spline where 2HL-E22 makes contact. Picture "wear 2HL-E22.jpg" shows the mating region of 2HL-E22 with very little wear.
I'm thinking to build up the worn areas with silicon bronze using TIG and then hand filing back to the original spline contour. Does anyone have comments on this approach or want to recommend a different way?
I've also been looking for possible misalignment that might have caused this wear. When I removed the spindle speed gear box, I found that a 0.012 inch shim had been added at the rear face of item 85 (speed box 2HL-D885), the main gear box casting. This displaced the mating end of 2HL-D97 rearward and also changed the mating angle. I suspect the shims were not put there by the factory because the edges of the shims where they were cut for bolt holes are very ragged.
I've been looking for possible misalignment that the shims might have been installed to correct but have not found any so far. The machined faces on the column where the speed box 2HL-D885 and the pulley bracket 2HL-E17 attach measure 10.625 +/- 0.0005 inch apart and are parallel. I've trammed between the Pulley 2HL-E12 and Pulley bracket 2HL-E17 and there is 0.0015 inch variation. The setup is in Picture "tram 2HL-E17.jpg".
So far, I have not found anything that would justify adding the 0.012 shim. I'm thinking that the wear was caused by misalignment introduced by the shim. Does anyone have alternative ideas I should consider or thoughts about how to check other areas for misalignment?
Walter