New Machine Build Second build - Baltic Birch Frame - Page 11


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Thread: Second build - Baltic Birch Frame

  1. #121
    Registered Biggs427's Avatar
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    Default Re: Second build - Baltic Birch Frame

    Finally got the time to finish my new Z axis.

    The taller axis (195mm vs 110mm) gives me more clearance which is great when I have long cutter or drills bits.
    Second build - Baltic Birch Frame-img_1746-2-jpg


    The XL belt seems to work well. I'm running 1:1 ratio with the 10mm pitch ballscrew and the 270oz stepper seems to keep up. The ballscrew, even if it is chinese, have less backlash than the T8 leadscrew I had. Even if it was preloaded. The only mising thing is the cable management for the spindle power and control.
    Second build - Baltic Birch Frame-z-build1-jpg

    I'm glad with th enew Z axis of the machine, I can now access ALL bolts easily so a bolt check shouldn't take more than ten minutes!

    Attached Thumbnails Attached Thumbnails Second build - Baltic Birch Frame-img-1643-jpg   Second build - Baltic Birch Frame-z-build1-jpg   Second build - Baltic Birch Frame-img_1746-2-jpg  


  2. #122
    *Registered User* Carl10's Avatar
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    Default Re: Second build - Baltic Birch Frame

    That is a great machine and is similar to the type of design I plan to build. To that end I have a few questions about your build:
    1) What was the reason for the leveled epoxy under all the slides? With the care you took building the pieces I would have thought the Birch would have been flat (or is it for strength, other?)
    2) The epoxied in inserts you showed, the holes were 1mm larger than the insert with a semi-cured epoxy coating? And these were stronger than the tapped sandwiched aluminum plate?
    3) I noticed along the way that your spindle bracket was beefed up (as I see many others do as well). Was this from a performance observation or just a precaution?
    4) I know you checked for flex early on, but now that you have used it for a while is there any area you see as a weakness?

    Thanks for sharing your project.



  3. #123
    Registered Biggs427's Avatar
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    Default Re: Second build - Baltic Birch Frame

    Carl10:

    1- I used epoxy to make certain that each axis have the most leveled plane possible. IMO the level of precision I wanted was not possible to obtain with wood only construction. Also, the structure was sealed with epoxy as I wanted to minimize dilatation due to humidity.

    2- The steel inserts tend to strip less than the aluminium and it is way easier/ faster to install with a simple template. This was not semi cured epoxy but thickened epoxy. I used West 403 filler to thicken the epoxy but I think 404 or 406 would have been better filler for that type of use.

    3- My first spindle bracket was doing a fair job but I rebuild it for two reasons: I needed it taller for when I'm using longer cutter and I wanted the maintenance to be easier so I designed it with maintenance in mind. Before the rebuild, it took 60-75 minutes to do a simple bolt check on the Z axis and had to disassemble some parts. Now it takes less than 5-6 minutes to do a bolt check and put grease where it is needed. Also to have a better motion control. Ballscrew to replace the T8 leadscrew.

    4- Probably the MGN12 rails but if I beef up my Z axis with 15mm rails, I'd probably need a bigger spindle as I'm already pushing my Hitachi router. When you beef up a weaker part, some other part will become the weaker part and so on...

    For wood working it is more than enough for my needs. I can even do some basic alu machining with "decent" speed and finish so I'm happy.



  4. #124
    Registered Biggs427's Avatar
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    Default Re: Second build - Baltic Birch Frame

    Since the new Z axis is a little bit stiffer and have less backlash I decided to give a try to steel again.

    I needed a 1/4 drive 24mm socket ground flat to proprely torque my mountain bike fork top caps.

    I used 1.5in round stock

    I used 1/4 and 7/64 2 flutes cutters from carbide.ca with AlTiN coating (I think...).

    For facing operations I used 0.5mm (0.019) DOC with 1.5mm (0.059) WOC. I could have used 1mm DOC.

    For pocket operations I used same WOC but with 1mm DOC. Both facing and pocket operations were generated using 2D adaptive clearing. (trochoidal cutting)

    For coutour operations, I used 2mm DOC and 0.75 WOD.

    With the 1/4 cutter I went with 0.001 chipload and 0.00075 for the 7/64.

    Second build - Baltic Birch Frame-img_2001-jpg

    The work holding for the first side was too ghetto for my taste so I made a fixture using plywood using the same work offset as the socket.
    Second build - Baltic Birch Frame-img_2057-jpg

    I used the same recipe for the other side.

    The dimensions are within 0.001-0.003. The surface finish is less than stellar but for a router made of wood I'm quite happy.
    Second build - Baltic Birch Frame-img_2061-jpg

    One important thing I had to take into account was to take my spindle runout (0.0015) into account when I installed my cutter.

    With the proper recipe and runout taken into account, no cutters were harmed during this job.

    Attached Thumbnails Attached Thumbnails Second build - Baltic Birch Frame-img_2001-jpg   Second build - Baltic Birch Frame-img_2057-jpg   Second build - Baltic Birch Frame-img_2061-jpg  


  5. #125
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    Default

    Looks awesome. Nice work!



  6. #126
    Registered Biggs427's Avatar
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    Default Re: Second build - Baltic Birch Frame

    Thanks!

    I am not winning a surface finish contest with this one but the part is fully functional and that's what is important.



  7. #127
    Community Moderator ger21's Avatar
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    Default Re: Second build - Baltic Birch Frame

    That's awesome, but I'd be more inclined to drive a mile down the street and buy one for $12.

    Gerry

    UCCNC 2017 Screenset
    http://www.thecncwoodworker.com/2017.html

    Mach3 2010 Screenset
    http://www.thecncwoodworker.com/2010.html

    JointCAM - CNC Dovetails & Box Joints
    http://www.g-forcecnc.com/jointcam.html

    (Note: The opinions expressed in this post are my own and are not necessarily those of CNCzone and its management)


  8. #128
    Registered Biggs427's Avatar
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    Quote Originally Posted by ger21 View Post
    That's awesome, but I'd be more inclined to drive a mile down the street and buy one for $12.
    Where's the fun then?



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Second build - Baltic Birch Frame

Second build - Baltic Birch Frame