New Machine Build Gantry mill for precise milling of aluminium


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Thread: Gantry mill for precise milling of aluminium

  1. #1
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    Default Gantry mill for precise milling of aluminium

    I will post some pictures and videos here about my new build. It is a moving gantry mill for milling aluminium. Why do it yourself and not just buy it? Well, there are very few machined with small footprint, large working area, not bulky..
    One machine that comes to my mind is Datron.. But its expensive. Most routers that are on market and advertised as capable of milling aluminium are just not rigid. Some origami style made machines are ok for wood, but not so much for aluminium.

    Some basic data:

    Working area: 1250mm x 620mm x 220mm
    Weight: 850KG
    Structure: Stress releived weldment, T slot table 37mm thick made of steel - 200KG
    Bridge: All aluminium made structure
    Milling head: 1x ER25 3.2KW spindle with max 18K rpm, 1x NT30 German milling head, driven with 2.6KW servo motor - max 5000rpm
    Motion: Ballscews on all axes, 25mm square rails on all axes, Mitsubishi MR J3 400W servo motors with 17bit encoders and brakes on all axes

    I will use 3.2KW spindle for tools up to 12mm, and bigger NT30 for larger tools, like surface mill.
    Currently I have 80% finished bridge, electronic is finished.. But I am still waiting on base and table, which should arrive next week.

    Please check video for current progress:


    I have built few routers before, and decided not to go with side arms like most have, as they tend to oscilate no matter how much you reinforce them. So I went with one piece plate in front, and then with various enforcements in all directions to make bridge
    strong in all directions and also to make it torsionally rigid. This bridge will have less than 0.003mm deviation in any direction with cutting force of 30KG in worst Y and Z position - When Z is lowered and Y in the middle of bridge. Actuall cutting forces will not exceed 10KG in any direction. So it should work ok for milling aluminium.

    If any questions, fell free to ask.

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    Attached Thumbnails Attached Thumbnails Gantry mill for precise milling of aluminium-i19-cimgpsh_orig-jpg   Gantry mill for precise milling of aluminium-i21-cimgpsh_orig-jpg   Gantry mill for precise milling of aluminium-i22-cimgpsh_orig-jpg   Gantry mill for precise milling of aluminium-i23-cimgpsh_orig-jpg  

    Gantry mill for precise milling of aluminium-i24-cimgpsh_orig-jpg   Gantry mill for precise milling of aluminium-i25-cimgpsh_orig-jpg   Gantry mill for precise milling of aluminium-i26-cimgpsh_orig-jpg   Gantry mill for precise milling of aluminium-img_0768-jpg  

    Gantry mill for precise milling of aluminium-img_0769-jpg  


  2. #2
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    Default Re: Gantry mill for precise milling of aluminium

    Nice one there



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    Default Re: Gantry mill for precise milling of aluminium

    Thank you, lets wait and see how machine will behave. I have some high expectations, but you never know until you put all together and test it.



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    Default Re: Gantry mill for precise milling of aluminium

    Beautiful work. I was surprised to see Mach3 running on a linux fan's build (why no linuxcnc?).

    Also, unless you made sure against the specs of those ballnuts, I would say you are running them too fast at rapid speed. Why did you go with what appears rolled 5mm pitch, instead of ground 10 or 20mm pitch, especially since you are using 17 bit encoders?



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    Default Re: Gantry mill for precise milling of aluminium

    Quote Originally Posted by alan_3301 View Post
    Beautiful work. I was surprised to see Mach3 running on a linux fan's build (why no linuxcnc?).

    Also, unless you made sure against the specs of those ballnuts, I would say you are running them too fast at rapid speed. Why did you go with what appears rolled 5mm pitch, instead of ground 10 or 20mm pitch, especially since you are using 17 bit encoders?
    I was expecting question about why not linuxcnc, as my nickname suggest Im more of a linux user I started using mach for my first build and I found cheap and reliable USB motion control card for it. About ballscrews, you are corrrect. If I had unlimited budget, I would go with 10mm pitch ground ballscrews. I actually already have some rexroth brand new 40mm diameter C3 ground ballscrews with 40mm pitch, but they are for another build, and only ballscrews cost more than this whole machine. But as this motors are "only" 400W" I think 5mm pitch is OK, it is small machine, so I dont need rapids of more than 12M/min, and I also think 17M/min is too fast - 3400rpm. I will run them at max 2400rpm. When you go with Chinese ballscrews, I think it is better to go with 5mm pitch, at least in my case as I dont need very fast rapids, due to force of the ball on screw. 10mm pitch screws will produce twice as much force on the wall of screw, and I wouldnt be surprised to see backlash even faster on 10mm pitch screws.



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    Default Re: Gantry mill for precise milling of aluminium

    Progres.. Table is finished.. Milled and grinded.

    Gantry mill for precise milling of aluminium-img_0774-jpg



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    Default Re: Gantry mill for precise milling of aluminium

    Finally, yesterday bed arrived. I already put table on bed, gantry is also on its position and few other items are already mounted. Screws from table and gantry are not tightened yet, as all needs to be aligned first.
    Gantry mill for precise milling of aluminium-img_0779-jpg
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    Gantry mill for precise milling of aluminium-img_0795-jpg
    Gantry mill for precise milling of aluminium-img_0797-jpg
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    Gantry mill for precise milling of aluminium-img_0803-jpg
    Gantry mill for precise milling of aluminium-img_0804-jpg
    Gantry mill for precise milling of aluminium-img_0807-jpg



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    Default Re: Gantry mill for precise milling of aluminium

    amazing design and neat job on that machine..difenitly you will precisely machine aluminum as well as steel

    http://free3dscans.blogspot.com/ http://my-woodcarving.blogspot.com/
    http://my-diysolarwind.blogspot.com/


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    Default Re: Gantry mill for precise milling of aluminium

    Thanks. I am not sure about steel, as steel needs very rigid machine, but aluminium should be no problem.
    Yesterday I made some progress with power cabinet..

    Gantry mill for precise milling of aluminium-img_0809-jpg
    Gantry mill for precise milling of aluminium-img_0810-jpg
    Gantry mill for precise milling of aluminium-img_0812-jpg
    Gantry mill for precise milling of aluminium-img_0814-jpg
    Gantry mill for precise milling of aluminium-img_0815-jpg



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    Default Re: Gantry mill for precise milling of aluminium

    Outstanding work.

    Probably the best small one I have ever seen, since 2003.



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    Default Re: Gantry mill for precise milling of aluminium

    Thank you



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    Default Re: Gantry mill for precise milling of aluminium

    My Optimus Prime 4G CNC router made of Wood+Aluminum+Steel can cut Carbon-steel quite easily... Your will definitely...

    http://free3dscans.blogspot.com/ http://my-woodcarving.blogspot.com/
    http://my-diysolarwind.blogspot.com/


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