3-Axis CNC Mill Project

[Hobgoblin]

After spending a few weeks contemplating ideas for a new hobby project; then longer deciding on a design I was happy with I finally got my hands on the Aluminium extrusion profile wanted to build the frame.

Aims are to have a complete unit, machine base and storage, 3 axis CNC control with Mach3 software, A3 paper size capability, High precision with zero backlash, hardened linear rails ball screws and stepper motors and finally a special purpose milling spindle.

First making a sketch of the idea:
https://img.photobucket.com/albums/v248/ROBOTIX/3-Axis%20CNC%20Mill%20Project/IMAG0124e.jpg

Then realising things look a lot smaller on paper when I get the aluminium home:
https://img.photobucket.com/albums/v248/ROBOTIX/3-Axis%20CNC%20Mill%20Project/IMAG0102.jpg

Anyway, first up is to end tap the profiles required M8, thankfully its extruded with the 6.8mm hole required for such:
https://img.photobucket.com/albums/v248/ROBOTIX/3-Axis%20CNC%20Mill%20Project/IMAG0104.jpg

That done:
https://img.photobucket.com/albums/v248/ROBOTIX/3-Axis%20CNC%20Mill%20Project/IMAG0109.jpg

It was on with marking out the holes to assemble the frame:
https://img.photobucket.com/albums/v248/ROBOTIX/3-Axis%20CNC%20Mill%20Project/IMAG0111.jpg

And then on with drilling them:
https://img.photobucket.com/albums/v248/ROBOTIX/3-Axis%20CNC%20Mill%20Project/IMAG0112.jpg
https://img.photobucket.com/albums/v248/ROBOTIX/3-Axis%20CNC%20Mill%20Project/IMAG0113.jpg

Then on to a mock assembly to make sure it looks ok:
https://img.photobucket.com/albums/v248/ROBOTIX/3-Axis%20CNC%20Mill%20Project/IMAG0114.jpg
https://img.photobucket.com/albums/v248/ROBOTIX/3-Axis%20CNC%20Mill%20Project/IMAG0116.jpg
https://img.photobucket.com/albums/v248/ROBOTIX/3-Axis%20CNC%20Mill%20Project/IMAG0118.jpg
https://img.photobucket.com/albums/v248/ROBOTIX/3-Axis%20CNC%20Mill%20Project/IMAG0119.jpg

Perfect, a solid accurate level frame with enough room underneath the table for housing the control, pc, drives, tooling etc. Finally I laid the aluminium extrusion profile I’m using for the machine table on top:
https://img.photobucket.com/albums/v248/ROBOTIX/3-Axis%20CNC%20Mill%20Project/IMAG0120.jpg
https://img.photobucket.com/albums/v248/ROBOTIX/3-Axis%20CNC%20Mill%20Project/IMAG0121.jpg
https://img.photobucket.com/albums/v248/ROBOTIX/3-Axis%20CNC%20Mill%20Project/IMAG0122.jpg
https://img.photobucket.com/albums/v248/ROBOTIX/3-Axis%20CNC%20Mill%20Project/IMAG0123.jpg

Next up is to finalise the design for the hardened linear rails, linear bearing guide blocks, ball screws and stepper motors; that said I can then cut this profile to suit, and make the carriage for the x axis as shown atop the sketch:
https://img.photobucket.com/albums/v248/ROBOTIX/3-Axis%20CNC%20Mill%20Project/IMAG0125.jpg

Sit down time with a good bottle of ale:
https://img.photobucket.com/albums/v248/ROBOTIX/3-Axis%20CNC%20Mill%20Project/IMAG0127.jpg

Hopefully when its complete I’ll be able to mill 2D images to 3D, and produce high precision parts for a range of purposes.

Thanks.
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Plodding along on my CG

[nowhere.elysium]

I think I'll be keeping an eye on this project.
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'10 SV650SF, '83 GS650GT (it lives!), Questionable DIY dash project, 3D Printer project, Lasercutter project

[Mr Krispy]

Looks like its going to be interesting.

I have to ask, why have you blanked the dimensions off from your drawing?

[Hobgoblin]

[Blackwolf]

This looks like it could be intresting..!
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Current: Ducati Multistrada 1200s

[Bike Bunker]

[nisp]

https://memecreator.eu/media/created/t2imge.jpg


I was thinking about asking someone if they could mill me a rear light bracket out of sheet
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Suzuki TS 50 1999 Honda CB 125 t2 1981 Yamaha XJ 600 s Diversion Honda cx 500 MZ ETZ 250 1985 Yamaha FZR 400 1981 Suzuki TS 185 1984 Triumph bonneville 790 2001 MZ TS250 1979 Suzuki sv 650 1999 KTM exc RFS 450 2007 Hercules mx 125 1976

[Redoko]

https://2.bp.blogspot.com/-ZkO915JKehc/TxzaeyGPcPI/AAAAAAAAAFk/fX74ciQBOZM/s1600/relevant.jpg
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"Let's face it, this is not the worst thing you've caught me doing."
Sudika Sportsman SK50QT > Gilera DNA50 > Honda CBR125 RW7 > Kawasaki Zephyr750 > Suzuki GSXR600 > Honda Hornet CB600F '51

[MaybeGuy]

I doubt you'll get any kind of accuracy with this. Looks like it'll flex far too much, and the bed if I'm honest looks pretty damn flimsy. Compare it to other ones you see which are a solid block of steel with the dovetails machined in them.

