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  1. #821
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    Default Re: Milli a new composite mill kit

    Evening All - Here's a historical lifting gantry machine, been busy finding some SiC and Alumina in china....... Peter

    Attached Thumbnails Attached Thumbnails Milli a new composite mill kit-lifting-gantry-history-jpg  


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    Default Re: Milli a new composite mill kit

    Evening All - I use Rule of Mixtures a lot thru here so I thought I'd include an example using some moulded plastic. Zytel 35% fibreglass has been around for a long time and has pretty std properties.

    A simple explanation of ROM is if you add a glass of 50C water to a glass of 100C water you get 75deg C water when mixed...

    https://dupont.materialdatacenter.co...35HSL%20BK039B

    Using the attached data and ROM calc shows the strain efficiency of the combination is n=0.85. In my calcs I have always used 0.5 as this is the bottom conservative figure. This is called "translation" ie how does the theory translate to reality... rounded particles don't transfer strain as well as longer fibres do... so round ed (like sand) tend to the 0.5 figure.. I'm getting some ALOX this coming wednesday if I use 0.5 solids ratio (by volume) with CSA I should get E90 (n=0.5 in both). If I use 0.6 solids and epoxy I should get E77 so they are my targets. If I use epoxy its about $17200AUD per m3 and if I use cement its about $11000AUD per m3 so hopefully the grout approach works out...I'm sure I can infuse ALOX I have infused sand before a few times.... Peter

    Attached Thumbnails Attached Thumbnails Milli a new composite mill kit-zytel-plastic-jpg  


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    Default Re: Milli a new composite mill kit

    Hey Peter,

    Have you thought about the anchors yet? Options:

    1. thinner mounting plate + (more) thinner anchors (more balanced?)
    2. thicker mounting plate + (less) thicker anchors



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    Default Re: Milli a new composite mill kit

    Quote Originally Posted by peteeng View Post
    Evening All - Here's a historical lifting gantry machine, been busy finding some SiC and Alumina in china....... Peter
    Yes a nice old planer if you can find one that size it most likely will still do a very good job a lot of machine builders added a milling head

    Mactec54


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    Default Re: Milli a new composite mill kit

    Hi Ard - I have two thoughts 1) cast the aluminium blocks in then machine all the required features into those blocks on a large router or VMC 2) cast in pockets then epoxy in anodised blocks then finish machine . I'm leaning towards 2) at the moment.... Sometimes aluminium and concrete don't like each other and the Al corrodes so epoxy is a good barrier. If I use steel I'll zinc plate them prior to in-situ casting or post placement... Doesn't affect the CAD work at the moment. Haven't had luck getting the Alumina I want local but a chinses company is quoting on a suitable spec. Local blasting grit is a bit more cost then it should be but it will be fine for casting test blocks, fingers crossed some may arrive tomorrow. I have made the CSA test blocks into trivets and they are now in my kitchen.... I will need to get some granite sealer they are a bit porous and suck up stains.... real machine parts will be sealed and painted. I'll have to get Gully onto that he's good with paint....

    Using local materials ALOX/EP E90-95 ~$17000AUD per m3 ALOX/CSA E80-85 $11000 AUD per m3...... Plate Alum at $9/kg $24300 AUD per m3 so not bad.... Peter

    CSA CTE 13.7 ALOX 8.1 Alum 21 steel 12 epoxy 45 cast iron 11 units um/m/C

    Yong Ju make big machines. I do like BIG machines....

    Attached Thumbnails Attached Thumbnails Milli a new composite mill kit-trivett-jpg   Milli a new composite mill kit-yong-ju-precision-jpg  


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    Default Re: Milli a new composite mill kit

    Quote Originally Posted by peteeng View Post
    Evening All - Here's a historical lifting gantry machine, been busy finding some SiC and Alumina in china....... Peter
    thats a planer.

    it only takes force in a single direction in a very controlled manner.

    doesnt really apply much to a multi axis cnc.

    Pie


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    Default Re: Milli a new composite mill kit

    Quote Originally Posted by peteeng View Post
    Hi Ard - I have two thoughts 1) cast the aluminium blocks in then machine all the required features into those blocks on a large router or VMC 2) cast in pockets then epoxy in anodised blocks then finish machine . I'm leaning towards 2) at the moment.... Sometimes aluminium and concrete don't like each other and the Al corrodes so epoxy is a good barrier. If I use steel I'll zinc plate them prior to in-situ casting or post placement... Doesn't affect the CAD work at the moment. Haven't had luck getting the Alumina I want local but a chinses company is quoting on a suitable spec. Local blasting grit is a bit more cost then it should be but it will be fine for casting test blocks, fingers crossed some may arrive tomorrow. I have made the CSA test blocks into trivets and they are now in my kitchen.... I will need to get some granite sealer they are a bit porous and suck up stains.... real machine parts will be sealed and painted. I'll have to get Gully onto that he's good with paint....

