ATC Spindle Part 12: Making a Sheet Metal VFD Operator Bracket

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Today we're making a sheet metal bracket for the new mill spindle controller--using the new mill spindle. Tool inception.
Tools shown in this video:
*This site contains affiliate links for which I may be compensated
6" Bending Brake Vise Jaws (Amazon*): amzn.to/3k78aUQ
Wilton 6-1/2" Tradesman Vise (Amazon*): amzn.to/33fqPXz
Shars 8" Dial Height Gauge (eBay*): ebay.to/2APqM7E
Loctite 414 Super Bonder Super Glue (Amazon*): amzn.to/2ZsZn7A
Shars Ultra Precision 1-2-3 Blocks (pair) (eBay*): ebay.to/2RxwqWc
HHIP 2-4-6 Blocks (pair) (Amazon*): amzn.to/2Wi03eM
Haimer Zero Master Mini 3D Sensor (Amazon*): amzn.to/2PVA7mn
Haimer Short Probe 0.2" Veraion (Amazon*): amzn.to/32Dl9Ir
Shars 440V 4" Mill Vise (Amazon*): amzn.to/3hZooyD
Noga MC1700 Mini-Cool Kit (Amazon*): amzn.to/2qgemiM
Noga MC1700 Mini-Cool Kit (Amazon*): amzn.to/2qgemiM
Grizzly G0704 Mill (Amazon*): amzn.to/32rutgP
Jorgensen Bar Clamp (Amazon*): amzn.to/32i0PeY
Allen Metric Metric Hex Key Set (*Amazon): amzn.to/2BVUYNw
Allen SAE Hex Key Set (*Amazon): amzn.to/2BsnIfP

Опубликовано:

14 окт 2024

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Комментарии : 180

@jobkneppers 4 года назад

James, I stick thin sheet metal with double sided carpet tape to a flat piece of material and stop milling 0,1 mm above the bottom of the part. This 0,1 mm keeps your part from moving. After this I just pour boiling water in between the part and the fixture plate which softens the glue and I can peel of the part. I remove the tape residue with white spirit and, depending on the shape, cut or saw the circumference loose. Afterwards I use a small chamfer bit with a tiny roller bearing on the end is a dedicated upside down router underneath a steel table (Makra KEG 250) to clean the shape completely. A file is also a way to clean the part. I use this all the time even with thick aluminium parts up to 10 mm or so. Maybe a helpful tip for you to. Thanks for sharing and best regards, Job

@leec2106 3 года назад

I was not yelling, but I did say your drawing showed it in the upper 2 holes. Thanks again. Lee

@EverettsWorkshop 3 года назад

The masking tape and crazy glue idea is genius, that can be used by us manual folks as well, thanks for sharing the idea!

@johnmarshall2660 Год назад

Hi James, I found your channel by chance but it was great, after watching John Saunders build an Arduino based CNC 5 years ago my journey started, I live in UK, I eventually finished up with a 2.2kw Spindle Motor and Huanyang Invertor on a third sctratch build CNC Router and I use Mach 3 also I need an RJ45 controller after seeing yours, doesnt get used a lot as I seem to spend more time on Electronics and Model railway, PCB Design, 3D printing and designs I do on a copy of Solidworks and Sketchup being retired plenty of time, also I love your Leadscrew convertion on the Lathe ... I will be watching more videos for ideas Thank You .... Regards John

@madisonrollings1845 3 года назад

You can also use double sided tape to hold sheet metal parts like that. Nitto P-02 is what I prefer. It doesn't leave any residue behind. Alcohol solvent acts as an off-on switch. Also, try fewer flutes on your endmill when cutting parts like this. My first employer would routinely use 1 flute endmills on their router table. They used used an oil mister as coolant with a non diluted machining oil.

@klaasbloem 4 года назад

Nice first job with the new ATC spindle!

@AllenCavedo Год назад

Amazing hold down method.

@bassgojoe 4 года назад

I’m impressed you can concentrate on your work while also doing such a thorough job filming. Nice work!

