My Bucket Full of Aluminium Parts

[Harpye]

Hello World!

For this is my first post here in CNC zone forum I first would like to introduce myself ...

My name is Hansjoerg (34) and I'm from Southern Germany. The origin of my wish to get a CNC is based on my RC aricraft modelling hobby. Until now I contructed every single plane on the CAD ( Rhino ) but printed out the parts and cut them out manually... - This to change, I decided to build myself a CNC mill...

For I'm rather new to this forum ( as I already told) - the only channel with DIY content was this one ... I surely know, that it is about wooden mills and mine is mainly Aluminium ?? ??.. so Admin, - if there is a better place to move this thread to, please feel free to move it.

Now, here is some specification about my project...

Base :

760mmx1100mm Aluminium ladderframe with 5 steps 50mmx100mm lead bars and 50mmx50mm step bars all made from high duty Aluminium extrudes.

x axis:

2x 20mm ball/ rail guides with 4 long sliders ( low preload) and spindle bridges

Spindle:

2x Ballscrews C5 16x5mm DIN ~ 23um accumulated axial thread tolerances on load with double nut for high loads (3% preload)

Protal side plates:

Aluminium plates with fittings for ball bearings and y axis bars 50x50 hd Aluminium extrudes.

y axis:

2x 20mm ball/ rail guides with 4 short sliders ( low preload)

1x Ballscrews C5 16x5mm DIN~ 23um accumulated axial thread tolerances on load with single nut and selected ball set axial tolerances on change <5um

z axis:

2x 15mm ball/ rail guides with 4 short sliders ( low preload)

1x Ballscrews C5 16x5mm DIN~ 23um accumulated axial thread tolerances on load with single nut and selected ball set axial tolerances on change <5um

Motors:

X Axis 2x 1,9Nm Stepper
y Axis 1x 1,2 Nm Stepper
Z Axis 1x 1,2 Nm Stepper with ~ 1:2,5 belt transmission

Controller:

4x 6 Ampere microstep amps with parallel interace PCB

Software still not choosen ... actual option to start with the trials of Meshcam and Mach ... future is open.....

Here is the proposal ( May07):


"The Bucket full of Parts"

[Harpye]

Here is now the Bucket of Aluminium parts..



Here the pre asembly of the Z axis without spindle...




same wit the y axis...


Parts the second...



... and some other impressions....




at the moment I'm assemling the controller unit ( had to change the structure to implement an 1,5 KW inverter...)

pics as soon as possible...


Good night so far..


Hansjoerg

[Harpye]

Here the contol unit-> 4 axis microstep control - Interface PCB
50 V 8 A switching supply
1,5 KW <400 Hz inverter
prepared for use of a standard f / U converter PCB to control the inverter.



setup in an old ATX midi tower housing..... ( Connectors system is manufactured by Amphenol...) ( the connectors of the four axis are on top of the housing...)


Good night!

Hansjoerg

[WeCheat]

Sweat little project you got there. real nice and welcome to CNC Zone

[FrankM]

Wow !
Very nice work , wellcome

[walter]

Solidly build, two ballscrews.. This is exemplary work.

[dsquire]

Originally Posted by Harpye Hello World! For this is my first post here in CNC zone forum I first would like to introduce myself ... My name is Hansjoerg (34) and I'm from Southern Germany. The origin of my wish to get a CNC is based on my RC aricraft modelling hobby. Until now I contructed every single plane on the CAD ( Rhino ) but printed out the parts and cut them out manually... - This to change, I decided to build myself a CNC mill... ........ "The Bucket full of Parts"

Hansjoerg

WOW!

What can I say? This is amazing.

Welcome aboard.

You sure seem to have done your homework on designing your machine. I too do R/C aircraft, cars and boats.

I think with a machine like this you will be able to mill all your parts out of aluminum and hold some very close tolerances. Using it to cut balsa and plywood should be a breeze with this machine.

I hope that when I get around to building mine that my "Bucket full of Parts" will look half as good as yours.

Keep up the fine work on your machine and I will be following it every post.

cheers

Don

[ImanCarrot]

Very nice indeed!

Welcome to the forums and thanks for sharing.

Iain

[CRFultz]

Welcome Hansjoerg,

Very nice indeed.
Clean lines and very solid. Very professional looking.

Chuck

[Harpye]

Thanks for all the comments!

I tried my very best for I just wanted to build ONCE.

Construction took me about 6 months... ( basically 12 versions and 4 revisions of the final version) and the built took about 8 to 10 weeks only.... ( but we are still not finshed yet... )

Only thing I would like to have but I'm not able to do is a modal analysis sweep to get an estimated behaviour of this machine in resonance mode...
Because of the risk of this I implemented some resonanceattenuation systems ( for to eliminate high frequent vibrationsor just to shift the Resonance.. but I hope I wouldn't have to use. ( ode is to fill the y axis Bars with sand or sand/epoxy ant the second is to install pull rods in the Y axis bars similar done in building bridges ( steel strings)...

How ever...

Went a bit further .... adapted the transmission on the Z axis

the gears for the sychronisation belt for the X spindles...

and set the gears for tension on ballbearings... ( sorry about that bad pic)





Hansjoerg

[Ken_Shea]

I tried my very best for I just wanted to build ONCE.

And it looks it to Hansjoerg.

Nice work.

[Harpye]

... with the mounted spindle.... ( ELTE 750W @24000 rpm aircooled) .. I will add a 612 J fan for to cool the spindle at lower speed when the internal radial blower doesn't cause enough volume flow....




Hansjoerg