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Thread: E/G CNC Mill

  1. #1
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    Talking E/G CNC Mill

    Hello everyone!
    I'm from Finland so you have to excuse my broken English

    This is going to be my second machine build so I hope that I'm not going to do the same mistakes this time.
    Previous build: Svenska ElektronikForumet • Visa tråd - Daniels lilla cnc fräs // ny skärvätskeannordning
    It's in swedish but google translate might help or you could just look at the pictures

    So on to the new bigger machine, it's going to be built of epoxygranite and will be using star/bosch and THK linear rails. The ballscrews are 1605's from lmb2008 at ebay.
    The work envelope is going to be around: (mm)
    X: 490
    Y: 305
    Z: 334-490

    All axis in zero:

    And in their maximum position:

    This is an rather old drawing but sketchup is a real pain to work with..
    I'm drawing up a version in solidworks at the moment.

    Here is all the screws and linear rails i'm going to use for this project:


    Some blocks didn't make the shot but you get the point
    The bearing blocks for the ballscrews feels very cheap but after some cleaning they feel at least ok.
    I did this to get my inspiration flowing and hopefully get this project done:


    I almost forgot about the electronics:
    I'll be using 1.5NM (1NM @ 1000rpm) steppers for X & Y but I still need to find one for the Z axis. I haven't decided on any bob's or drivers at this point.
    It's always fun with some feedback so feel free to leave a comment or two

    Similar Threads:


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    hi, looks pretty cool so far, can you tell about your plans with the E/G and please give some details? thanks!



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    I don't really know what my plan is The epoxy is ordered but not received yet.
    But I will put some steel in the mold where the rails and ballscrews is going to be. They will then be faced of on a bigger mill.
    I will probably end up shimsing (?) to get the column 90°. Or is there some clever way to get it perfect on a mill? The column itself will probably be almost 90cm's long and I can't see a way to get it faced. I guess it would be possible IF the mill had a horizontal spindle.



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    Registered Zach_G's Avatar
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    Couple of ideas for getting your mill square. If you make the base and colummn separately, you can clamp the two together on the flat surfaces using a good size angle plate. Leave a gap between the columns to squish out or inject a thin E/G mixture. If you dont have a large enough angle plate (I plan to use the bare end of a 9x42 mill table) you could design the base and column to attach with a bolt flange. Put 3-4 set screws in your flange as leveling feet, then adjust until square and lightly tighten the bolts until you're satisfied it wont move while injecting your E/G mix. This is how many large machines are built where there is nothing larger to machine it.

    Looks like you got the same cheapo chinese ballscrews as I did. Did you find removing the rubber seals helped reduce the drag? I still need to play with mine and get em turning nice.



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    I couldn't spin the screw at all with them there so we need to figure something out here
    Small update:
    The owner of the värnamo mill said ok to the job. It has about 1m in x travel so the whole column can be faced in one go. It also has a tilting head so if it's dialed in correctly you could do the bottom of the column to -I hope.
    And I have finished 1/3 of the mill in solidworks



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    Some progress with the cad drawing:

    I need to figure out some smart chip guards for all axis to.



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    Thought I would update this project a bit
    The molds






    Then I made a design change. I had no where near enough epoxy to make the base so I bought a big piece of granite


    I then drilled and glued some nuts into the granite


    This is pretty much where I am now


    And some updated renderings of the cad drawing



    This mill will probably (hopefully) be a great improvement to my first cnc mill Here's a crappy photo of it




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    Thumbs up



    Principles of Rapid Machine Des
    page 83
    page 84
    http://www.mech.utah.edu/~bamberg/re...e%20Design.pdf

    Attached Thumbnails Attached Thumbnails E/G CNC Mill-principles-rapid-machine-design-83_84-pdf  
    Last edited by hesham morsy; 10-01-2011 at 04:56 PM.


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    From what you've posted here, it doesn't appear that a lot of planning or thought was put into the EG mix. I can't be optimistic about the stiffness achieved in the column...

    There is lot that goes into EG, and getting the ingredients correct is just the beginning.



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    giz:
    You are probably right, I think the column can be seen as a faliure.

    The question now is what to make the column out of?
    -solid piece of granite like the base
    -a welded structure
    -other?

    Some thoughts about alternative 2:
    the structure will probably need to be stress relived? and I don't know of any company here that can do it.
    What will happen with if I didn't stress relived it? Will it bend over time?



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    am i missing something? where is the failure? is there another page floating around where the failure is documented.



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    I haven't taken any pics of the supposed failure yet. But the epoxy wont seem to harden properly I had some moisture in the gravel I used that I think is causing the problem



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