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Thread: Designing new Router called Maximus

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    Default Re: Designing new Router called Maximus

    Hi Ericks - I have a bench size machine for sale and a half sheet machine for sale. Look up gumtree. Brevis and Scoot are their names. But Maximus is in development. Regards Peter



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    Default Re: Designing new Router called Maximus

    Quote Originally Posted by peteeng View Post
    Hi Ericks - I have a bench size machine for sale and a half sheet machine for sale. Look up gumtree. Brevis and Scoot are their names. But Maximus is in development. Regards Peter
    Thanks Peter



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    Default Re: Designing new Router called Maximus

    Hi All - I'm back behind my monitors after a short trip. I visited Ram3D in New Zealand along the way to get an understanding of their metal printing capacity. Additive Manufacturing | RAM3D I'm particularly interested in how to do the internal latticework to create very light metal parts. They use expensive specialist software to create various internal latticework geometry. I intend to use grasshopper and rhino. https://www.grasshopper3d.com

    Anyways had a great chat to the Chief Executive Warwick Downing and got to see the many fantastically light titanium, aluminium and other metal parts that they make 24/7. Analysing internal latticework using traditional FEA is quite difficult as the mesh size has to be smaller than the feature size, so if you have a 0.5mm thick lattice then you need say 0.2mm mesh. Then it has to transition to the skin which means you have a mega mesh count for a small part, consequently a huge solve time. Simsolids approach is different in that it does not use a mesh and solves lattices very efficiently. So investigating and designing very light optimised metal parts is very doable. Comes down to the price!! Attached is a pic of some Ti6-4 bicycle parts with internal lattice. I handled these and they are much lighter then the aluminium parts I used to have made. So regather my thoughts about Maximus, been sketching madly on the trip and reviewing the gantry brackets... but ended up back where I started!! nearly. So get some other things done and get the flow going again. Peter

    Attached Thumbnails Attached Thumbnails Designing new Router called Maximus-bike-parts-jpg  


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    Default Re: Designing new Router called Maximus

    It must be a great shift in thinking to create such pieces with no concerns about the machinery fouling the table or adjacent components and to be able to create those internal lattices with no consideration of tool geometry.In the longer term,does it make great swathes of traditional manufacturing obsolete?



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    Default Re: Designing new Router called Maximus

    Hi Routalot - Most of the industry observers and the trends indicate that 3D metal printing will out strip traditional manufacture within 10 years. Most major machine makers have large scale combined printers and mills in the works or already available. Additive has limitations but a combined system is very flexible. Like threads. Ram3D print the threads in but they still need chasing. The surface finish is getting better and better but for a precise finish to a surface spec it still requires subtractive. By combining the two machines in one this eliminates the issue of resetting parts in differing machines. Like transistors replacing valves, additive will replace milling in the next generation wherever possible. The aerospace industry already have printing farms pumping out things like seat brackets and secondary structures for their planes. They will move to primary structures very soon. An international std has been released for structural properties of various printed metals so now designers can design in confidence and manufacturers have to make systems to a standard if they want to get into that game.

    Back to Maximus - I got excited with my holiday sketches for the gantry brackets, But when I got into the geometry the actual aspect ratio was wrong so I couldn't achieve the art deco design I wanted. I was in Napier in NZ and it has many art deco buildings which I thought was a good muse. So I worked on a 3D printed part anyway and ran it in the simulation. No change to the deflections so I suppose the gantry brackets are not significant in the global deflection at present. I'll have to look for a more significant part for the 3D printed part. It seems the brackets are correctly placed in the loadpath to resist the bending, good to know. So I think it's time to review and start on Round 2.

    The stress video shows that the max stress is in a corner at the gantry brackets. Remember this is from a 10,000N load which is in service never to be over 1000N. So the actual max stress is 10MPa or less. So over stressing of the parts is totally unlikely. So those people out there that say their machines have to be stronger need to change their thinking to stiffness!! Peter

    Attached Thumbnails Attached Thumbnails Designing new Router called Maximus-gantry-bracket-1-jpg  
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    Default Re: Designing new Router called Maximus

    Hi All - Seems no-one likes opening zip files so you all will have to wait until the forum allows MP4s to play to get more videos. There's a common comment about using std hollow sections for the gantry so I have looked at this at this juncture. Now the inertia requirement for the Maximus gantry has been established we can look at the square sections to find out what works. The Metal Shop has a tube laser and this is the preferred manufacturing method. Unfortunately its max size is 150mm square. A 150mmx6mm thick SHS is about half the required stiffness in all directions and torsion. If I go to 200x6 SHS it's much stiffer but I'd have to have a machinist set it up to do the holes and this would be too expensive. So I suppose I have to go looking for a tube laser that is bigger than 150sq. Also the 200sq has a side span that does not allow the same bearing spacing as Maximus. So for now it's the sheet metal version. I'll try to optimise this shape a bit better for Round 2. Peter

    Attached Thumbnails Attached Thumbnails Designing new Router called Maximus-inertia-jpg  
    Last edited by peteeng; 05-16-2019 at 12:53 AM.


