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I would really Like to thank Jonathan for today I really enjoyed my self cheers mate( I hope you don't mind a old git like me saying MATE) BUT YOU REALLY HAVE A FRIEND FOR LIFE.
The postman dropped of a big big doughnut today but no supported rails or ballscrews (bastard)
I will post some video and photos when I've worked it out
James & Luke
well I've got around to doing the video from Saturday cutting of the Gantry
so here it is (this is my first ever video posting)
oops I have to load it to youtube first
http://www.youtube.com/watch?v=Zou87qbtEPU
and some photos
Attachment 4516
Attachment 4518
Attachment 4519
Attachment 4517
Jonathan I didn't get a finished photo so maybe you could post some??
sweet I cant believe I got it right FIRST TIME:whistling::whistling:
James and Luke:heehee::heehee:
Here it is, along with the rest of the bits I've just done:Quote:
Originally Posted by luke11cnc
Attachment 4520
Attachment 4521
Attachment 4522
All done with single flute carbide cutter and 1mm DOC. The first part at 540mm/min and the rest at 600mm/min. Due to the aluminium bar not being flat (even though it's called flat bar!) the cutter on the first pass went up to about 2mm depth of cut at the same feedrate. It was still perfectly happy at that, though a little more noisy. The line on the edge of the first of them was caused by a chip in the cutter. For the rest I was going to use a new cutter, but due to negligence on my part (putting a screw where it was going to cut) it got smashed so I put the original cutter in, and for no apparent reason the machine decided to go and machine a different screw which subsequently melted with lots of red sparks! Hopefully I can regrind that one into something useful as only the last 5mm or so is bad. After that I put the last one I have in which I have reground by hand twice, so the above parts are done with that. Quite pleased that it has still attained a nice finish.
P.S. Is it just me or is the aspect ratio wrong on your video?
Nice job there mate(Jonathan), bet luke's getting well excited not to mention Dad. :heehee:Quote:
Originally Posted by Jonathan
Here's what I cut @ with Ali.
Using a 10mm single flute HSS/Cobalt, (mainly because thats the only size I have with 19mm flutes, other wise normally 6mm) I cut full slot @3mmDOC(33%-Dia) 1000-1200mm/min, 7-10,000rpm depending how happy she's sounds.
If side cutting 0.25-Dia Step, DOC 75%-Dia, similiar feeds/speeds or slightly higher depending how it cutts. Always adjusting feed over-ride on how it sounds or cutts.
Blown air for cooling and chip clearence with the odd squirt of cutting fluid if sticky Ali or hard spots. (Messy as hell with flying chips but no nasty lumps on surface from re-cut and cutters last much longer.)
Then finish with 0.2 full depth finish pass @ 800mm/min 10,000rpm.
Makes me laugh to think that when I first started used to cut 0.3-0.5 max and if really brave I pushed it upto 0.75mm at a scary 500mm/min. . . It was mostly the noise that scared me and I soon found out that I was actually scratching it away rather than cutting and the cutters actually performed better and lasted longer when pushed harder or more to the point at or nearer to there intended chipload's. . . . Much less heat.
Jonathan I think it's just you
all look's Ok to me
Those parts look really good big thank you see you Saturday I can't wait to start fitting parts to the CNC next Sunday
Luke has sprained his wrist and got it all strapped up (playing Rugby) we had to take him for a X-ray last night Bless him
well the computer is in the workshop and all working ok, how ever I spent all day trying to find a video controller driver as the one with my xp didn't load.It's a good job I have a toggle or what ever it's call
James
Jazz - are those feeds/speeds on your CNC router or milling machine?
I'm using 12600rpm as that's what it sounded best at. I added a little cutting fluid into the slot every so often.
That's why I always did anything I could to avoid playing Rugby! Hope he gets better soon...Quote:
Originally Posted by luke11cnc
On my CNC machine, I don't have a mill.Quote:
Originally Posted by Jonathan
I used to cut squirting with Industrial WD40 type stuff called workmate 40(WM40. .:naughty:) that I have manufactured and sell in my day job.
This was ok but has the negative affect (like you'll know) of making the chips stick and clog the slot rather than fly away. . . this has 2 negative affect's.(Other than fumes)
1: The heat doesn't leave with the chip.
2: The fluid heats because it's not flooded away so just sits there boiling.
Both together heat the Ali so the chips are warm before the cutter actually cut's, on cheap Ali or if too hot can cause sticky bits or chips which weld them selfs onto cutters.