@bobuk5722 3 года назад

Hi Folks. I ordered an 8 inch set of the vise (vice!) bending jaws from the US via Amazon UK. Not available over here as far as I could see. They arrived within a few days and are very, very good and a joy to use. Excellent product. Worth the money. BobUK.

@belatoth3763 9 месяцев назад

Simply astonishing!

@cwgreen1938 4 года назад

James, beautiful job. Looks better than factory produced parts.

@MrPatdeeee 4 года назад

Awesome James. It is indeed a joy to watch your wizardry. Thank you kind Sir.

@billstrahan4791 4 года назад

I've found that repeating the engraving pass by itself often removes the burrs. If that doesn't get it, and it's the last operation for the part I'll adjust my Z by .02mm and run the engraving again and that almost always gets it. I usually post my full operation plus the engraving separately so I have the engraving file by itself to run. Good work as always!

@Clough42 4 года назад

Great suggestion. Thanks. I should probably do some experimenting. Supposedly this particular tool can make clean one-pass cuts.

@michaelmiller3359 4 года назад

One thing I am an aircraft mech you never want to scribe aluminum (we use a Sharpie pen) , that will cause a crack with vibration we are constantly sanding out scratches for this reason. Love your videos keep up the good work

@kjmcf68 4 года назад

That makes a lot of sense for aviation purposes. This is a bracket for a controller.

@spehropefhany 4 года назад

Yes, I was thinking unnecessary stress risers. Just spent a day remaking a hardened steel part that snapped because of a thin (0.35mm) slot so the lesson is fresh.

@michaelmiller3359 4 года назад

@@kjmcf68 I understand it is bad habit, most of the time it will crack when you bend it using thin sheet metal

@combin8or 4 года назад

I was thinking the same thing, but I convinced myself that wouldn’t really matter since it’s on the inside of the bend.

@davebroere9078 4 года назад

just set up a tool with a sharpie pen. - best of both worlds. also can be chemically erased after bending.

@CCCfeinman55 4 года назад

26:21, but I thought you were going to use the upper pair of holes...will you catch it? 26:44, ah! There you go! It really does look better at your preferred location. Nice work! Warts and all, this is one of the best RU-vid channels going....probably because of the warts a little less than because of the caliber of your work, but both are instructional.

@TrPrecisionMachining 4 года назад

very good video..thanks for your time

@TomChame 4 года назад

Beautiful job and I love the bending jaws. Thanks.

@stu-po 4 года назад

Your workflow is a thing of beauty!

@airgunningyup 4 года назад

brilliant..youre attention to detail is priceless.

@k2smd 4 года назад

carpet tape is double sided and holds very well. saves a few steps

@ronwilken5219 2 года назад

James, I told you it was in the wrong holes but you "woodent" listen. Also you need a cable clamp under the top screw to remove the flex off of the connector, cat 5 I'm assuming. I also hope that all your cat 5 is of the stranded variety or the constant flexing will end with broken conductors inside the insulation which can be difficult to find. The engraving needs highlighting in red or black. Maybe both. Regards from banana land, Ontario.

@MR-um5wj 4 года назад

You're so lucky to be able to clean or just take your toolholder by hand .... if I do the same, it will rust on the day !! Gloves are my obligatory companions Btw thank's for your time sharing, keep going !

@Clough42 4 года назад

Yeah, living in a dry climate has its advantages.

@robdonaldson4837 3 года назад

Nice job. The vice mounted bending tool is too easy. Think I’ll go and pick up a set as well. Love the engraving as it finishes off the part very well. 👍👍👍

@samvoelkel2046 4 года назад

I learn something from each of your excellent videos. Thanks.

@xConundrumx 2 года назад

You need a vacuum table bud. Love mine.

@xConundrumx Год назад

Can confirm, it's the way.

@billdoodson4232 13 дней назад

I can see the need for a green ethernet cable to the VFD pad with a 90 degree RJ45 connector to point the cable in the "right" direction. The way it is at the moment is doing my OCD tendencies no good at all, god only knows what it will do for yours James.

@GiterdoneAllTaken 4 года назад

have you considered using the CNC to make the bending lines? using the engraving bit even, might automate just one more task.

