New to Forum but done CNC for years

[rfrenzl]

Hello all,

I'm new to this site but have been doing CNC and equipment conversions for some time. I currently have an X3 Mill converted to 4 axis CNC with the CNC-Fusion Deluxe kit. I will say that this kit works very well and goes together quickly.

I also have a Taig micro-lathe I converted to CNC several years ago and just purchased a new 10x22 Lathe from Grizzly. I am in the process of adding steppers to the new lathe but plan on keeping the original gears and lead screws so I can do threading. I still have to add a spindle encoder for synchro-moves.

Everything is running from a single PC with Linux and EMC2 2.2.5 and 3 parallel ports. On port is for the lathe and the other for the Mill. I also use Dolphin PartMaster CAD/CAM for the Mill.

I'd be interested in knowing what others have done with their equipment and any projects they've done that might be interesting. I am just a hobbyist with an extensive programming and hardware background and a MS in applied mathematics (mainly trig. and geometry so G-Code is easy for me). I live in the KC area so would be interested in meeting people of similar interests. I have training in electronics too so I build some of the parts myself though commercial stuff is usually cheaper and easier to use.

I hope to contribute to this forum and look forward to seeing what others are doing.

Ron

[brendanjerwin]

3 ports? Cool. Can you run more than one machine at once with that setup? What did you use to add the other ports?

Welcome to the forums, btw. I'm not really much of a contributer unfortunately, but I've learned a whole hell of a lot! I have an X2 with cncfusion z axis (soon to be X+Y too) and a mini-lathe I'll want to convert. I'm also building a 3D printer a-la RepRap.org (technically I'm building a RepStrap...)

[rfrenzl]

Thank you for the welcome, brendanjerwin.

To add more ports is easy. I just went to the local computer store and picked up a couple of PCI Expansion boards (about $20 each). Both Windows and Linux will detect them on boot up. One just needs to know what address the board is on and configure the software to point to that particular board. In the case of Windows, you can use the Device Manager to find the ports. In Linux, use the PCI Scan. Most driver software has a place to tell the program what boards are in use and if they are input or output in nature.

As for running two machines at once, no. Since the PC is doing all of the motor steps and other management for the machines, it can not run in more than one instance or the two programs will compete for the same hardware bus and make a mess of things. I just run several different configurations and pull up the one I need. I do have a couple of spare computers hanging around so I could just set up each to run a different machine. As I still have my Micro-Lathe intact, I may just do that and use it for small parts. The big lathe will be used for threading and turning large parts and steel. I am planning to swap out the motor on the new lathe for a DC motor and use one of the KB controllers I have to run it. This will eliminate the need to change the belts around when doing AL, Steel, Plastics, etc. I should be able to get from <50 to 700 rpm without changing things. If I do need more speed, I can then change the belts and get from about 300 to 1500+ rpm with decent power.

I also have an X2 mill which is now in pieces. It was just not big enough for what I wanted to do so I upgraded it to an X3. I converted the X2 to CNC using spare parts, threaded rods, etc. to learn how things work. I had it set up with Spindle control, 4 Axis, and Home Switches. The Home Switches are something I really liked so put them on the X3. The spindle control was nice but not really necessary for the Mill. I will use it on the new Lathe and add feedback (encoder) so I can do threading and other synchronous moves.

If anyone is looking for a Belt Drive conversion for the X2 or a Milling Attachment for the Taig Lathe, I have both that I'll get rid of for a lot less than new. Both are a little used but are in good working condition and will make a nice addition to your machine.

Again, thanks for the welcome and wish you luck on your machine upgrades.

[fretsman]

Hi Ron,

Welcome, I'd love to see the CNC Taig Lathe you've done, any pics? I'm just starting into mine but it never hurts to see more of the successful builds out there -

Dave-

[brendanjerwin]

I'm actually interested in your X2 conversion stuff. Are there ballscrews for the X-Y? Are you willing to just sell off the X-Y stuff alone?

----

I thought it might be tough to run more than one machine at a time... I too have plenty of spare computer parts so I will probably go the route of dedicating a PC to each machine.

