Thor, or should that be Zeus?

[Robin Hewitt]

Just for fun, here's the safety data sheet
http://www.wd40.co.uk/Files/WD40%20M...07-2015_EN.pdf
Curiously drying out of the HT circuits when your car won't start is no longer one of it's uses.

[Chaz]

Have updated the design somewhat taking numerous feedback into consideration. Lots more to do before I start to make castings. I bought a lathe today, oldish Boxford Model A, should help with some round stuff I need for this build.

[Chaz]

Guys,

Where can I buy cold rolled mild steel plate. I need pieces of metal of around 150mm x 150mm x 80mm (QTY 3). I dont really want to buy a full plate at 80mm size, struggling to find anywhere that will supply in small volume. Alu plate, easily source in this size, but not for mild steel.

Thanks

[Davek0974]

Just a quick question - Why so much mass in this design? Looking at the likes of production mills like Tormach etc, there is nowhere near as much mass in them and they are proven designs.

I like the ideas but over designing is surely as bad as under designing something ??

[Chaz]

Just a quick question - Why so much mass in this design? Looking at the likes of production mills like Tormach etc, there is nowhere near as much mass in them and they are proven designs.

I like the ideas but over designing is surely as bad as under designing something ??

The idea is to allow for absorption of vibration etc. The hollows in the base structures improve strength and keep the weight bit more palatable. I need to check what the final weight estimate will be, I have had some issues with the files in Fusion, so redrawing some of the machine.

The idea here too is that this machine could be running a lot quicker (velocity and acceleration) than a Tormach. Considering the cost of a Tormach (ignore shipment / import duties, just the raw buy price), Thor should be a better machine.

The Tormach 1100 specs are below:-

Feed Rate:

110 IPM (X,Y) 90 IPM (Z)

110 IPM is 2800 mm/min. I am aiming for upwards of 10 000mm/min at least. The rails, ballscrews and motors that I am using cost more than the entire Tormach machine if I paid full new price (which I did not). This is before adding the controller, electronics, structure costs, spindle etc.

[Davek0974]

The idea is to allow for absorption of vibration etc. The hollows in the base structures improve strength and keep the weight bit more palatable. I need to check what the final weight estimate will be, I have had some issues with the files in Fusion, so redrawing some of the machine.

The idea here too is that this machine could be running a lot quicker (velocity and acceleration) than a Tormach. Considering the cost of a Tormach (ignore shipment / import duties, just the raw buy price), Thor should be a better machine.

The Tormach 1100 specs are below:-

Feed Rate:

110 IPM (X,Y) 90 IPM (Z)

110 IPM is 2800 mm/min. I am aiming for upwards of 10 000mm/min at least. The rails, ballscrews and motors that I am using cost more than the entire Tormach machine if I paid full new price (which I did not). This is before adding the controller, electronics, structure costs, spindle etc.

Interesting, thanks.

I was only using Torch as an example really but those feed specs are interesting, any idea of the spindle HP rating? It's obviously designed for normal mill usage - bigger tooling, more cut depth, more radial cut depth so I guess 2800mm/min would be in that area.

I guess you will be running fairly high power motors to gain decent acceleration in small distances or it may never reach your high feeds??

Following your build with interest.

[Chaz]

Interesting, thanks.

I was only using Torch as an example really but those feed specs are interesting, any idea of the spindle HP rating? It's obviously designed for normal mill usage - bigger tooling, more cut depth, more radial cut depth so I guess 2800mm/min would be in that area.

I guess you will be running fairly high power motors to gain decent acceleration in small distances or it may never reach your high feeds??

Following your build with interest.

The motors spec were in the first post. 1.5 KW servo for Y, 750W for X and Z.

Spindle power will likely be around 4 KW / 5 HP.

One of the goals of this machine is to be able to run this all from single phase, 32A supply.

The higher feeds allow for more creative milling techniques like Adaptive clearing. Having good speed and acceleration opens the machine up for more uses and will hopefully reduce the typical times currently experienced with my Denford.

[JAZZCNC]

110 IPM is 2800 mm/min. I am aiming for upwards of 10 000mm/min at least. The rails, ballscrews and motors that I am using cost more than the entire Tormach machine if I paid full new price (which I did not). This is before adding the controller, electronics, structure costs, spindle etc.

Well you better get ready for dissappointment if you think 4Kw spindle is going to let you cut at 10mtr/min with any DOC.! There's Reason why Industrial Strength VMC's have 15-20Hp spindles.

[Chaz]

Well you better get ready for dissappointment if you think 4Kw spindle is going to let you cut at 10mtr/min with any DOC.! There's Reason why Industrial Strength VMC's have 15-20Hp spindles.

The plan is not to cut at 10m/min. It will be nice to do some tracordial milling and not be limited by speed of 'non cutting' movements. Id rather have too much speed than to little, even if its not used all the time.

[Boyan Silyavski]

Well you better get ready for dissappointment if you think 4Kw spindle is going to let you cut at 10mtr/min with any DOC.! There's Reason why Industrial Strength VMC's have 15-20Hp spindles.

This is more for the ability to cut at lower spindle speeds the metals and have there enough power, and i agree with that, but i wonder then if the small mill head rated 10 000rpm, BT30 spindle coupled with servo motor would not do the job better here? I can not remember if there was 10 000rpm variant, cause typically it was 6000rpm. Or just have to be ordered with other bearings.

That could change the design so should be clear before hand. But will give ability to tool change, and hard tap. Cause at the end of the day, why so fast machine if then you will loose time changing tools.

I read a study that said most time in production was spend changing tools, and we are talking a bout machines with tool changers. So obviously not only a tool changer, but a fast one is better.

But i like to say, if the purpose is not clear, the result could be mediocre