@joeldriver381 4 года назад

chuck up a Sharpie! haha

@andarthome142 4 года назад

If the bendings are all in the same directions you can, you can't engrave on the bottom side 😎

@ww55d 4 года назад

@@andarthome142 i was originally thinking of the cnc to engrave the lines but the backside presents a problem

@steinmargunnarsson3709 4 года назад

@@ww55d You can mark them by milling small slots on the edges

@somebodyelse6673 4 года назад

@@ww55d - Bend lines don't have to be done to .001" accuracy, flipping the part and doing it in two operations would still be more than accurate enough.

@dariushmilani6760 3 года назад

Great project James, just don't forget to put back the two setscrews for the bottom two holes 👍😂

@canadianavenger 4 года назад

Nice job, looks great. Really enjoying following along with this upgrade. One suggestion would be to put some kind of boot or cover over that RJ45 connector, as they are not sealed or protected in anyway from chips or coolant. I realize you placed it fairly high up to reduce this, but I would still suggest protecting it somehow.

@joeldriver381 4 года назад

I have had similar gummy issues with 3003- Chip welding was a major issue. LOL- I was also talking to the screen the whole time you were putting that in the bottom holes. Nice work!

@ADBBuild 4 года назад

If you put a thin sheet of telfon in between the part and the concave jaw when bending, it will help eliminate the marks left from the jaw.

@Clough42 4 года назад

Great idea!

@shrikedecil 4 года назад

Epoxy/paint/fingernail enamel in color of choice into logo + repolish face -> high-contrast logo on visible part. Even if you decide it's ultimately not useful here particularly, experimenting/researching a bit covers a lot of aesthetic variation that's *extremely* easy to add. And the hard part is the CNC chamfered logo :D

@bbrazen 3 года назад

Very cool video. I've had good luck bending 6061 if you heat the bend area first then let it cool to room temperature before bending.

@Clough42 3 года назад

This world suggest that the T6 temper is more of an issue for bending than the actual alloy.

@orange-micro-fiber9740 4 года назад

2:45 I would love to see you model sheet metal stuff in fusion.

@sumduma55 4 года назад

I second this.

@Ale_Lab 4 года назад

Me too!

@annacermed4468 4 года назад

@@Ale_Lab me too also.

@kevinlynch3372 4 года назад

orange-micro-fiber Me too!

@bokkievatikaki5676 4 года назад

Hi James, If you run the last pass counter clockwise i.e. conventional milling, it would not leave the tape residue on the sides. If you check your cutoffs you will notice they are clean. Actually there is no reason why you can't run all the passes conventional. On softer material like plastics and in this case the tape the cutter will "clean" the sides instead of leaving cutting residue.

@jasonjoens279 4 года назад

Excellent work! This video and the F3D sheet metal design video you made to go along with it taught me a great deal, and have given me a really good bit of knowledge to get started learning to do my own small sheet metal parts. Thank you for the time and effort you put into sharing this!

@billstrahan4791 4 года назад

Also, you would love flood coolant! I messed with many different approaches to mist and mql coolant/cutting fluid. I put off switching to flood on the 1100mx for months. Should have done it day one. Nothing sticks, chips are evacuated (my system is heavily modified) and I can operate at speeds that would have been an almost instant gummed and snapped end mill in the past. The occasional mess occurs, but it is totally worth it!

@RobertLopez66 3 года назад

Amazing series. I can’t wait to see what you can do with this thing.

@gordonjones1516 4 года назад

They make a network cable with a 90 degree bend that would plug into the controller nicely and help streamline the setup.

@Clough42 4 года назад

Got a link?

@pdj26 4 года назад

Love your videos ❤️ if you keep posting I'll keep watching💪💪 very cool😎😎thank you for sharing👍👍👍

@pdj26 4 года назад

Currently printing some of your Tool storage boxes from thingerverse drag and drop print Thank you for Sharing

@_frio_ 4 года назад

Yes, sheet metal demo

@MrCrankyface 4 года назад

Wow, that cutter sure is moving along! Really happy to see how well this came out for you. You have definitely inspired me to try and make a spindle/head(considering replicating a bridgeport style but a bit easier construction) for my old horizontal mill in the future!

@argee55 4 года назад

Thanks for another fine project video.

