Well here goes... Aluminium frame router design

[ba99297]

Hi
First of all be polite with my English

About your plan
I think that the tube where the rails rest, should be wider (60mm at least ). When you apply the epoxy you will need 20mm for the rail and 15mm-20mm left right of the rail for the meniscus effect ( the tension that has the epoxy at the edges ) . So your tube should be at 50-60 wide minimum)

At the top view I saw 8 diagonal braces. I think you will need only 4 at the edge corners.
I see that you have the y axis ball screw at the middle protected by a plate. Think how you are going to work install and adjust the ballscrew as many time we think “I will think about it later” and finally you find out that you cant even bolt is in place”


Things you must be careful (others told me do so and they are right)

Spot weld in order not to produce too much heat. Even with 80X80X4mm distortion is an option ). After the frame get a first shape you can make bigger welds, no more 3-4 cm at a time. I know everybody want to make big weld with many amperes at the arc welder but this produce too much heat.
Try to be as accurate as possible at every step, even if you finally apply epoxy. Of course don’t make excesses.


It is very similar to mine machine that I design for about a year and start to build 2 months ago


My build starts at page 12 of the thread

http://www.mycncuk.com/threads/6674-...-please/page12

My main specs are
80X80X4mm tube for frame and gantry (gantry at the middle has a piece 120X60X3mm )
80X40X3mm steel tube for the bed.
Working area
750 X 1400 X 180mm

4 Yaskawa 400 watt servos (2 for x axis )
20mm profiled rails

The design of the table was mainly based on syliavski construction.
Also the one who help me most is Dean. I change my mind many times, I get the basic idea for the table from Syliavski, Dean answers all my questions and I think that I make a good start. Of course i made mistakes. I think it is very difficult to avoid mistakes at the first construction. It is very important to have people that inspired you by their ideas, also people who are there to help whenever you have a question.It would be wrong if I didn’t mention the help of Jonathan for his servo size calculator, and Eddy Current for his information and all the people that ansewr to my thread.

Finally I want to suggest you to think how you are going to move that monster. First things are easy but as you add weight it would be difficult to move and turn the frame. Mine now is nearly 250kgr. If I didn’t install a winch it would be a nightmare to move it. You can see the photos to understand what I mean

. http://www.mycncuk.com/threads/6674-...-please/page13


Have a good start

Vagelis