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19-03-2014 #1
I'm OK with blunt so don't worry.

Individual PSUs running @60V @6A to the motors so I think they'll be OK.
Not sure about the high feed rates in softer material statement though - I haven't worked with wood previously but have cut plastics before and feeds / speeds can be adjusted accordingly.
40mm box was for the frame only - was going to use 125 x 20mm BMS for the gantry sides, with 50 x 20mm flat bar as anchor points and mounting. Can beef up the frame to 60 box no probs, but was going to anchor to the floor after leveling so thought it didn't matter about 40 box.
Chose 1605 deliberately as I though accuracy was was a better trade off. In no rush to make things as this is going to be a hobby not a career.
Will re-start the design on the weekend and will post it bit by bit. Use Inventor to draw 3D so will have to draw all up from fresh - so won't be quick
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20-03-2014 #2
No not really.!!. . 60V is low for a nema34 motor and 75V would be a minimum to get anything like decent speed and torque from them. You'll be lucky to reach 800rpm with 60Vdc and get anything like usable torque. So with your 5mm pitch you'll have maximum speed of around 4000-4500mm/min and that will be rapid speed with torque at it's lowest so realistic maximum cutting speed will be around 3500-4000mm/min. Which for wood's and some plastics just isn't fast enough to get anything like correct chip load.
It's wrong to think about feedrates in terms of Business or Hobby because it's more to do with tool life and quality of finish than whether or not your in a rush.!
I've built plenty of steel framed machines now and 50x50 is the minimum I'd use for a machine this size on any major frame parts. 40x40 will be ok for diagonal braces etc but not structural frame work. 60x60x5 is my prefered choice.
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