An Aussie Router called RPM

[bones]

Hi Guys,
Recently at the CNC BBQ in Melbourne I spoke to a few people there about some of my projects. But none have really been posted.
So here they are. Mainly a machine called RPM.
It is a router that 2 mates are building. Rod M and Rod P.
So that's where the RPM comes from.

So we sat down and looked at what parts we had and how it was going to be built.
Out came the linear actuators, linear rail, high speed spindles, driver boards, Alloy plate, Steppers and Ballscrews that we just had sitting around.

First the design. Rod M builds him machines with strength and precision, so we looked at the machines he has built and the addition that we wanted from those machines.

The usual things:
*Designed to covers ballscrews from dust and swarf
*Ease of clamping jobs of all types
*Easy to clean after jobs
*Type of spindle to use
*Ease of machine manufacture with maxium rigitity

It has a cutting envelope of 300 by 210 by 120
Which is an A4 size sheet. Perfect.

First photo is the base frame which is made from 100 by 10 flat and 40 by 6 angle.

Second has the table sitting on the frame. It has grub screws next to each mounting screw so that we can dial the table to the Z axis. Push pull fixing.

Third photo is the Y and Z axis which are actuators and they are ready to mount to the gantry sides.

Enough rambling here are some photo's

Bones

[bones]

I will continue the posting as to break it all up a bit.

The other machines I spoke of at the BBQ to some people.
Hafco AL-50G lathe CNC'ed
Hafco My-T-Mill CNC'ed
Societe Genevoice Jig borer
And a Zoltar Router

The lathe:
Stripped off the gearbox and used the mounting holes to bolt the stepper motor mount too.
The other end I made a bearing mount using the same holes as orginal again.
The cross slide I bolted some alloy to the front of the slide and bolted the ballscrew nut to it.
Removed the apron and replaced it with 20mm thing Aluminium.
This allowed me to make mounts to hold the steppers, screw bearing holder etc.

I am going to mount a wolfgang high speed spindle onto a small linear actuator for a live tooling idea I have.

The Mill:
Stripped it down and replaced the Compound table straight away.
I could fit screws in it and was Munted by the last owner.
The super solid base was made by a mate Rod and we fitted motors, screws, made motors mounts etc.
A bit of paint and it came up a ripper.

The Jig borer:
A machinist bloke we met and I started talking about cncing machines.
He was dumbfounded to hear how easy it is to cnc.
So we bought a few servo's and though them on the machine.
Mind you the machine is a 1969 Sai Jig borer.
Made from high quality cast iron none of this crap these days.
And precision to a 10th of a thou.
It was made when machines were made properly in Germany I think.
Any hoo Z axis was the problem but we found the other day that we can replace the Z-axis motor for a say 1100oz/in servo.

This is his baby! I mean baby. This is a sai #1 he has a #5 sitting oput side.
It measures 4M high, 3.5M Wide and 4.5M long.
I'm not sure about cncing that one.

Zoltar:
Laser cut the parts from 3mm stainless.
Fused some of the joins with a Tig and thats as far as I got.


Now the pictures

Cheers
Bones

[crocky]

Hi Rod,

You certainly have a nice range of equipment to play with and your typing has not been done in vain, I am reading it with interest while my CNC Router is cutting another lithophane.

Cheers,
Bob

[bones]

Hi Bob,
Yes I like my toys.
I just need to stop building and actually use them. lol.

RPM is actually finished an up and running. We are building the extra's to finish it off.
A base, trolley to sit on, computer, MPG, enclosure etc.

So I will add the rest soon. So keep tuned in.

Bones

p.s. Those lithophane are great. Brilliant work.

[Rodm1954]

Rod,
Here is a video of RPM doing some work

"http://www.youtube.com/watch?v=IZOpKWCiQJY"]YouTube - CNC Gantry Router with Sherline Spindle

[bones]

Hi guys,
Well you can't comment on that can you. perfect.
Super strong build and the sherline 10,000 rpm spindle does the trick.

I best post the build upto this stage then. where we fitted the sherline spindle.

Rod P

[crocky]

looks marvellous

[Rodm1954]

While you were away RPM has been earning it's keep.
Who needs a mill when you can get results like this with a grantry router.

[ClaudioG]

Very nice work there Rod.

What size and type of bit were you using for the inner circle and outside cut at 780mm / min at 0.5mm per pass.

I noticed you switched to a 3mm end mill for the slot at 400mm / min at 0.3mm per pass.

And what software are you using to drive the machine. It has a nice fluid motion.

Cheers,

Claudio

[Rodm1954]

Thanks Claudio
I used a 1/4 inch carbide 2 flute mill bit.
Sofware is Mach3 and I have built my own screens for use with a 12 inch touchscreen. Gcode created in VCarvePro.

[CNCfun&games]

Hi RodM,

Very impressive video!!!

Looks like your RPM router does a very nice job milling thick aluminum.

I’ve been very tentative about using my Bridge Mill for aluminum plate, but it would be much easier to machine wide objects than using my Bridgeport. Particularly when I am machining nested Gantry Endplates (2- 3 up).
The 24” horizontal clearance under the Bridge would require only one set-up.

I’ve been upgrading this 10 yr old Mill with new Motors/Drives & Mach 3, and when the retrofit is complete,
I intend following your example and will try machining aluminum plate.

Thanks for another good idea !!
I’m presently working on a six axis console based on a design I “inherited” from you.

W. Smith

[contactirfu]

HI RodM,

I see the alu being machined for clamps for 3 different spindles, can you tell us more on these spindles please

RGDS
IRfan