DIY CNC Build

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Adverse Effects
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Post by Adverse Effects » Mon, 27 Apr 2015, 17:51

you closed your youtube account?

also am interested in how your going with it

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EV2Go
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Post by EV2Go » Wed, 13 May 2015, 23:45

Nope accidently deleted it :(

Been working on a new ball screw Z axis.

I was originally going to go with a design using some C channel, but after building several parts I visually noticed that I would need to pack the linear rails up by about 20-25mm.

Being the perfectionist I am I decided to start again with a piece of 600 x 130 x 40 billet aluminium.

Instead of build up the linear rails this time I will cut away where the ball screw sits.

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Adverse Effects
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Post by Adverse Effects » Thu, 14 May 2015, 02:49

owwww billet goodness

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Johny
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Post by Johny » Thu, 14 May 2015, 16:06

I don't comment as I have nothing to contribute but I'm reading your posts with interest Paul. I particularly like the way your machine is making spare parts for itself.
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Last edited by Johny on Thu, 14 May 2015, 06:08, edited 1 time in total.

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offgridQLD
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Post by offgridQLD » Thu, 14 May 2015, 16:30

+1 it's turning into a really nice setup well done. Image

Building one is on my ever growing to do list.

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EV2Go
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Post by EV2Go » Fri, 15 May 2015, 03:01

Thanks guys, even best wishes are post worthy :D

It has definitely taken on a life beyond my first expectations. Originally I didn't expect it to be anywhere near as big as it wound up becoming.

The budget has probably now blown out to beyond $6k, so I am hoping it has all been worth it in the end.
Last edited by EV2Go on Thu, 14 May 2015, 17:02, edited 1 time in total.

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EV2Go
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Post by EV2Go » Sat, 23 May 2015, 01:08

Couple of progress pics.

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T1 Terry
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Post by T1 Terry » Sat, 23 May 2015, 01:33

I'm still trying to figure out what the machined slots are for, so I'll wait for the next instalments, but it does look very impressive. On my list of things to learn about along with 3D printing, if I live that long of course, I still need to learn about the whole inverter/AC motor thing for my electric vehicle conversions but these toys would make that job so much easier.

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EV2Go
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Post by EV2Go » Sat, 23 May 2015, 01:59

Your looking at the back... The pockets are merely there to shed some weight. You want it as light as possible, while being as rigid as possible. Every bit of weight you can shed, the less load the motors will be under. The mass has to change directions frequently, the lighter it is the easier that job will be.

By the time I am finished I am hoping to be roughly half the weight I started with.
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Adverse Effects
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Post by Adverse Effects » Sat, 23 May 2015, 12:26

that is cutting nicely

love the curved hold downs as well

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EV2Go
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Post by EV2Go » Sat, 23 May 2015, 17:12

Broke a number of bits including a 14mm cutter trying to do slots in the back, but decided to keep my other 14mm cutter for the front face and go back to 6mm cutters and do Pockets.

I did use the 14mm bit to do some counter sink holes but because of the gap in the centre of the bit it left a piece of raised curled metal (can see it in the first photo).

I tried to drill it out from the other side once I finished doing the clean up cuts, but it didn't work, so I just milled the whole area down for better access (photo 2 and 3).

I have clogged a few cutters going too slow but cutting at 1m/min and only .25mm I seem to have found a bit of a sweet spot. It's not perfect but at least I have stopped breaking bits.

I have also reduced the overlap down from 75% to just 50% and 33%, this helps with the chatter, as it is trying to cut less and leaves more for the direction that doesn't chatter.

I have plans to make more of those curved hold downs, but I had to fix the CNC first as I was chewing up the alloy and breaking bits like crazy. Keen to try it again with a 3mm bit.

Ivan I have re-uploaded the videos and fixed links.



Last edited by EV2Go on Sat, 23 May 2015, 07:20, edited 1 time in total.

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Post by T1 Terry » Sat, 23 May 2015, 17:57

When I was doing alloy head modifications back in the turbo drag race days we used a candle to lubricate the bit regularly. Just a quick jab into the candle with the hot bit would form a wax coating and the alloy would just fall out of the teeth rather than building up. Maybe you could add a path in the program to dip the bit into surfboard wax or something on a regular basis to keep the bit clean. We also used a cutting lubricant in a white tin when I worked at the crane building place to lubricate the taps and drill bits to keep them cool and sharp for longer... but I can't remember what the stuff was called unfortunately.