    Using local materials ALOX/EP E90-95 ~$17000AUD per m3 ALOX/CSA E80-85 $11000 AUD per m3...... Plate Alum at $9/kg $24300 AUD per m3 so not bad.... Peter

    CSA CTE 13.7 ALOX 8.1 Alum 21 steel 12 epoxy 45 cast iron 11 units um/m/C

    Yong Ju make big machines. I do like BIG machines....
    If you are going to have the machining done outside then go with steel inserts it won't cost any more to have the steel machined vs, aluminum

    Mactec54


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    Default Re: Milli a new composite mill kit

    Hi Mactec - Agreed if I contract the machining then st or al does not matter. Once I have a mill I can machine moulds that only have thread inserts vs "blocks". I'd prefer aluminium but will decide once more detail is filled in. Peter



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    Default Re: Milli a new composite mill kit

    Hi All - The usual issue with mixing materials is the CTE delta. If I go with the ALOX/EP and I use 60%V alox and 40%EP then the CTE is (0.6*8)+(0.4*45)= 22.8 which is close to AL @ 21 , ST is half that. So aluminium is a good match.. If I use CSA then (0.5x13.7)+(0.5*8) = 10.9 which is closer to steel so the use steel.. Peter



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    Default Re: Milli a new composite mill kit

    Video from Keith Rucker about a metal planer he is restoring:



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    Default Re: Milli a new composite mill kit

    Evening All - I have 25kg of ALOX being delivered tomorrow so can continue the struggle for the Holy E70!! Peter



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    Default Re: Milli a new composite mill kit

    Hey Peter,
    Hope you got that alox today.

    https://i.imgur.com/hziPhBl.png

    Inside the spindle box, had to do an extension between the spindle and the cartridge, alternatively I could run it direct drive, but no way to do regular belt drive without compromising the structure of the bridge. I really want the bridge to carry most of the motor weight as close to the middle of it as possible.

    I'm not sure about the extension though, particularly the bearing config https://i.imgur.com/9xzCViQ.png



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    Default Re: Milli a new composite mill kit

    Hi All - waiting for ALOx looks like today. In the mean time I've been playing with the laser. Up to getting the CAD/CAM to talk to it. But I pushed two buttons in sequence trying to do something and it "reset" it cleared the memory of the machine!! Bummer. Now I'll have to figure how to set up the machine variables from scratch with no documents. The ARGUS mountain just got a little taller... Peter



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    Default Re: Milli a new composite mill kit

    Quote Originally Posted by peteeng View Post
    Evening All - Here's a historical lifting gantry machine, been busy finding some SiC and Alumina in china....... Peter
    yes, and the bridge is between the columns



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    Default Re: Milli a new composite mill kit

    Hi All - Been away for a couple of days. ALOX now in stock may do the first test tomorrow.. Peter



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    Default Re: Milli a new composite mill kit

    Here's a cool picture about UHPC inserts.





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    Default Re: Milli a new composite mill kit

    Hi Ard - Thanks Sudholt-Wasemannn have a lot of info about UHPC on their site.. Got home yesterday from a shirt trip and my main computer didn't boot!! Seems it liked the rest so much its staying cold... So its off to the tech tomorrow. Can't use my CAD system so I'm forced to do some ALOX casting.... Peter



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    Default Re: Milli a new composite mill kit

    Quote Originally Posted by peteeng View Post
    Hi Ard - Thanks Sudholt-Wasemannn have a lot of info about UHPC on their site.. Got home yesterday from a shirt trip and my main computer didn't boot!! Seems it liked the rest so much its staying cold... So its off to the tech tomorrow. Can't use my CAD system so I'm forced to do some ALOX casting.... Peter
    Hey good to hear from you, I was wondering whether one of the outback beasts ate you or something...
    Actually that data is direct copy from durcrete, here's the original repository:
    https://durcrete.de/downloads-english/?lang=en



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    Default Re: Milli a new composite mill kit

    Hi Ard - Haven't seen any Bunyips in my life. I think I've seen Min Min lights though and the occasional croc.... S-D get their material from Durcrete so the Nos are the same.

    So I figured out the weight ratios to get to E70 and set up the buckets and materials and added the alox in 250g units until it seemed too stiff. It didn't want to pour but was like very stiff concrete had to shovel it a bit. By the numbers this is E88+ so happy with that. Once I put it in the mould I jiggled it and it levelled, so wait until tomorrow to release. I think I'll do small manual epoxy mix as well. I'm sure it will infuse beautifully but a simple mix and pour approach would be great vs a vac bag and infusion. Next is to make a mould for a bend test... Peter

    some extra numbers:
    1) The addition weight ratio of the alox is 180% so there's heaps in there
    2) The volume ratio is 50/50 so if the alox is 300Gpa then just the ALOXS is E=0.5*300 = 150GPa tops and 0.5*300*0.5=75GPa least so I can back the current ratio off a bit to improve pouring.
    3) expected density is 3080kg/m3 so happy with that so much better then the steel. ALOX density is 3930kg/m3

    so comes down the actual stiffness now...

    Martec - I have left the high ratio steel block outside and it does show spot rusting...

    Attached Thumbnails Attached Thumbnails Milli a new composite mill kit-alox-mix-jpg   Milli a new composite mill kit-shaken-stirred-jpg   Milli a new composite mill kit-tucked-night-jpg  
    Last edited by peteeng; Yesterday at 08:57 PM.


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