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    Default Re: Designing new Router called Maximus

    Hi All- Preparing for adding the motion to the Z axis. So I looked at the drive screw nut mount dims. SF1204 H1=30mm SF1605 H1=40mm and SF2005 H1=44mm The stack ht of the bearings/rails is H15mm~24mm, H20mm~30mm and H25mm~36mm. Maximus currently has a gap of 43mm from the top of the car to the top of the gantry rail (see image) . This ignores the gutter in the tool tube. So if I make the tool tub flat backed the SF1605 will work. If I use the 20mm bearings I gain 6mm clearance meaning it would be 49mm so all choices would work. This is further support to go to the H20 linear bearing but it pushes the spindle out a further 12mm plus the gutter of 20mm so 32mm further out... If I use it as is then the gap is 23mm in which case none work using the conventional arrangement.

    I can mount the drive on the side but then that will take up transverse space, I can drive the tool tube from the top using an unconventional thrust bearing arrangement which would cost more... Seems like the move to 20mm is the go for now.

    I'll assume the drive nut flat is the same dim as the housing height as they don't have a dwg for the nut housing. I'll request a dwg so I can model the assembly... Peter

    Attached Thumbnails Attached Thumbnails Designing new Router called Maximus-nut-spacing-jpg   Designing new Router called Maximus-drive-nut-jpg  
    Last edited by peteeng; 05-16-2019 at 01:02 AM.


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    Default Re: Designing new Router called Maximus

    I've looked at a 1605 ballscrew arrangement with BK/BF12 bearings. If I mount these in the usual position it pushes the tool plate out a long way, see image. My aim with this machine is to minimise the cantilever of the Z axis stack. So I think I'll run the drive down the tool tube side. Waiting for dims from BST on their parts. I've drawn these up from other suppliers. More thinking to be done. Side mount doesn't look good yet... Peter

    Attached Thumbnails Attached Thumbnails Designing new Router called Maximus-ballscrew-jpg   Designing new Router called Maximus-side-jpg  
    Last edited by peteeng; 05-16-2019 at 04:35 PM.


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    Default Re: Designing new Router called Maximus

    I've placed the side drive in about the right position. The nut housing will need a spacer or I build a custom housing. I looked at running it down the inside but that turned into a monster long screw. So it's time to start building P2 I think. I've learned as much as I can from P1... One question for people out there as I have not used a drive screw like this before. Will this backdrive under the Z Axis deadloads? Do I need to use a balancer on it somehow to stop it from falling when the motors are off? I can calculate this once I get the weights better known but I'd like some thinking time on it to provide the right solution in P2... I used a gas strut on Scoot for this as it used a belt drive on the Z axis... Peter

    I've attached a 3D pdf of the assemble as well... best to look at it using "solid outline" view once you have activated it.

    Attached Thumbnails Attached Thumbnails Designing new Router called Maximus-side-drive-jpg  
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    Default Re: Designing new Router called Maximus

    Hi All - Did a bit more work on the Z Drive and I think it looks OK. Will modify the bearing plates to connect the bits!! I'm tending not to use the gutter shape in P2 so the "box" will be narrower due to the side drive. Also the box and bearing plates have to be high enough to accept the nut brackets properly so it may not be symmetric. So it may be a "box" with a lid vs using the same part twice. We shall see... I'm out to set up a laser on Brevis...Peter

    Attached Thumbnails Attached Thumbnails Designing new Router called Maximus-z-drive-jpg  


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    Default Re: Designing new Router called Maximus

    Hi All - More work on the Z drive. Looked at top driving but got to be very tall. Brevis has a top drive and it works great. But the bearing arrangement is different so it fits better. P1's current Z travel is 210mm and this will be tuned to 250mm. One thing to look at is the work "cone" so I can get into cavities. On Scoot I can angle the router so it points sideways. The tube type Z won't allow this I think. I think I'll have to get long tools when the time comes. I think the side drive is more compact but uses more transverse space but that's the compromise at the moment. So better get busy modelling the 20mm bearings so P2 can get started... Peter

    Attached Thumbnails Attached Thumbnails Designing new Router called Maximus-side-drive-1-jpg   Designing new Router called Maximus-brevis-top-drive-jpg   Designing new Router called Maximus-work-angle-jpg   Designing new Router called Maximus-brevis-jpg  



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    Default Re: Designing new Router called Maximus

    Hi All - I added an N34 motor to the drive assembly and the screw bearings and motor heights are all out of wack. So I'll have to use FK/FF bearings and make mounts. I have some new ideas for the tool tube so let's get into Round 2 and P2!! Peter

    The devil is in the detail and detail takes time... so be patient.

    Edit - I worked up the bearing plate to include the motor and bearing mounts. Now I can see where this is going I'm happy.

    Attached Thumbnails Attached Thumbnails Designing new Router called Maximus-p1-z-drive-2-jpg   Designing new Router called Maximus-fk-ff-bearings-jpg   Designing new Router called Maximus-nema-jpg   Designing new Router called Maximus-p1-z-drive-jpg  

    Last edited by peteeng; 05-18-2019 at 12:16 AM.


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