Another Aussie Hybrid Mill

[Rodm1954]

I built an X2 hybrid mill here
a couple of years ago and sold it twelve months later. I CNC'd an X3 in between but I have regretted selling the X2 ever since. It was far more rigid than the X3 so I got to thinking why not build another.

I have been collecting parts for quite a while now and got the last bits from Hoss this week. I have to give a plug here as Hoss has been fantastic helping me out with parts and his machining is something I aspire to. His rates are very good and it is a no fuss service so anybody thinking of using him I can highly recommend.

The final details of this machine are far from set in concrete and it will evolve rather than be meticulously planned. I don't have the patience for drawing everything out and prefer to have challenges along the way - good excuse hey.

The column will be a chunk of 200mm square RHS and Z axis will be 25mm four way linear rails mounted on 50 by 25 solid that I will mill flat after fixing to the column.

The compound table is a KT179 and it was the best quality table I could find. The cheaper models do not have a drain around the perimeter and I will be using flood on this machine so that was important to me.

The spindle will be an X2 with R8 taper and I have already fitted the belt drive kit to it – nice and quiet. I also have a 2HP 3phase 24,000 RPM water cooled spindle and VFD. I am thinking of being able to swap between the two but would like some feedback on this.

I have some 5056 drivers, 497oz dual shaft motors, 48 volt power supply, smoothstepper and C10 breakout board for the electronics. To house all this I have an electrical enclosure that I will play around with.

I will use Roton ballscrews and double nuts on X and Y and Hoss’s Z axis assembly.

I will build this from the ground up and incorporate a steel stand and enclosure in the design.

The build will be slow as I am still completing a gantry router but I thought I would chuck this up here so that the collective knowledge might offer some suggestions.

Forgot I have included a jpg of the laser cuts parts I have on order. Two column braces, base plate and plug for the column cut from 10mm steel plate.

[port_huon]

Hi Rod,

Where did you get the table from? A local supplier or did you import it yourself?

[cadmonkey]

I especially like the swap spindle capability with the 3 phase high speed spindle - I am considering that for my X3 actually - I've had my eye on the spindle/VFD HomeShopCNC carries. I recall following your thread - it was very interesting - I think you've got a solid background and concept so I think you'll make easy work of it and it'll come out a charm. Good luck and have fun!

Greg

[Rodm1954]

Hi Tumutbound,
I got it from McJing. These seem to be sold more in the European market.

Here

Page 58

[Rodm1954]

Hi Greg,
Trails of the spindle are impressive. Very quiet as well so that is always a bonus.
I think you have hit the nail on the head - having fun is what is it about and sure beats watching TV.

[BobWarfield]

Should be a good one to watch!

BW

[hoss2006]

I agree with Bob

[Oldmanandhistoy]

Hi Rod,

Will this complement your X3 or be a replacement?

I've been considering doing something similar to my mill since your last mill build as the column is VERY poor to say the least. You've probably already considered this but what do think about turning the table around and having the Y axis stepper inside the column out of the way? Do you think cutting a hole in the steel box for the stepper would compromise the rigidity of the column? Another possible issue might be dissipating the heat from the stepper motor. I'm probably just unnecessarily over complicating things but it would be so nice to have that stepper motor out of the way.

John

[Rodm1954]

Hi John,
I will keep the X3 as it is running well and as everybody knows we all need two CNC mills. I have a mate that says two are good but three is better.

You certainly are a lateral thinker. For me I will keep the motor out in front where it can be serviced easily. Room is not an issue as I can make the enclosure any size at this stage and the covers I put over the X3 motors have provided good protection with flood coolant.

Keep the ideas coming.

[Oldmanandhistoy]

I also have a 2HP 3phase 24,000 RPM water cooled spindle and VFD. I am thinking of being able to swap between the two but would like some feedback on this.

Hi Rod hows tricks, making progress I hope.

Any way I have been thinking about your spindle and wondering how much stick these can take milling aluminium? As you have one in hand what's your opinion or have you not had the time to investigate? If your too busy with other things I will try to get more info else where and let you know what I find out if your interested.

Regards,
John

[Rodm1954]

Hi John,

I have only bench tested the spindles but I loaned one to a mate and he has had very impressive results. So much so he kept it and brought me a replacement.
Here is his comment on the spindle and the material was aluminum.

The first test was a 20mm circular pocket, 2mm deep, 0.25 depth of cut, 40% stepover, 3 flute, 1/8” carbide cutter. I started at 600mm a min and ended up limited by the acceleration on the router, I saw the feed rate get up to 3.1m/min. It cut really well. Finish was spot on. On the cuts faster than 2m/min, I noticed that the circular pockets became a little oval shaped. Not sure if this was cutter flex (I was using stupid long cutters) or Mach’s constant velocity code.

I would never have run a 1/8th cutter at 3m/min for fear of snapping it off so the results are very impressive by my standards. The speed he ran the spindle was 24k. It was a water cooled 800 watt spindle. If the X2 head with a belt kit was not so quiet to run i would skip it and just run a spindle on this mill. I cut jobs late at night so stealth mode is necessary for me.

I haven't started this project yet as I am finishing off a gantry router - wrong gantry spindle.
Maybe in a coupla three weeks I might get going on the mill. Build for router is here
Aussie Adventure 5

[Oldmanandhistoy]

Thanks Rod,

I'm thinking I may go for a 3Kw (4hp) as I'd like to make some money with it. Do you think this mill build could handle that much power (rigid enough) as I may go a similar rout with my mill. I know I would need bigger steppers or servos? I am also considering a much bigger mill but could do this convention for less money.

I hope you don't mind all my questions,
John