[kanton]

rfrenzl,

I am interested in converting anX3 Mill to 4 axis CNC. Please provide more details of your conversion. What steppers and drivers did you use. What did you use for the 4th axis?

Thanks

[rfrenzl]

Originally Posted by fretsman Hi Ron, Welcome, I'd love to see the CNC Taig Lathe you've done, any pics? I'm just starting into mine but it never hurts to see more of the successful builds out there - Dave-

Sorry, no pictures. This thing has been my "play thing" for a while now. I bought it first to learn a little about machining, then wanted CNC so I could do things there, and it has evolved since then. The current version sports a 1/2" Acme lead screw for the Z axis, a 1/3 hp DC motor geared to 2.5:1, and an encoder tied to the spindle. The motor and encoder use timing belts. Since these changes were done only recently, I have no pictures and things aren't the way I would like them. As I now have a new 10x22 lathe, I don't see the micro changing for a while. It works but the slop is rather bad and I need to tighten things up and reset the backlash vlaues. It is still a good machine for small quick jobs but I don't have room for it at the moment.

If I get the urge, I'll take a picture or two and post them. As this not a real good example of how things should be done, I'd prefer that others use the more recent info found on this site for conversions as those are much better thought out and more precise. I will say this, my little lathe has been a great learning tool for step motors, g-code, and metal working in general.

[rfrenzl]

Originally Posted by brendanjerwin I'm actually interested in your X2 conversion stuff. Are there ballscrews for the X-Y? Are you willing to just sell off the X-Y stuff alone? ----

My X2 was a custom job using several different designs for the X and Y axis. I used the original lead screws, changed to different lead screws and added bearings, and a few other things. None of them I found to be satisfactory which is why I went with the CNC Fusion kit for the X3. If I really wanted to do the same kind of builkd myself, I could but it was a lot easier to buy someone else's design and I am very happy with the results.

What I do have on my X2 is not worth taking off as it really is not usable for most people.

As for step motors, I used three NEMA 23s with 208 ozin torque. I set it up to run from timing belts for the X and Y axis with a 2:1 reduction. This gave me lots of torque and the speed was not greatly impacted. The Z axis was a direct drive with a 280 ozin motor. The belts also allowed me to keep the motors near the tables and not proturde too far. I have a habit of bumping up against everything so this was to save my hips as much as function.

[rfrenzl]

Originally Posted by kanton rfrenzl, I am interested in converting anX3 Mill to 4 axis CNC. Please provide more details of your conversion. What steppers and drivers did you use. What did you use for the 4th axis? Thanks

Kanton,

I used the CNC Fusion deluxe kit for my conversion. I'm using a couple of NEMA 23 step motors for the X and Y axis that have about 350 ozin torque. I have used some with only 280 ozin and they worked fine. For the Z axis, it is a NEMA 34 with 650 ozin torque. I can make rapid moves at 55 in/m and there seems to be more there if I want.

The X ans Y axis are run from a 36v, 8A power supply and the Z from a 45v 8A power supply. I have to use the two different power sources as the drivers are not rated for more than 36v on the X and Y. If I decide to buy new drivers, they will all be rated for 60v so I will have even faster rapids but it is really not needed for this small of machine. The drivers were purchased from Circuit Specialist Inc. They are the 3a and 5a sizes that run about $50 each. Same goes for the motors, purchased from the same place.

The 4th axis is a rotary table that I mounted a step motor to. This was a $110 4" table I bought for my X2 from Grizzly. Too small and too cheap to do a lot with. I would suggest going to LittleMachineShop and picking up one of thier units. My table is nothing special but it works for what I need. I recently picked up a dividing head which will take the place of this device. I may convert it to CNC but not anytime soon. Now that I have a good Mill and Lathe, making a motor mount for the dividing head will not be to hard.

The homing switches are EBay specials and work great with the EMC2 software. The switches have rollers on the switch arms so they mounted very easily. They are also contained in cases so are out of harms way from cooling fluid and chips.