The best by far is blown air because it keeps all the slot clear and blows the chips away from in front of the cutters path. Thou like I say messy as hell with chips blown all over the place. . . . There's a 10feet perimeter round my machine that looks like it's rained glitter when doing big job's.:lol:
Tried using a mister but I couldn't breath so soon knocked that in the head.
At the minute I've just got 3 simple coolant nozzels connected to regulator pointed at the cutter blasting away all in it's path (Got big compressor)
When I get time(So never) I'm going to make Ali ring sandwich with 8 short directional squirt nozzles, 4 will be air, 4 coolant that fasten to the base of the spindle (Maybe put in some Led's for light as well) then with selonoid's control both with Mach3.
Air will be constant but turned on off by Mach and coolant will squirt every so often just enough to stop sticking but not fume me out the shop like mister.
James: If you think rugby is bad for broken bones try MotoX, I've been in just about every A&E with either my son or me in the hot seat. .:lmao:
You've just described exactly all of the things I've tried (except mister, not tried that) and the same effects!
I agree compressed air is great. So far I've done that just by holding the air gun close and following it which works reasonably well. The main problem is heat getting into the part I am machining - as soon as that gets hot say bye bye to the finish/cutter. Compressed air doesn't seem to be effective in that situation, you need liquid cooling. On the parts I just posted this wasn't an issue as they were cut from a 12"x3/4"x2000mm bar which nicely conducted the heat away.
One day I'll attach hoses for coolant and air...
It depends a lot on the grade of the aluminium...6061 is the best I've used so far.
Going to buy some more 6mm 1fl cutters now.
Completely agree agreesive flood coolant is best by far and my next SUPER HD MILL (For diy anyway) will have full "drown if you stand still" coolant and enough air to blow the knickers off a Nun at 50yards.:whistling:
The next best thing I've found for ALi is air but lots of it, don't need high pressure just plenty of volume. . . .This and playing with the chipload/RPM and I tend to find the happy medium.
Best alloy cut so far small amount 7075-T6 for some motor bike engine covers very expensive stuff and scrounged from a mate. . Wish I could get some more.!!
Worst stuff some really crappy 5 series that was like cutting string cheese. . . Night mare.:thumbdown:
Anyway I'm off to watch F1 Grandprix on Iplayer been away MotoX-ing all day so missed it. . . . . Don't even think of telling me who won because I'm not returning after posting this. .:rofl:
LOLQuote:
Originally Posted by JAZZCNC
I think the extrusion you've mounted the ballscrew and rail for X on is 45mm tall? The centre height of the BK/BF block on ballscrew is 25mm, you've said 30mm for the ballnut blocks and the SBR25 rails are 60mm total height. So distance between mounting plate for linear bearings and ballnut block is 30+25+45+60=160mm. That makes the distance between hole centers, with 3/4" thick aluminium 160+19.05=179.05mm. Call it 179mm...
The distance between the mounting holes for linear bearings and ballnut mount plate on the gantry sides I just made is 180mm, shall I make the ballnut blocks 31mm centre height to compensate? I know the sides are slotted so it would still work, but still nicer to have it correct to start with?
Edit: reading that again makes me think it's probably negligible
Jonathan we have slotted holes on the gantry??
and as I said "I did the drawing dimensions off the ballnut support as it is fixed in place" but I suppose I lost a 1mm on the pencil line ??
James
I now know where I went wrong Jonathan my drawings where based on 20mm material and the material is actually 19.050075 however we do have slotted holes so that should be ok
James
That would explain it yes. The only thing that worries me is these errors/tolerances all add up and could ultimately cause the remaining 1mm clearance you will have in the slot, if I make the ballnut mounts 30mm, to disappear. Still it's probably negligible...Quote:
Originally Posted by luke11cnc
Jonathan make it with the extra 1 mm as we can always mill it off if needed??
James
Just a small up date of parts I have
fitted or waiting to fit
Attachment 4532
Attachment 4530
Attachment 4531
Attachment 4533
as you can see the last photo is the extrusion waiting for Luke to fit
in photo 2 and 3 shows the transformer given by a really nice member of this forum
you know who you are, & a BIG BIG THANK YOU I will find a way of paying you. if not for the item then for the postage you have been warned
Items to get this month a forth stepper and a water pump for the spindle
Items to have machined this month Y , Z-axis supports Ie the 20mm material that connects y to z and z to spindle
belts for y and z plus pulleys and stepper mounts O'my god Jonathan has his work cut out for him
James
I think I may restart my build log?
what do you think ?
