steel/aluminium fixed gantry build

[fretman_2]

Good looking machine!

[v2tiller]

Time for an update.
I have switched to UCCNC and a UC400ETH. Also got an old touch screen hp all in one pc. So far loving the combo.
I made some dodgy y axis way covers which are working good. Started on some side and rear machine covers so chips aren"t going everywhere.
I got a 19mm thick piece of cast ally tooling plate for my table which i need to machine up bolt holes for.
In the meantime i fabbed up a mdf spoilboard to muck around on, which i did my first cutting on ( facing and drilling grid holes ).
when i got that done i was eager to try some aluminium so today i gave it a shot.

Now im very new to cad/cam and only have been learning fusion 360 for a few months so i have a long way to go.
Anyway, heres a couple of pics of my first part in ally.




i used a 4mm spot drill for spot holes and chamfers, 8mm 2 flute for facing and contour and 8mm drill for hole.
this was using the settings fusion gave me, which i need to slow down a bit next time, but im happy with how it turned out. I was only using a spray bottle with a metho/water mix.
I have a mister on the way.
Anyway for a first attempt im very hapy. The size of the part was drawn at 70 x 38 and it measured 70 x 38.05.
So now i need to finish my guarding ( chips flew everywhere ), get the coolant mister going, I def need a tool height setter and edge finder and the list goes on and on.
I need to finish the other side of this part and make 3 more so i will make a video next time.
Feel free to throw any advice in as a have a lot of learning to do.

Cheers.
Barry.

[wizard]

Barry

Looks like you are off to a great start. As you are learning chip and dust management can be a bear. A machine enclosure can help but done well cost about as much as your build. That is if you are building water proof / fluids proof rigid enclosure. The alternatives are shower curtain type solutions. A vacuum is needed for wood or other dusty materials.

[v2tiller]

Bit of an update.
Fitted cast ally table with steel thread insets. Took a risk and did machining on the router myself and it turned out great.
I then stripped it down double checked alignments and gave it a paint job. Was sick of constant surface rust.
Fitted coolant mist and enclosure which still needs some work.
Still a few things to go but getting close.
Heres a pic.
Cheers.

[Sterob]

Very nice Barry.
Where in Oz are you?
Curious as to why you went with a 'moving table' design?
Have you owned a 'moving gantry' model before and was not happy with its weaknesses?

Steve

[v2tiller]

Hi Steve.
I'm in Hervey Bay QLD.
Main reason for fixed gantry is for cutting aluminum. I don't need a big cutting area and from all the info i read this design is a lot more rigid.
Plus using steel in my build.
This is my first finished build and mainly a learning machine.
I hope one day i can find a decent used vmc to fit in my shed.

[v2tiller]

Some more work done.
Enclosure finished. Z axis covers back on.

[v2tiller]

Time for an update.
My all in one touch screen pc crapped out so had to get a new laptop, so made a stand so its closer to the front opening. Makes setting up a whole lot easier.
Also got myself a tool height setter which is a great time saver.
I have been practicing cutting aluminium a lot and chips just get everywhere, even with covers. The other day the y axis started making a horrible grinding noise sounding like chips in the ballscrew, just great.
Luckily after pulling it down discovered it was chips in the timing belt. So i made a sheet metal cover which should help. I have some custom made x axis bellows coming from china and if they work out ok i will replace
my home made y axis covers.
I brought my first ever ball end mill ( 6mm 2 flute ) and have been playing around with 3d in fusion. Attached is a pic of some basic ally i have cut.
I am having a great time learning this and want to get more end mills and work on finishes.
I have a video of 3d cutting, just need to do some editing and upload it.
cheers till next time.

[Sterob]

Need to work out posting pics right way around

I've found that if you crop the pics to make them wider than they are tall, they orientate correctly.

Great build, by the way. Looks like a corker.

[v2tiller]

Couple of parts i have made for fun.
The machine is cutting ally great.
Dogbone is 130 x 24 x 40mm. It didn't line up properly when i flipped it because i have no edge finder yet and had to manually find x and y edges.
I have ordered a 3d touch probe to make that easier.

hopefully a video link coming soon.

Cheers.

[machinedude]

a piece of paper and the tool will work to locate your edges. it's just not very high tech

[v2tiller]

Yes, i use 0.038mm feeler gauge and ground dowel pin to locate edges. I should say that the other side was only out by about 0.05mm. But could be better.
I'm a fussy bugger!

[machinedude]

you could sweep the hole in with a indicator as long as the part is straight and enter the the value that the part is programmed for to match the center of the holes. soft jaws milled to the profile of your part. all kinds of ways to locate things. any kind of blend can be tricky. best solution would be to start with thicker material so you have a clamping hub so you can mill the whole profile in one shot and use soft jaws or fixture to locate any secondary work on the back side. with something with holes in an irregular shape putting the holes in first before could be a solution. planning the order of operations goes a long way when your only working with a 3 axis machine.

[v2tiller]

It's finished ( for now ).
Received my x axis bellows, so i pulled machine down for a small re-do.
Moved x axis limit and home switches to inside rails for protection. Re balled x axis carriages ( they were a bit sloppy, but now like new with just a bit of preload )
Added some extra bracing to gantry sides. Made some new, wider y axis covers. Also made a spindle cover to offer bit of cover for the fan intake.
Still hoping to get some vids up soon.
But for now its time to see what this can do.

Cheers.

[v2tiller]

here is a video of me practicing some 3d machining.

[machinedude]

so what are you using for the control software? looks like the movement is pretty smooth and responsive for a tool path like that.

[v2tiller]

Im using uccnc with a uc400 eth motion board.

[v2tiller]

Bit of an update.
My diy build has got a big brother