Converting a Warco Mill to CNC

[njhussey]

I'll be converting a Warco Major next year. For the drives you'll need over 100V to make the Nema 34 steppers perform, ideally 240v drivers. The one area you don't want to scrimp is the electronics. Zapp is a good place to buy these, or you could try Aliexpress.

[kingcreaky]

i definately need a milling machine in my life.

no further comment.

[JAZZCNC]

i definately need a milling machine in my life.

no further comment.

What like my new little toy.!

[i2i]

What like my new little toy.!

Nice Semco bedmill there Jazz, is it an 800 or 1000. I have 4 x 600's, great machines the first vmc's.

[JAZZCNC]

Nice Semco bedmill there Jazz, is it an 800 or 1000. I have 4 x 600's, great machines the first vmc's.

It's 1000 and cracking machine or it will be when it's done. Still under cover at minute waiting for my attention when weather breaks and I eventually get some free time for my self.

[gavztheouch]

Jazz, what brand of servos are you thinking about using?

[i2i]

i've got plans to throw HSD router heads on two (24k rpm 6.8kw bt30 atc), a slotting head on the third and keep a low speed head for steel work on the forth. Great machines and mega value.

[thorphar]

Thanks for all the help with the suggestions and advise.


I have made some progress :). I have decided to go for the Nema 23 from zapp 3.0Nm for all axis'. I have also chosen to only control the x,y slides and the quill hand-wheel. I have chosen the Quill rather than the knee due to many reasons. The main problem is that there is a lot of slack between handwheel and the actual movement of the knee, the only way to fix that would be to change out the gear. Due to money and time being a major factor in this project I decided to say clear of that. The way in which I think the machine will work is by lowing the quill about an 1" or depending on the max height for clearance and then bringing up the knee to meet the work piece to the tip of the cutter. Once I have raised the knee manually, I would lock the knee and then all the z operations would occur through the quill. I am aware of the problems with lowing the quill on such a small machine, however Im prepared to bare with the limitation that would ensue with opting for the quill option.


As i mentioned earlier I will be buying the Nema 23 from Zapp
http://www.zappautomation.co.uk/sy60...per-motor.html

and my fav ZP5a-INT
http://www.zappautomation.co.uk/zp5a-int.html

using the AM882 Driver
http://www.aliexpress.com/store/prod...570168083.html

and a custom power supply.

I will be using rectangular box section for the mounting system between the stepper and the axis
http://www.ebay.co.uk/itm/281145148732?var=580212490514

For the xy and I guess z depending on if I operate the z through the quill or the knee i will be using (16:48) stepper: axis drive however I could go for (14:60) for the knee.
http://www.beltingonline.com/timing-pulleys-bars-272/

Im also looking for a NEMA Wall mounted like Enclosure to mount everything inside however Im not having any luck.

Any suggestions or views on the knee Vs. quill would be very helpful. Suggestions on removing the slack between the hand-wheel and the actual movement of the axis would be awesome too :).

[JAZZCNC]

Don't go higher than nema 34's it's not needed.
Like neil says you need lots of voltage with 34's to get good performance so buy mains voltage drives. These are what I use with nema 34's http://www.zappautomation.co.uk/elec...n/2m2280n.html

Seem expensive but you don't need a PSU so it cuts down on price and complexity and they are the only thing I'd fit to large 34's.

Size wise then you won't need massive motors these should work but I would get some idea of weight your lifting or moving first. I've seen nema 23's fitted to X & Y on these before so these will easily do it with some to spare. Thou I think you'll need the extra for the Knee.
http://www.zappautomation.co.uk/elec...118-6004b.html

[Neale]

I'll be interested to see how this goes as I have a Warco VMC myself that is on the list for a CNC conversion. There was an earlier thread on converting a VMC but that was a few years ago and technology and components have moved on a bit since then, maybe. Certainly the x and y slides move easily with the handwheels but the z is pretty heavy if you are driving the knee (although it doesn't need the same feed speeds, I guess, unless you are into 3D milling, so could be geared down somewhat).