@Mistakeful_Learning 4 года назад

It doesn’t look like a grizzly anymore. Very interesting project. Have you ever thought about filling the engraving with some black or red paint to make it stand out on the aluminum?

@combin8or 4 года назад

Green paint!

@Clough42 4 года назад

I did that on a control panel a while back. It looks sharp.

@Jonnywoods_049 4 года назад

Seems to be cutting great , I’ve found the tape method works best if you cut shy of full depth by a thou or two and either use a simple debur tool or flip it and champher . Tape gums up cutter instantly

@ligius3 4 года назад

You could use the engraver to mark the bending lines. Or make a sharpie attachment, though it would be a bit scary having that thing in the spindle.

@Clough42 4 года назад

I was planning on engraving the bend lines until I realized two of the three needed to be on the other side of the part.

@bernhard_derProtoTyp 4 года назад

I really enjoy your videos! Two tips: I had good luck re-running engraving toolpaths to get rid of a burr. sometimes just ever so lightly lower in z. and I have the same vice bending thing (or looks very similar at least) the "bottom" V part is a very rough casting on mine. only the V is ground but the top surface where the sheetmetal touches initially is quite rough. the stuff is not hardened and I was able to file and polish it a bit to get way less marring.

@misterfixit1952 4 года назад

Next time chuck up a tungsten Tig rod in a tool holder and have the mill scribe your bend lines. I use Tig points for all kinds of scribing, usually in a mechanical pencil body. They are cheap always available (in my shop) and they stay sharp, regardless of the material being scribed. Also, easy to resharpen, if needed. My Tig welding is bad enough that I have plenty of practice repointing rods.

@richardcurtis556 4 года назад

I love that bending attachment for your vise. For machinability with non-structural strength you might try 3004 in the full hard (H 19) condition.

@MichaelLloyd 4 года назад

Chris @ Clickspring does a lot of work holding with Superglue. I"m always amazed at how well it holds. "Murdering the fly" or performing life altering surgery" :o) The modifications are outstanding! Well done (as always)

@DZMech 3 года назад

awesome! that looks really nice!

@FarCryFromSanity 3 года назад

Clough, watch the Titans of cnc video on coolant methods, when you spray mist on the front face of the tool and it goes behind a part, it doesn't get coolant any more. Then it gets chip weld and recut

@LarrysMachineShop 4 года назад

Awesome job, As always. Yes++ for Sheet Metal Fusion Video

@jescheffler 4 года назад

Congrats on the successful first "real" cuts. Any plans on putting doors on your enclosure and using flood coolant?

@davebroere9078 4 года назад

I’d like to see you build new stainless steel way covers for the Z axis of your machine. Those bellows-type covers always look so messy. This would be a great opportunity to see you do a sheet metal design on Fusion 360. (Grizzley’s 12” mini-brake is relatively inexpensive.)

@makosharkcnc7730 4 года назад

WELL DONE very clean job

@TheJR914 4 года назад

Nice job. Is the remote VFD display panel for control and display or is Mach3 controlling speed doing the CNC operations? Very neat set up.

@Clough42 4 года назад

THe remote panel today. MACH3 at some point in the future.

@rhost714 4 года назад

I just purchased that same wilton tradesman vise from Amazon. They literally shipped it in a cardboard box with the little packing pillows. Handle and screw were bent. With the pandemic, I won't be able to get a replacement from wilton till Dec or January due to shipping delays.

@somebodyelse6673 4 года назад

Handling during shipping must be horrific if they managed to damage a VISE.

@misterfixit1952 4 года назад

I think amazon must be having trouble hiring packers who can think. I just received a shipment of hard drives with no packing at all. Just 2 drives rattling around in an overly large box. I'm surprised even one spun up. The second one just went tick, tick, tick..........

@vladanovakovic87 4 года назад

Love to see your video about sheet metal in fusion 360 👍

@Cromwell648 4 года назад

Fantastic.

@ajfreeze215 3 года назад

Love the videos! Love that little vise press brake! When did you get that vise and where was it made? The link you have goes to a vise that doesn't show up in Wilton's amazon store, and there is a link to Newer version.......I'm hoping this is an older version that is made in the USA......