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EV2Go
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Post by EV2Go » Sat, 23 May 2015, 20:49

I am currently using a mixture of a soluble oil mixed with water to spray on the tip, but might try the candle trick. For taping I use a cutting compound called Trefolex, it makes light work of cutting and helps keep things sharp. There are different mixtures for different cutting jobs.

http://www.crcindustries.com.au/trefole ... utting-oil

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EV2Go
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Post by EV2Go » Fri, 29 May 2015, 02:16

Got the first 8mm machined out today.

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Adverse Effects
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Post by Adverse Effects » Fri, 29 May 2015, 04:16

that looks to be a nice clean cut

how long it take?

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EV2Go
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Post by EV2Go » Fri, 29 May 2015, 17:04

About 3hrs. .25mm cut, 1.2m/min, 14mm cutter, 40% overlap.

Still getting a fair amount of chatter in one direction, but the other is as clean as a whistle.

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Adverse Effects
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Post by Adverse Effects » Fri, 29 May 2015, 22:16

some of the time chatter can also be caused by the job not held down right
try 1 in each corner and 1 on each side 1/2 way along when you continue the cut

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EV2Go
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Post by EV2Go » Sat, 30 May 2015, 01:45

No it's definitely a design flaw of some kind. If you put your hand on the Z axis going one way there is virtually no movement, but the other way it flexes a considerable amount causing the chatter.

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EV2Go
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Post by EV2Go » Wed, 03 Jun 2015, 03:13

Now have the pocket approximately 26mm deep and ready for some final clean up work on all sides. Took about 15hrs to machine out this piece so far.

I ran out of 6mm bits, so I had to starting using 5mm cutters. So I didn't hit the sides with the shank, I stepped the cut in 1mm on all sides.

You can see the step on the back face.

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Last edited by EV2Go on Tue, 02 Jun 2015, 17:19, edited 1 time in total.

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Adverse Effects
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Post by Adverse Effects » Wed, 03 Jun 2015, 03:40

you shouldn't be going through cutters that quick should you? or are they cheap ones

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EV2Go
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Post by EV2Go » Wed, 03 Jun 2015, 17:13

Some days I will break four, and other days none. Depends if there is a slight bit of movement, or the software tries to put the cutter down in a corner or something equally dumb where it catches an edge and snaps the cutter (that's how I broke the second 14mm cutter). Did all of that cutting yesterday without a single problem. Going to do the little pocket at the top today with the same 5mm cutter before changing to a new 6mm 2 flute cutter that turned up yesterday.

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EV2Go
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Post by EV2Go » Tue, 26 Jan 2016, 23:38

Been a while since I have updated this build thread so I thought I might post a couple of "nearly done" photos. Of course we all know there is no such thing as near done as there will always be something to modify in a DIY project.

Some of the progress since I last posted...

Finished the new Z axis and fit it in place. Needed to make few new temporary brackets which were replaced by other temporary brackets with some final brackets on the horizon.

The chatter I once had is now gone and cutting at faster speeds.

I remade the Y axis end plates once again, and as a result I had to move the Y axis ball screw which meant more temporary brackets.

Made a new alloy motor mount for the Y axis.

Finally put the second X axis ball screw in place and made associated pieces to make it fit like spacers etc.

Bought a water cooling kit the other day with the intention of replacing the big bucket of water under the table with a fan cooled radiator setup on the Z axis so I can get rid of a lot of plastic water tube.

Just need to reload all the CNC software back on my laptop after a soft HDD fail and I can start making parts.

Think I will make the radiator bracket first, already have a place and design in mind.

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Adverse Effects
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Post by Adverse Effects » Wed, 27 Jan 2016, 00:50

realy looking good

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EV2Go
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Post by EV2Go » Sat, 30 Jan 2016, 02:51

Cooler ready for mounting...

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Adverse Effects
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Post by Adverse Effects » Sat, 30 Jan 2016, 03:31

that looks like a clean cut did you dress that cut after the mill?

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