Quite an Unusual one

[mitchejc]

Silyafski, I really don't know the first thing about making those drum surfaces but the other day I saw this video and thought if this kind of forming process might not work for you as an alternative to hammer forming the sheet metal.
https://www.youtube.com/watch?v=eh0d...8P7aRhF_WqV0Ug

[Boyan Silyavski]

Silyafski, I really don't know the first thing about making those drum surfaces but the other day I saw this video and thought if this kind of forming process might not work for you as an alternative to hammer forming the sheet metal.
https://www.youtube.com/watch?v=eh0d...8P7aRhF_WqV0Ug

Exactly. Thats one of the reasons i made such strong Z and the cheese holes on the Z. I will not push the spindle bearings, instead will fit it somehow directly to the boxed Z.;

[Boyan Silyavski]

Some updates. 2 very hot weeks, especially if you are working alone in 70% humidity, 40C temperature and soldering all day long +weekends and moving heavy stuff.


Had to clean all stuff from the garage. Draw white lines for the footprint. This machine will take a lot of space. Of course it rained right after i took everything out, did i tell you it hadn't rained like 11 months.






Started with the gantry. decided to keep sides square, so later could flip and support easier the gantry. Do you see the blotch further on the floor. Guess what, just before starting all my boxes with paint fell on the floor and some spilled. A little diversion :-)





I have mixed feelings about the Evolution saw. While the motor and blade is great/made in japan/ the saw is very very flimsy. Next project will be to throw away the base and do a new one. I wish i have bought the Makita. It was 100eur more expensive and don't come with blade- another 100, so thats why. Anyway, an essential machine for the project.



Ventilator to cool myself and change of plans. The 60x60 profiles cut to size that were meant to support the rails were discarded. There was no way i can solder them from all sides. Instead i cut all of the 60x10 plate/6m in total/ and decided to separate them by the 60mm using at least the profiles i have already cut. Some carefull soldering from here and there. Very rigid result.




As you see from the pictures above everything is soldered till the end. Now there was another momentary decision. No legs for now untill i decide something clever and the steel from the legs went just inside the sides of the machine. So stair like sides with no holes, there lie the rests of the profiles meant for legs.




I cant explain how strong that machine frame feels. Including that bestial gantry. Vertical bend or twist- i did not even bother to measure it with the indicator. Its solid as a rock. starts to look like a Frankenstein thing from movie.

So today i finished working at 20.30 and couldn't help but move all elements with last available effort, as i wanted to see how it would look. I am a strong man, no lift or whatever help, so i am becoming stronger moving all day these pieces around while soldering. Did i tell you that all the soldered pieces weight around 500kg .


So here is my baby. Its huge. I am a bit surprised how big that is. Still has no name but i think it would be something military:




So after ~15kg of wire, 2 CO2 bottles and some crazy days i start to see how will look. Still have no color in mind.

[GEOFFREY]

looking like a really solid lump!!! How about drab (a sort of olive green) and "big bertha"? Well done. G.

[EddyCurrent]

How about drab (a sort of olive green)

I remember it was Mid Brunswick Green that was the preferred colour year ago.

[Clive S]

So here is my baby. Its huge. I am a bit surprised how big that is.

I have found you a ball screw to fit it:-

Attachment 13332

You might need bigger servo's though. ..Clive

[Boyan Silyavski]

where did you find that ball screw picture?

Olive green is a good idea. Some pieces black or and dark grey. I tried with the other green Mid Brunswick Green, but did not like it
Unfortunately someone took the name big berta . But lets make it alive, then the name.

Today started soldering the bed frame and bought the epoxy. As i stopped working at all except on the machine, money flows like water through my fingers. So i bought at the end the Spanish epoxy with very similar properties like the WS. from choice of three i choose the most similar. There were seemingly better though some data was not clear, from the one that could concern, i mean. 125eur with shipping for 5kg pack +1.6kg hardener.

Basically 90 min gel time, max isotherm 40C, compression strength 580kg/cm2, yellowish, contraction 0.1%, density 1.08 gr/cm3 which roughly translates to 6.5l so ~20eur /lit mix, I cross my fingers that it works ok.




It seems that the machine will lay on the floor with no legs. have to figure where to fix some hooks for the future and most importantly some plates to lift it using car jack. To level it for the epoxy pouring. Cause now it is unliftable already.

[Clive S]

where did you find that ball screw picture?

I made it on my router with the 4th axis. ..Clive

[EddyCurrent]

el martillo de Thoryavski

[Boyan Silyavski]

Today started soldering the bed frame and bought the epoxy. As i stopped working at all except on the machine, money flows like water through my fingers. So i bought at the end the Spanish epoxy with very similar properties like the WS. from choice of three i choose the most similar. There were seemingly better though some data was not clear, from the one that could concern, i mean. 125eur with shipping for 5kg pack +1.6kg hardener.

Basically 90 min gel time, max isotherm 40C, compression strength 580kg/cm2, yellowish, contraction 0.1%, density 1.08 gr/cm3 which roughly translates to 6.5l so ~20eur /lit mix, I cross my fingers that it works ok.




It seems that the machine will lay on the floor with no legs. have to figure where to fix some hooks for the future and most importantly some plates to lift it using car jack. To level it for the epoxy pouring. Cause now it is unliftable already.

Now going cheap was really bad idea. Ok, it would have saved me 100euro on this size of structure...

But here is what happened:
The epoxy poured extremely well. It leveled well. And for 4 hours it was perfect. As gel time was 90min, i thought well, i cheated destiny. But no. After the 4rth hour it shrank in volume and there was not 20mm wide flat area in the center to munt the rail. I did the test 50mm wide channel, instead of the 40mm normal with WS 105+209. Read a lot why and it seems the reason is that the epoxy is low quality and contains non reacting solvents that vaporize when the hardening starts. On the long axis it was straight, so its not a mixing problem, anyways i mix it at least 5 minutes and change the can before pouring, so not my mistake. Repeated twice the test-same result.

So i took a risque and lost. My reasons were not that i am greedy, but the price difference multiplied by the future machines is quite some money. However i just returned the 5_1.6kg epoxy so the loss is about the cost of shipping, the time and 1 lit of epoxy.

Conclusions:
1.Seems the biggest unaccounted problem for that purpose is the shrinkage, in other words the purity of the epoxy. Hence the price of good epoxies :-). Otherwise flatness and surface quality is more a result of good mixing and following exact mixture to the gram and temperature when pouring.
2. Judging epoxies from their technical sheets means nothing. It can seem on paper right but poor in reality
3. Epoxies with very high viscosity >700 cps of mixture maybe contain something that will evaporate later

Left on the picture is WS 105+209 at the time of pouring and cured. Also the spanish epoxy untill 4h. Right is the shrinkage when 8h passed



At the moment of pouring till 4h



The problem after 8h of curing, a bit difficult to be seen but the drawing above shows it better. On the second picture the shrinkage lines can be seen at the reflection distortion . Not that it could not have worked as we are talking about 0.3mm here and on the long axis was straight, but not worth the additional fiddling.