@matthewhelton1725 4 года назад

You didn't murder the fly... you returned it to God.

@bradley3549 4 года назад

Have you looked into single flute bits? At those higher RPM they make a world of difference on aluminum.

@Clough42 4 года назад

I have thought about it, but not yet tried one.

@tiredoldmechanic1791 4 года назад

I suspect you will either remake the bracket or make a backing plate for the plastic controller.

@pauljeffery 4 года назад

When are you going to finish the leadscrew project

@FriedrichKegel 4 года назад

13:04 "This footage is realtime not speed up" - people over at the Datron headquater rolling laughing on the floor^^

@davewilliams6172 4 года назад

and I thought the old head was fast compared to my old Emco FB2

@Clough42 4 года назад

Yeah, for sure. Until you compare the price.

@FriedrichKegel 4 года назад

@@Clough42 Haha I know, you made a super cool project here! Just got a second hand one myself - decent 12m/min

@Clough42 4 года назад

@@FriedrichKegel yeah...that's fast.

@LayerCakeMakes 4 года назад

How do you feel about the new limitations that were put on the free version of Fusion360? Are you impacted or do you already have a paid subscription?

@Clough42 4 года назад

I'm not using the hobbyist license. I assumed from the very beginning that Fusion would not be free forever. (Or that they would keep "something" free, but I would want more than that.) When I started using it, the viable alternatives were SolidWorks, which is very expensive, FreeCAD, which was unstable when I tried it, and OpenSCAD, which is a completely different kind of tool. So here we are. :)

@trialnterror 4 года назад

I found 5052 bends easier but your right it gums when machining

@reddcube 4 года назад

The bluetape / super glue trick work faster if you spray CA Activator on the other side.

@Bigwingrider1800 4 года назад

When i make brackets like that i use wood in the vise and screw it down. Save the plate of alum, besides and coolant may loosen up the tape or glue..prototype kinda guy here...

@Clough42 4 года назад

I was worried about the coolant releasing the tape, but haven't had trouble yet. When it goes one day, I'll try to get it on video. :)

@piccilos 4 года назад

You should look into getting a jog pendant for mach 3.

@patchvonbraun 5 месяцев назад

You're a little nervous? The "machine" I'm currently working on weighs in at 5.6 heart-pounding tonnes :)

@FEV369 4 года назад

Thx for the work!

@mrx.2233 2 года назад

Hi James, In terms of vairous metal grading is there a site where we can reference diff kinds of metals.

@osgeld 4 года назад

oh I got to have that bending tool

@leswakeham3596 4 года назад

As always, whenever you're trying something new / different, without fail "there's a fly in the ointment somewhere".

@JamesChurchill3 4 года назад

Your Fusion360 workflows are always so professional, how will the new changes to the hobbyist license affect you?

@Clough42 4 года назад

I'm not using a personal license. From the very beginning, I assumed the day would come that the tool (or the version I wanted) was no longer free. I had to make the same decision with the Adobe tools, moving from a student version to retail upgrades, and now to a paid subscription. I didn't like it, but the value was there for me, so I paid.

@davebroere9078 4 года назад

@@Clough42 I get it. I made the move to paid F360 last year too. I’m totally hobyist so my reasoning was a bit different. F360 is an extremely active development product. What little it costs us to do a yearly license keeps this development going. I can live with that.

@KyrychenkoAnton Год назад

I wonder if its possible to add high speed spindle as a secondary spindle on the side of the existing one, so that we have the best of both worlds.. Or is it going to be too unstable because of speed spindle point of pressure will be not at the exact center of milling table, so saddle/dovetails will flex, you havent though about it?

@KyrychenkoAnton Год назад

having though a bit about it though - 4th axis for HAAS that I saw have even bigger overhang xD..

@EngineeringSpareTime 4 года назад

Nice spindle! I built a CNC Milling Machine from scratch (including the ATC) - you might enjoy watching it :)

@spehropefhany 4 года назад

Nice. What RPM/feed were you using for the 1/4” endmill? Sounded pretty fast.

