looking for ideas to build 5 axis mill turn machine

[Ross77]

Interesting project Ross and one I'm interested in pursuing with you if you are interested. However, being honest the Cam will be more complicated whichever design you go with simply because of the nature of the beast of Multi-axis working together. Or should say getting out of each other way.! . . . and that is is just 3+2, it goes to another level when start talking simultaneous 5 axis.!

Thanks Jazz, your input would be amazing. I keep changing my mind (shocker !) but I think I only need a 3+2 and I've kind of accepted that I will have to hand stitch the g-code and a do dry runs to check clearances.

I've got some rough sketches done for a new lathe with live tooling, but I need to get my big mill running first, as I'll need that to machine parts

Yes a lathe with live tooling would be another option, the live tooling would be simpler than a rotating head like the SwissMak.

The biggest issue I still can't make a decision over is the spindle.
I'd like to maintain a reasonable speed, but retain good holding torque for machining.
Oversizing the spindle servo is one option, but it gets expensive, and needs quite a hefty power supply.
Adding a gearbox introduces backlash, unless you have a very large budget for a suitably sized backlash free gearbox.
Or you add a second motor you can engage/disengage, which adds it's own set of problems.

Glad its not just me then. Switching from high speed to accurate indexing is a problem and also I would like some sort of auto collet chuck (5C maybe)
I've seen people use brakes to help with the holding when a lower power servo motor is used so that could be an option.

So far I have a Myford ML10 bed as the lathe base and a Centec 3b column for the milling base.


What's the best way to move this forward? create a spec list and work through it?

[JAZZCNC]

So far I have a Myford ML10 bed as the lathe base and a Centec 3b column for the milling base.


What's the best way to move this forward? create a spec list and work through it?

What's that Column off Ross, that's a weird looking thing.! . . .It's like a cross between a bed Mill and wood burning stove..

[m_c]

What's the best way to move this forward? create a spec list and work through it?

Pretty much.
Make a list of what you'd like to achieve, then work through the list of issues you need to deal with, and consider the pros/cons of whatever solutions you find.

Personally, my plan is an epoxy granite base, linear rails, gang/live tools, and a spindle cartridge.
I'm still trying to decide between a flat or a slant bed. Slant is far better for chip management, but it means I'll need to find/make a couple big precision wedges for machining the base.



Jazz, it's a small horizontal mill column, which would normally have a gearbox in the 'window'.

[JAZZCNC]

Personally, my plan is an epoxy granite base, linear rails, gang/live tools, and a spindle cartridge.
I'm still trying to decide between a flat or a slant bed. Slant is far better for chip management, but it means I'll need to find/make a couple big precision wedges for machining the base.

Think that would be my approach as well but using a mixture of precision granite surface plates for the surfaces fastened to aluminum structure for positioning/angles etc then cast around these with epoxy granite to give the vibration mass and finished structure.? Think it will be easier this way than trying to cast precision surfaces at the correct angles etc. What ya think.?

Jazz, it's a small horizontal mill column, which would normally have a gearbox in the 'window'.

Thanks, I've since found a pic.

[m_c]

Think that would be my approach as well but using a mixture of precision granite surface plates for the surfaces fastened to aluminum structure for positioning/angles etc then cast around these with epoxy granite to give the vibration mass and finished structure.? Think it will be easier this way than trying to cast precision surfaces at the correct angles etc. What ya think.?

My plan would be to cast the base, then do the finish machining off the rails once cured.
The other option would be to machine everything prior to casting, then have an internal metal structure to hold everything in alignment, but I'm guessing over a 3-4 foot bed length, there is always going to be some level of movement as things cure.

[JAZZCNC]

My plan would be to cast the base, then do the finish machining off the rails once cured.
The other option would be to machine everything prior to casting, then have an internal metal structure to hold everything in alignment, but I'm guessing over a 3-4 foot bed length, there is always going to be some level of movement as things cure.

Suppose it's all down to what machines you have to help with the machining.?

[m_c]

Suppose it's all down to what machines you have to help with the machining.?

A mill with a 40"x10" table, with ~27"x~15" travel, provided I actually get it working.
I just need two more servos and drives, and I think I've got all the major bits needed to get it functional, but I've got a few other projects I want to get finished first.

[JAZZCNC]

A mill with a 40"x10" table, with ~27"x~15" travel, provided I actually get it working.
I just need two more servos and drives, and I think I've got all the major bits needed to get it functional, but I've got a few other projects I want to get finished first.

Ye I'm in a similar position I've got the Semco with 1100mm x 450mm travel, the beds about 1250 x 400 I think. Also Fadal VMC with 500 x 400 travel with bed around 650 x 400.
Fadal is closest to working just sat waiting for motors and controller but the Semco only needs rebuilding and electronics. But with the current state of things and not being able to work then both will be on the back boiler for a good while.!