Diy Brushless Spindle

[blackburn mark]

did you put a groove in the ER collet shaft for the circlip or not?

no.... my thoughts where that the tight fit (bearings n housing) would hold it all in place, iv had no problems so far using the double row a/c... i did have an issue with one my C8 spindle bearings (cheap skate bearings/bad fit on the shaft) resonating the inner race around the shaft at certain speeds so i used a bit of epoxy on that and its been ok so far.... now i think about it i guess the bellville washers become redundant once the glue has set and when the bearings wear i might get some slop ... it may need some further thought

What RPM do you use the flycutter at?

hi adam... iv not measured rpm's for a while however im pretty sure i skim acetal at 1500rpm and aluminium at less (maybe 1000rpm) thats with a 30mm radius fly cutter

with aluminium i have to be pretty careful (light cuts) or i get resonance patterns but im pretty certain thats my gantry sides and not my spindle

i should really do a test to see how low i can take the rpm and still cut with the fly cutter but iv never seen the need as iv allways got by at those speeds

[njhussey]

Dissassembled the motor, worryingly there was no locktite on the grub screw holding the body onto the shaft....needless to say there will be when it goes on the collet :naughty:

Am ashamed to say that for the first housing I'm cheating and getting someone else to machine the housing as they have offered to do it for nothing (our local machinist we use at work) in between jobs they are currently doing...which is very nice of them. I'll use the other bits I've started to do a smaller high speed spindle for engraving

At some stage I'll re-wind it as the winding is poor and also the potting/epoxying of the magnets wasn't too clever either as some was proud and was rubbing on the armature. Still you get what you pay for so I shouldn't be too surprised I guess...