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30-05-2013 #11
For every material there is an optimal speed (feedrate) at which to cut it and a minimum speed. Optimal is hard to define - it could mean the speed which obtains the best tool life, the highest material removal rate or numerous other factors. The reason we're concerned with maximising the feedrate is if it is too low, you wont be able to cut some materials. Again, weather you can or cannot cut a material with a particular machine is hard to define - for example you could cut aluminium really slowly with a file, but that doesn't really count. For example, since plastics exhibit poor thermal conductivity, they need to be cut with a (relatively) high chipload, to reduce the heat generated by the cutting. Since the spindles we use generally operate best at high speed, this necessitates using a high feedrate to cut plastics otherwise at best the tool life will be poor and at worst it simply wont work. There are ways round this (e.g. using tools with less flutes, use a different lower speed spindl), but in general it's a much better option to choose a drive system which will meet the requirements you expect from these materials.
Even if you don't end up needing the high speed available, the fact the machine is capable of it is advantageous since the machine will be more reliable at lower speeds - e.g you can pretty much guarantee if you've chosen motors/drivers which will move the machine at 10m/min they will never stall or have problems at 5m/min.
In princible there's nothing wrong with having several drivers integrated into one board, so long as they're reliable and suitably rated. The problem is in reality none of them will output enough current/voltage for what you need, so trying to get one to work will not be reliable. Just forget them and please don't post more pictures of TB6560 drivers ;)
You can try Irving's motor calculation spreadsheet (just search that on the forum) to work out which motors would be best. I'd advise using the common 3Nm motors with a 75V power supply. The difference in price between this and other options isn't that great, and it's the best performance you can get without spending a lot more money. I think CNC4You is currently the cheapest place to get the motors and eBay/aliexpress for the drivers.
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