Need some final decisions before start building…

[msacnc]

Some most helpful people (espically JAZZCNC and Silyavski) answered me in my previous thread about many questions that make me rethinking deeply in everything in my machine (design, electronics, linear guide…)

After investigations i decide to reduce my steel machine dimensions to be 2000mm * 1500mm frame to fit MDF sheet because I concerned mainly with cutting and engraving all type of wood and may be thin plastic only. Of course I am looking for high precision with reasonable speed.

Working area: 1700mm*1220mm*200mm

Machine design:

All machine frame is 100*100*3mm

the machine will be the same main design like this but with some differences





Gantry will be two welded steel tube 100*100*2mm to reduce the weight, length 1500mm. like this


Gantry side is 100*100*3mm steel length 250mm like this image



Gantry attached with gantry side using steel angle brackets in the front for more rigidity and stiffens like this.




Linear guide: (I choose profiled rather round rails for rigidity and easy to align)

Profiled linear rails 25mm for X axis HIWIN
Profiled linear rails 20mm for Y and Z axis HIWIN

Electronics:

• 4 Nema 23 JK57HS112-3004 (NM 3 - 425 oZ 3A 6.8mh)
• 1 Power supply 70~90V adj. 12A
• 4 M880A Leadshine micro step drivers 80V 7.8A

Spindle:

• 2.2kw Chinese spindle air cooling 5.5kg 80mm

What about choosing 3kw Chinese spindle water cooling 9kg 100mm. Is this best for my machine?
Motion: I replace R&P with ball screw for cutting and engraving wood with high precision.

• Double 2510 Ballscrew 1750mm on X axis
• 1610 Ballscrew on Y 1250mm axis.
• 1605 Ballscrew 400mm on Z axis.

All screw will be attached to belts and pulleys for flexibility to increase torque and resolution of X and Y axis Esp for 3Nm Nema 23. I can test 1:1 or 1:2 ratios to achieve the best speed with high possible precision.

THE BIG PROBLEM
Note: (there is no 2005 or 2010 screws just 1605,1610,2505,2510)
I think no problem with (critical speed, moment of inertia and fade rate) for Y and Z due to their length. The problem is in X axis. I read many threads that taking about this issue. First rotating ball nut (to eliminate whipping) for 1610 is not an option. So rotate the 1610 screw of that length 1750mm may be a problem (critical speed). I know that 1610 screw has small around 3times moment of inertia than 2510. Also with 1610 screw i can get high speed especially with 3Nm steppers (need lower torque for achieving high fade rate).
Due to this information
Critical speeds with BK/BF bearings (approximate):

16mm dia, 10mm pitch, 1600mm long - 800rpm = 8m/min
16mm dia, 10mm pitch, 1500mm long - 910rpm = 9.1m/min
25mm dia, 10mm pitch, 1600mm long - 1220rpm = 12.2m/min
25mm dia, 10mm pitch, 1500mm long - 1400rpm = 14m/min

I think I can achieve 800~1000 rpm
What about cutting speed?


There is many options:

1. 2510 with 3Nm steppers with 1/2 gearing will give extra resolution and torque but this will reduce speed to half.
2. 2510 with 3Nm steppers with belts and pulleys 1:1 ratio
3. 1610 with 3Nm steppers with 1/2 gearing will give extra resolution and torque but this will reduce speed to half.
4. 1610 with 3Nm steppers with belts and pulleys 1:1 ratio

May be Nema 34 651oz 5.6A 3.4Hm is an option with 2 PS and Leadshine drivers

Rely I need advice in this problem…