Looks like a nice table though.
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Blue_SV650S wrote: it was a sh1te wheelie, but it proves that he can get it up in 3rd and can do angles. In summery, mattsprattuk is a gobby little sh1tebag, dopehead tw4t, but sadly for all of us, he probably isn't THAT full of sh1te!!
Kickstart wrote: Hi I tend to agree with Matt. All the best Keith

[Werny]

[Pete.]

Good luck with your project. I've just bought a used bench-top milling machine to do a similar thing, but mine will be quite a bit more robust because I want to mill ally and steel.
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a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[U_W v2.0]

GL hope it works out.

if it doesnt however, get some plexi glass cut and turn it into a vivarium, can name a few species of tarantula that would love that as its enclosure!

also link to where you brought it from.
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BCF's biggest cunt list: Cansa, Pits, Rob

[Teflon-Mike]

[Jenks]

im with the others. i work as a cnc machiner. - it will have too much vibration and play...

still. will be watching.
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1978 MZ TS 250 1 Supa 5
1992 yamaha fzr1000 exup
1998 aprilia af1 sintesi

[Hobgoblin]

Just to clear a few things up.


I do welcome the feedback and criticism good or bad as it helps to keep in mind the planning and checking process.


The purpose of this project for me is, first of all just to be able to, and then for as said engraving, hard woods, plastics (acrylic lexan etc) and possibly aluminium. This isn’t unachievable with this setup, however trying to skim a cylinder head or reproducing engine parts is.


Achieving a level table, parallel axis and zero backlash can be achieved with the right setting equipment, depth micrometers height vernier's DTI's (which I can borrow freely as I do this stuff for a living but on a much greater scale), as for backlash if any is present when finished this can be compensated for in the software I intent to use to control the machine.


Vibration and tool chatter will be a problem in certain situations and of course it won’t be as easy to overcome as removing some of the inserts from a cutter to stop such resonating because this isn’t a large machine with a large face milling cutter.


But I can only try to design what I can afford for the intended purpose and strengthen it where possible. Reducing depth of cut, feed per tooth per rev, spindle RPM tweaking all the basic parameters if in a situation where I’m still getting chatter/vibration.


I was actually quite impressed by the overall mass of just the base once it was assembled and it certainly isn’t flimsy stuff even the 20x80 is very strong.


Link to the supplier of the profile:
https://www.boldman.co.uk/


I have considered making some brackets coming off the bottom corners of the frame that, once the machine is levelled at the base, will also bolt into the ground.


In the final stages of designing the next steps at the moment, all the planning for the traversing carriage, the guide rails, ball screws, stepper motors, and brackets needs to be carefully considered so that I don’t encounter any parts fouling on others.


The machining area should be about 400x500x150mm when complete but thus depends on how things develop; there will defiantly be room for A3 though.


Thanks.
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Plodding along on my CG

[Werny]

[Hobgoblin]

I've made a little more progress this afternoon.


I've finished a mock assembly of the carriage. This is subject to being shortened on the height as much as the finished design will allow so that I can still get a good travel in the Z axis (up and down).


https://img.photobucket.com/albums/v248/ROBOTIX/3-Axis%20CNC%20Mill%20Project/IMAG0129.jpg


https://img.photobucket.com/albums/v248/ROBOTIX/3-Axis%20CNC%20Mill%20Project/IMAG0130.jpg


As a contingency factor I’m considering the prospect of using 4 linear rails in the X axis rather than just 2. This isn’t my first choice though as it costs more. BUT if I can get good stability without drastic effects from inertia of the carriage rapid traversing then I'll leave it with just 2. There will always be the option to upgrade to the 4 though so that will be a bonus if like said required.


Just doodled over a picture if any can can’t understand what I’m babbling on about, the square blocks are the linear bearing blocks and the “?” are the extra ones factored.


https://img.photobucket.com/albums/v248/ROBOTIX/3-Axis%20CNC%20Mill%20Project/IMAG0132a.jpg


https://img.photobucket.com/albums/v248/ROBOTIX/3-Axis%20CNC%20Mill%20Project/IMAG0133.jpg


The side supports like said are subject to being shortened as much as I can with the top brace to follow suit so the set up is as pictured, just shorter.


Next thing to do will be to order some hardened rails, support brackets and linear bearings and take things from there as and when funds allow or the missus signs my pass to take over the kitchen.
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Plodding along on my CG

[Hobgoblin]

Still toying with ideas, this is what ive come up (see attached) with this evening, should create a larger footprint for the gantry in x whilst also stiffning it in y.
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Plodding along on my CG

[Hobgoblin]

New to CAD but getting there.

Fucked up with this animation as I made the wrong part in the assembly the fixed part, So just view the video as the gantry moving, not the rails.

https://videobam.com/PLxcP

Thanks.
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Plodding along on my CG

[Werny]

Any more progress on this? It's still a properly interesting project

[Hobgoblin]