Adopted Build - my first CNC router

[mike os]

Well not at all what I was expecting! I was talking to a friend about a build and the conversation has ended up with me adopting a partially completed build.
The machine was started as a project by a precision engineer friend and has been abandoned because of lack of time and his moving overseas for work... I still find it hard to believe he is allowing me to play with it.

Not much detail yet, I am still waiting for the original drawings so I know what the partially finished parts are for and what machining is still needed...but collected a few bits last week.... probably 350kg of them...

A pallet full of parts, some machined, some partially machined and some waterjetted.... the visible ballscrews are x axis and 32mm!!!

[mike os]

30mm hiwin x rails, 20mm for y &Z
most of the frame is 30mm aluminium... gantry is extrusion, sixes to follow

everything except the BOB in the electrics... servos and controlers etc...
2kw watercooled spindle
extruded aluminium table

http://www.mycncuk.com/attachment.php?attachmentid=14443&stc=1http://www.mycncuk.com/attachment.php?attachmentid=14441&stc=1http://www.mycncuk.com/attachment.php?attachmentid=14442&stc=1


Hoping to start work on it next week... far sooner than I would have chosen and still far too many basics to learn.. but we will have some fun along the way

[GEOFFREY]

And I thought Christmas was in December!!! Good luck with the rest of it. G.

[EddyCurrent]

By the sound of those parts it's going to be big and a beast when completed, very good deal.

[mike os]

Unfortunately I am building it for them... but good experience, and I will be able to use it... I hate to think what it cost so far as they are genuine hiwin and quality screws...oh, and I get paid pocket money too

I think it is about 2 by 1.5m "externally "

[mike os]

Got a little bit done this week, finding it helping with my rehabilitation as I need to use both hands for most of it

28 m16x50 holes tapped, 48 m8 tapped holes for the rails, all by hand as the company that did the original machining "forgot"... thanks for that:livid:

http://www.mycncuk.com/attachment.php?attachmentid=14498&stc=1

test assembly... I now know the approximate size is 2m x 1.1m between rails, and first problem... one of the cross rails is drilled about 2mm out, still thinking on how to best fix that, any suggestions gratefully recieved

http://www.mycncuk.com/attachment.php?attachmentid=14501&stc=1http://www.mycncuk.com/attachment.php?attachmentid=14500&stc=1


nice chunky assembly, 160x30mm plate

http://www.mycncuk.com/attachment.php?attachmentid=14502&stc=1

[routercnc]

Interesting machine

The cross rail being drilled about 2mm out- if I understand correctly then I think you need to slot the through hole. If you don't have a mill then you may be able to use a router and carbide bit or pillar drill with counterbore bit plus some filing.

[mike os]

Interesting machine

The cross rail being drilled about 2mm out- if I understand correctly then I think you need to slot the through hole. If you don't have a mill then you may be able to use a router and carbide bit or pillar drill with counterbore bit plus some filing.

not an ideal solution, but I think it will be adequate, there is a 3rd bolt for each end from underneath so plenty of fixing, and the counterbores are going to be covered at some point with something to keep the ballscrews and rails clean

[EddyCurrent]

What about filling the holes with stuff then drill new holes.
https://www.machinemart.co.uk/shop/product/details/aluminium-repair-starter-kit?da=1&TC=SRC-aluminium%20repair

[mike os]

I would worry doing it that way eddy, as the new hole would mainly be in the filler... and is 50mm deep

only alternative is to drill out to about 24mm tap & plug, pin it and then redrill & tap.... but holding this vertically to drill will be a right pain.

think it will end up on the inside and ream holes to suit in the side rails

[Boyan Silyavski]

i would use a propane torch, melt some aluminum and pour it in the hole. then machine it again. i have done it, it works. 15 min fix.

[Lee Roberts]

I would just plug the hole, then do a new hole...if you can machine the plug to fit snugly of course.

.Me

[mike os]

Just slotted the holes in the end.. far easier and really no need to mess further, especially as no one will ever see them once the covers are on

need to start thinking about a base/frame for this to sit on, and am struggling to find a control panel... steel enclosure IP55 or better and wih a mains isolator through the front panel so you cant open door while power is on... any suggestions?

[mike os]

got some machining done this week, been a while since I ran a milling machine, but thanks to a friendly engineer, a bit of a refresher and use of a rather nice Bridgeport (no wear or backlash, probably the nicest BP I have ever used), Cant believe they let me loose on it really :beguiled:

just got to blend the curves and finish a few of the non machined surfaces then drill, counterbore and tap about a hundred holes.... so only a day or so marking out :whistle:

[EddyCurrent]

Just slotted the holes in the end.. far easier and really no need to mess further, especially as no one will ever see them once the covers are on

need to start thinking about a base/frame for this to sit on, and am struggling to find a control panel... steel enclosure IP55 or better and wih a mains isolator through the front panel so you cant open door while power is on... any suggestions?

