Diy Brushless Spindle

[njhussey]

Got my 2" Ali pieces today, too late to do any machining in my lunch break but might come in early tomorrow to have a play :naughty:

iv used cheep skate bearing in my ER C8 spindle... iv used belleville washers to put some tention between the two outer races.... i havnt had to change them yet but it only gets light use

Mark, where did you get your belleville washers from? Was going to stick a couple in between my single row AC bearings?

[njhussey]

I'll have to wait until I get the motor for the through mounting hole dimensions but was thinking of something along these lines.....

[blackburn mark]

Mark, where did you get your belleville washers from? Was going to stick a couple in between my single row AC bearings?

eeeerrrr, dunno?? pretty sure i got them on ebay.... i just did a search and they are all coming up USA which is a bit of a bind, iv got some left (8.2mm inside 18.9mm outside diameter) so measure the distance your going to have between your bearings ill send you enough to fit that gap (n youll owe me a favour ... its not the washers, its the dragging my arse over to the post office that youll owe me for )

iv used 12 washers and compressing them about 0.5mm (very light, less than 1kg) i guess you could be a little more aggressive with those A/C bearings but im not sure to what advantage ?? id play it safe and keep it light... if you get any signs of movement slop chatter add a shim etc.

[njhussey]

I've found some at Bellville Springs...Part code: D18842
Price: £10.33 per 100 pcs, Postage: £5.50 with a min order charge of £15...could always flog the rest on fleabay lol.

I think I've left a 3mm gap between the bearings atm but am open to suggestions!

[blackburn mark]

I think I've left a 3mm gap between the bearings atm but am open to suggestions!

your not going to get many washers in there

id try to get them a little further apart so you can get at least a few pairs of washers twixed

i know its a bit late now but if i was starting from scratch id use up the full length of the ER shaft
i didnt do this on mine, i have 22mm of shaft protruding out of the motor bell, i could have made the bearing bell 22mm longer utilsing the theoretical extra stability however the best performing spindle i have only has one double row A/C at the nose so i guess the diffrence may be negligible for our aplication

the new ER20 with two double row is suffering with resonance when cutting quite hard at the moment, something is rolling or skidding in there.
that should stop when i do my final strip and loctite.... errr.... maybe

[njhussey]

Well if I'm going to use the ER16 x 8mm (http://www.ebay.co.uk/itm/ER16-8MM-S...item19c9b3098b) then I've got 100mm of shaft to play with. The motor I'm proposing to use (http://www.giantcod.co.uk/xyh5065-32...-p-404606.html) is an XYH 50-65 so 50mm dia and 65mm long, that only leaves me 35mm to play with. If I have a 5mm cap/lid (whatever) and leave 3mm at the back I'll have 28mm to house the bearings (7mm wide each) and the belleville washers so I'll have 14mm to fill up....better or too much?

Getting into Google Sketchup now, but takes a long time to draw anything as my laptop is slowwwwwwwwwwwwwww..........

[blackburn mark]

so I'll have 14mm to fill up....better or too much?

sounds better to me :)

Getting into Google Sketchup now, but takes a long time to draw anything as my laptop is slowwwwwwwwwwwwwww..........

worth it though... when im designing something with production in mind i can spend hours just looking at the same drawing to see if it can be stream lined or knock some of the pain out of production and make it look posh etc etc etc....

[njhussey]

worth it though... when im designing something with production in mind i can spend hours just looking at the same drawing to see if it can be stream lined or knock some of the pain out of production and make it look posh etc etc etc....

Certainly is I find it usefull for visualising what somethign is going to look like. Gives you an idea whether it's going to work or not. Also use it at work to draw 3D (without having to get the DO involved) pics of what I'm quoting. Just starting to build up a library of standard parts. Slow progress tho as it has to be done in lunchtimes etc and I'm still trying to get into it....

[njhussey]

Went to play with the lathe at lunch and was greeted with it in this state... Bloody hairy arsed fitters. Spent lunch cleaning and setting the tailstock up as it was miles out...never got to do any cutting!

[Joe]

Hi Guys
I havedesigned and made a brushless spindle as well but my design is a big biggerthan most (overkill really) it has a FAG angular contact double row on thebottom and FAG standard bearing on the top with a 20mm shank ER16 collet chuckfrom ebay.

I waswondering what people use for the power supply as I fund that my 15Amp batterycharger doesn’t provide enough power.
The picture shows a drill chuck but that is being held by the ER16 chuck because i did not have the right size collet

Joe