James
NO It's always nice to see it from the very begining, shows others later how a build is ever changing and just what goes into building a nice machine, which I'm sure yours will turn into.Quote:
Originally Posted by luke11cnc
Leave it be. . is my vote.!
Hear hear.
OK Jazz it's just getting clogged up with silly comments by me and doesn't look very professorial at all
James
It's not a fashion contest it's diary of your build. It's fine and the silly comments just show your excitment, just wait untill the frustrated comments appear then you'll want to delete the whole machine. . LolQuote:
Originally Posted by luke11cnc
OK I will leave it well alone
Luke is really playing on his wrist
Kids who'd have em eh. . LolQuote:
Originally Posted by luke11cnc
I'll try and dig the Xray out of my lads smashed wrist with pins, screws and titanium rods so you can use it as ammunition to show him it could be worse. . . Maybe also put him off expensive motoX as well if your lucky. . lol (Didn't work for my lad thou.!!)
Cool Jazz
do you want to see a x-ray of a pace maker??
James
No thanks and on that note don't be playing with those capacitors.!!Quote:
Originally Posted by luke11cnc
Did you get to keep the titatium? Useful stuff...Quote:
Originally Posted by JAZZCNC
If I'd known I wouldn't have shown him my wind turbine as there's lots of big magnets in that. Field is pretty enclosed so should be fine. I've since moved the big neodymium magnet I had left stuck to my lathe just in case!Quote:
Originally Posted by JAZZCNC
No it's still in there replacing the smashed bit, I've threatened to remove it a few times thou. .LolQuote:
Originally Posted by Jonathan
Thank's people and yes Jonathan I did see the big magnet on the lathe
I had to go for a recalibration this week as I walk through a security point and then realized it was a big magnet one
I'm so lucky it doesn't happen to often:surprised:
I was at the court house(in Leicester) paying a old old speeding fine from March
I now have 3 points on my licence and i was only going to the f***ing dentist
James
Speeding to the dentist, that's a bit keen!Quote:
Originally Posted by luke11cnc
I will do that.Quote:
Originally Posted by luke11cnc
Quote:
Originally Posted by Jonathan
Yes I was really poorly at Christmas (swine flu) and as a result I smashed three teeth as I hit the floor a bit to fast as I past out, But the pace maker kicked in and I came around pretty quick( go job it's working)
I also ended up in A&E at one point as I went over in the dentist (police and ambulance turned up) I felt such a fool.:redface:
The teeth cost me a small fortune £600.00 lab fee's alone glad I'm covered on denplan
James
well I've tried to get all rails and ballscrews on one plane as suggested and recommended by Jonathan but I can't
Yes yes I screwed up
my gantry is to short
so I have gone with this But I am open to suggestion
Attachment 4552
I am going to use 50x100 mm extrusion as my main support for the rails and bolted to 6" aluminium
James & Luke
I think I have cracked it what is your views on this drawing
Attachment 4553
Extrusion 50x50 mm but the down side is they only do it in light
James & Luke
I think your latest design, but mirrored so that the Z-axis is mounted on to the same plate as the ballnut will be strongest:
Attachment 4554
That way the spindle is closest to the Y-axis ballnut which should reduce flex parallel to the Y axis.
It should be the other way around I don't how how that happened ???
Thank you Jonathan
Oops just realized you mirrored it all ready
James
James what thickness you using on the plates for Z?
Michael
It's 3/4" - same as gantry sides.Quote:
Originally Posted by m.marino
Ok my stepper motor covers have arrived but
the stepper motor has 8 wires and the plug for the cover only has 6 pins
are all the wires require ??
do I need to buy new plugs for the stepper motors
James
I will add a photo later as I'm just having my eat
James
Nah you only need 4 pins wires are joined in pairs so only 4 needed.Quote:
Originally Posted by luke11cnc
The reason they put 6 pins in probably in case you're using a unipolar stepper driver as that requires six wires.
Which covers did you get out of interest?
here is a link to the covers I bought
http://www.ebay.co.uk/itm/2207881762...ht_1071wt_1163
James
It is as I feared, you bought the ones that 'will not fit the SY60 motor'. The motors you have are actually slightly bigger than Nema 23, so Nema24 ish...23 mean 2.3 inches, 34 means 3.4 inches etc...Quote:
Originally Posted by luke11cnc
Maybe they can be modified. At least it looks like you only bought 2 not 4.