@Clough42 4 года назад

12KRPM, 54IPM, .0015IPT. I do most roughing (adaptive clearing) in 6061T6 at 12KRPM, .002IPT, 72IPM, .0625" WOC, .250"DOC.

@spehropefhany 4 года назад

@@Clough42 Thanks!

@somebodyelse6673 4 года назад

---- adds CNC vise to project list, for bracket bending ---- :-)

@eatonmotorworks7531 4 года назад

Nice work! Have you used double-sided tape from McMaster? Works just as good & its exactly.007" thick. Faster setup time & cheaper if you need to cut multiple pieces. Either option gets tricky if there's a slight bow in the material.

@ADBBuild 4 года назад

I like using 3M 467MP. It's incredibly sticky, resists solvents and is very thin (.002"). Bit of a pain to clean/rub off, but it does hold VERY well.

@spehropefhany 4 года назад

Andrew Bird 467MP is what I specify for permanent graphic overlays - it holds very well

@eatonmotorworks7531 4 года назад

@@ADBBuild I haven't used 3M tape on the CNC but this is what I use. Hardly any cleanup. The only thing to keep in mind is the subplate used should be surfaced flat to eliminate any pockets. Then both pieces cleaned super well before applying. .010-.015" doc with even step downs works very well. Keeps the aluminum from gumming up the endmill. Link to the tape I use - www.mcmaster.com/double-sided-tape/light-duty-mounting-tape/ Another machining Buddy uses a slightly more expensive tape like this, I've compared and this tape here works the best.

@Domesticabbage 4 года назад

Thats a very nice tool chest that you have your knife in. Do you know the make and model?

@Clough42 4 года назад

It's a Kennedy. amzn.to/3hq9n8t

@Artnovetor 4 года назад

Muito bom 👍

@bfx8185 4 года назад

I'm using double-sided tape instead of your solution;) But it's really nice spindle.

@johnhoffman8830 4 года назад

Hey what software are you using with your camera? At about 21 minutes into the video we see three cameras on a screen in the back ground.

@Clough42 4 года назад

I'm using an HDMI quad-view box to display all of the cameras on one monitor while shooting.

@MakeTechPtyLtd 4 года назад

Well done!

@wags9777 4 года назад

I though the bottom holes were for coolant? Edit...lol you got it.

@makerbit3970 4 года назад

Can you still use the “fly cutter” with the higher speeds? If not, what will you do for a large facing operation, and aren’t you going to miss that tool?

@Clough42 4 года назад

I think a fly cutter would be sketchy with this setup, and I already miss it. I've done some experiments with a 1/2" carbide end mill, and the results are promising. instagram.com/p/CFzawWwp6y3

@DoRC 4 года назад

What is the purpose of doing the drilling first in those holes as opposed to just going straight in with the end mill?

@sumduma55 4 года назад

I asked this of someone else a while ago and the answer was chip management. Perhaps someone can confirm. But the end mill doesn't pull chips upwards to evacuate the hole like a drill bit does. Its more of a cutting motion that flings them more to the side. So once you plunge into the work material, there is no place for them to initially go and you run into that chip gumming the cutter and welding to the endmill problem that breaks them. I think the type of end mill and material plus the experience of the operator plays a role in it too.

@P8ntbaLLA56 4 года назад

Is coolant going into the operator panel a concern? Or is it IP rated? Failure mode could be sketchy until you get to the estop.

@Clough42 4 года назад

Yeah, that could be a concern. I've never had coolant get that high on the spindle housing. All of the electronics on the original head were in a similar location without issue, but it's something to keep an eye on.

@peterciurea7771 4 года назад

Make yourself a vacuum plate fixture to hold stuff like this

@air54plane 4 года назад

nice !!!

@trialnterror 4 года назад

Did you show how you made you toolbox tool holders in your drawers?

@Clough42 4 года назад

Yes. ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-kJDb__3mCfo.html

@trialnterror 4 года назад

Clough42 thank you

@dollarsamount3805 Год назад

Send us full video on how you’ve designed this machine in fusion 360

@c4fishfood 4 года назад

What if you replace the cap that holds the bearing with a piece that has a friction lock onto the screw shaft (the cylinder part near the handle)? That will let you lock the vice as needed