MK1 Steel router build log 1500x800x200

[driftspin]

Hi all, this is the first post of my build log.

After reading a lot on this site i made some of the build decisions.


Basically it is a half raised gantry router.
Planning on 15mm alu toolingplate Z-Axis




1st.. size.

- 1500x 800 x 200 mm work area.

2nd materials to be cut.

- Wood and aluminium.

3rd basic building material.

- Steel box section. 120×80×4mm and 80x80x4mm

Router type.

- 4 bearing Chinese WC ER20 2..2kw

VFD ...

-Danfoss FC-51 type.

linear stuff.

- 20mm rail, c7 rolled ballscrew1610 for Y, 1605 for Z, 2010 for X

- 4 x nema 23 3 or 4 NM type

Or maybe 2 nema23 and 1 nema 34...
Is undecided for now.


Tools
-I have no access to mill.
-I have access to old lathe. but no real experience

- Basic hand / power tools.

- Design sw
Solidworks.

Cnc controls

- Eyeballing uccnc300eth

- Digital drivers 68v diy psu


So that is the plan.

I do notice i am refining the plan on the go.



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[Nr1madman]

Hello!

Sounds awsome :D
Good luck and for ours sake post a lot of pictures..!

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[driftspin]

Hello!

Sounds awsome :D
Good luck and for ours sake post a lot of pictures..!

Skickat från min SM-N910C via Tapatalk

Yes... pictures... ill try to post on every progress..

Actually i started work on a design over a year ago.

1st the plan was to make an adjustable bed.




This over complicated the design.... or weakened it...

now the design is more basic.



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[driftspin]

Buying steel is not a problem.
Getting 6mtr length box section cut or stored in my shed is..

Shed is just 5.7m X 3.7m



So i orderd the steel box section, and some end plates pre cut, ready to weld up.

A friend of mine works with steel, he is my main supplier for steel related stuff.
We share a hobby 150 Amp migwelder. (Cebora)

It was bought for automotive related welding.

[driftspin]

This is what the start of my cnc hobby looked like in the back of my car


I spirit levelled the top of a standard used desk for setting up the bed box section.


Dont ask me why i did not start with the legs of the frame.



Ok .... its gonna be bulky...

Tag welding it up










After final welding i found out warping will happen...

Total distortion is now +/- 1.5 mm

1850x1160 mm total size.

I have read on this forum this could happen... But is was still more than i expected.


Epoxy has to solve this problem in a later stage...



More to come.





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[Clive S]

linear stuff.

- 20mm rail, c7 rolled ballscrew1610 for Y,Z, 2010 for X

- 4 x nema 23 3 or 4 NM type

Or maybe 2 nema23 and 1 nema 34...
Is undecided for now.

I would re think this for me I would use 1610 for X & Y and 1605 for Z

With nema 23 3.1nM

Have a look a Joe's build http://www.mycncuk.com/threads/4513-...ight=joeharris

[Zeeflyboy]

looks nice, I'd just be a little concerned about how you are going to make the rails work on the gantry? That orientation is going to be very tricky to align within the required tolerances on a steel beam. What was your plan in that regard?

[driftspin]

looks nice, I'd just be a little concerned about how you are going to make the rails work on the gantry? That orientation is going to be very tricky to align within the required tolerances on a steel beam. What was your plan in that regard?

Dear Zeeflyboy,

I hope for a miracle by epoxy

First one needs a zero reference for horizontal level.

I think it was Boyan who explained on the forum he made a reference level surface for this on a concrete floor by pouring epoxy.

I will try this way.
I will spirit level and anker bolt my frame to the concrete floor before pourings so nothing can move and use the x poured epoxy rail mounting surface for this.


Pouring the rail mounting surface for X will be done like the example from a forum member see picture.


like the X axis the 4 mounting surfaces on the gantry will be epoxy levelled.

In 2 steps...

Step 1 I will do the 2 gantry X rail carriage mounting surfaces, and bottom Y rail mounting surface pouring, in 1 go. ( gantry upside down )
There will be an epoxy levelling bridge between the 2 carriage mounting surfaces
Similar to x rail pouring setup


So now those 3 surfaces will be in the same plain.

After curing..

Step 2 The gantry can now be flipped to normal position and top Y axis rail mounting surface can be poured..

Placing the gantry in the normal position on the mounting surface of the x rail should give the best possible reference for a level plain.

After pouring Y bottom and top should be in the same plain..

In theory this should work.


I know this will be a critical process.
When this method fails i will redesign and have the gantry (rail) mounting surfaces milled. nothing much changes only a few pounds of steel added.


When milling is needed i will upgrade the gantry box section to 80x120x8 or 10 to have some meat to mill
I do want to avoid **bolting** the gantry sides to the gantry Y-axis.
I prefer welded solid for best rigidity.
But welding solid must be avoided going that route, because of warping.

I have no friends with a mill capable of box section 1200X120x80.

Would a surface grinder work for this purpose?

Any other thoughts?




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[Boyan Silyavski]

Thats how i did it on the gantry, my first build. gantry was flipped 180 degree and i poured gantry sides and lower beam epoxy. Then flipped and did upper rail. No problem.

But you will need a straight edge and 2 precision squares for later when mounting the rails and so...

[Zeeflyboy]

Dear Zeeflyboy,

I hope for a miracle by epoxy

First one needs a zero reference for horizontal level.

I think it was Boyan who explained on the forum he made a reference level surface for this on a concrete floor by pouring epoxy.

I will try this way.
I will spirit level and anker bolt my frame to the concrete floor before pourings so nothing can move and use the x poured epoxy rail mounting surface for this.


Pouring the rail mounting surface for X will be done like the example from a forum member see picture.


like the X axis the 4 mounting surfaces on the gantry will be epoxy levelled.

In 2 steps...

Step 1 I will do the 2 gantry X rail carriage mounting surfaces, and bottom Y rail mounting surface pouring, in 1 go. ( gantry upside down )
There will be an epoxy levelling bridge between the 2 carriage mounting surfaces
Similar to x rail pouring setup


So now those 3 surfaces will be in the same plain.

After curing..

Step 2 The gantry can now be flipped to normal position and top Y axis rail mounting surface can be poured..

Placing the gantry in the normal position on the mounting surface of the x rail should give the best possible reference for a level plain.

After pouring Y bottom and top should be in the same plain..

In theory this should work.


I know this will be a critical process.
When this method fails i will redesign and have the gantry (rail) mounting surfaces milled. nothing much changes only a few pounds of steel added.


When milling is needed i will upgrade the gantry box section to 80x120x8 or 10 to have some meat to mill
I do want to avoid **bolting** the gantry sides to the gantry Y-axis.
I prefer welded solid for best rigidity.
But welding solid must be avoided going that route, because of warping.

I have no friends with a mill capable of box section 1200X120x80.

Would a surface grinder work for this purpose?

Any other thoughts?

Sounds good! Will watch with interest. Good luck!