This is where I got my enclosure, it was a good price at the time but things can change quickly; http://www.fastlec.co.uk/control-automation/enclosures

[mike os]

they look usefull, thanks Eddy

[JAZZCNC]

need to start thinking about a base/frame for this to sit on, and am struggling to find a control panel... steel enclosure IP55 or better and wih a mains isolator through the front panel so you cant open door while power is on... any suggestions?

These are who i use good price and nice quality. http://www.tlc-direct.co.uk/Main_Index/Boxes_and_Enclosures_Index/CM_Metal_Enclosures/index.html

[mike os]

cheers guys.. I will try to take some pics soon

basic question I guess but not one I have managed to find a satisfactory answer to....

Hiwin rails and bearing block fitting (and hopefully removal)

I need to trial fit some of the carriage parts to check a couple of things work as we want.... so I need to temporary fit the rails & bearings. Reading the manual it seems the rails must be horizontal when i fit the bearings... ie bolt holes up, slide on using the plastic packing piece as a guide and I assume ball bearing keeper?

Is this the only way to do it?
can I remove the bearings using the reverse ie sliding off the rail onto the plastic packing piece?

are the balls free to fall out if I get it wrong?

thanks

[EddyCurrent]

The Hiwin bearings I used needed the plastic keeper in place otherwise the balls fell out, I found out the hard way. I found that by being careful the bearings would slide onto the rail if it was horizontal or vertical but in all cases the plastic keeper must be kept pressed up against the end of the rail leaving no gaps for the balls to escape. I can't remember if this applied to both the 15 and 20 sizes but it certainly applied to the 15's. Having them well greased helps to keep the balls in place.

[mike os]

thought that would be the case... thanks eddy

removal the same way?

[EddyCurrent]

removal the same way?

Yes it is.

[Neale]

I've slid my blocks on to the rails and removed them multiple times while setting up, using the plastic retainer pushed against the end of the rail each time. No problems so far, although I just know I'm going to have a wobble some time...

[mike os]

cut the rails to length and slipped on 2 blocks this afternoon... don't know what I was worried about :highly_amused:
I assume these are double seals?

http://www.mycncuk.com/attachment.php?attachmentid=14683&stc=1

is it worth adding the scraper? I assume it is just a case of unbolting the existing seal & slipping it on?

[mike os]

wow cant believe it has been so long since I last posted

progress is slow but steady, various bits & pieces required to complete the x axis frame are now machined except for about a dozen holes... as usual for me... I keep forgetting to take pictures, not that a pile of aluminium plate machined & drilled is terribly interesting

progress has not been as linear or as logical as I would have done myself, as I am working on bits I have while designing stuff like the base frame and control box... normally I would do all the design then start from the ground up...

so... mocking up the bearing carriage for the x axis, the wooden block was made as a model to see how the clearances worked out and to visualise the ballnut mounting method, as I could not see the wood for the trees in cad. once assembled the mounting for the ballnut is obvious immediately. working in wood is an easy and cheap way to prototype parts, the block of 6082 this will be machined from is about £100 and will take the best part of a day to machine so cant afford many mistakes

http://www.mycncuk.com/attachment.php?attachmentid=14875&stc=1

http://www.mycncuk.com/attachment.php?attachmentid=14874&stc=1

final design..

[mike os]

gantry risers are finished... ready for trial assembly


http://www.mycncuk.com/attachment.php?attachmentid=14882&stc=1

upside down but shows how the top plates interlock with the gantry rail to help with alignment

http://www.mycncuk.com/attachment.php?attachmentid=14883&stc=1

detail

http://www.mycncuk.com/attachment.php?attachmentid=14884&stc=1

[GEOFFREY]

Pics look great. G.

[mike os]

bit more progress, x axis is hopefully "finished" ie only needs minor changes like limit switches and guarding fitting.... and base frame is made, so I can start a trial assembly soon

http://www.mycncuk.com/attachment.php?attachmentid=15094&stc=1http://www.mycncuk.com/attachment.php?attachmentid=15093&stc=1

[mike os]

x axis on its stand, square and levelled..

http://www.mycncuk.com/attachment.php?attachmentid=15201&stc=1

bearing carriage machining...

http://www.mycncuk.com/attachment.php?attachmentid=15200&stc=1

and one finished

http://www.mycncuk.com/attachment.php?attachmentid=15199&stc=1

both now done... bit of aping & counterboring then I can start assembling the gantry

[mike os]

Progress is finally being made

Ballnut, 32mm, housing and bearing carriage ready to fit

http://www.mycncuk.com/attachment.php?attachmentid=15386&stc=1


little vid of axis testing


https://www.youtube.com/watch?v=XmE4SS4QVRM

runs very smooth :kiwi-fruit:

[Lee Roberts]

Looking good, thanks for sharing!