DIY CNC machine directors cut 3of3 - FINISHED !

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Well, here it is! This is the final part 3 of a heavily edited shorter version of the original build series which ran for 24 episodes. I've also added timestamps so you can come back and find certain sections. At the end of the video I explain how to download the CAD for free. A written guide is below.
Free CAD download (Fusion 360 format):
1. Link to the mycncuk forum post (#1) is below.
www.mycncuk.com/threads/15107-...
2. Click the link then scroll part way down post #1 and there is an optional link to the British Red Cross Ukraine to help with humanitarian efforts. They have a Paypal option so it is nice and easy, should you wish to donate.
3. Then scroll down to the bottom of post #1 and there is a link to the free download file itself in F360 format.
This CAD is completely free, but if you want to support the channel I'm experimenting with a "Thanks" button which if I've done it right (!) should appear someone around the video which I think allows you to send over a few dollars to help the workshop funds. Again, no obligation at all, just enjoy the videos.
You don't need to be a forum member to download it, but you may wish to join and access the wealth of information from all the experienced builders on there. There is also a build log section which is well worth a browse. Then when you are ready start a thread, talk about your project, then ask all the questions you want !
TIMESTAMPS
0:00 - Introduction to Mk4
0:18 - Mk3 CNC machine teardown
0:44 - BED: Modifying the bed
1:52 - BED: Building up the sides
3:10 - BED: Adding the crossbeams, end plates, and cable trays
5:45 - BED: Epoxy levelling the X axis - PROBLEMS !
7:34 - BED: Epoxy levelling the X axis - SUCCESS !
9:49 - BED: How flat are the 20mm Hiwin Linear Rails ?
11:53 - BED: Lateral alignment of the X axis linear rails
12:50 - BED: Checking vertical alignment of the rails with a precision level
14:15 - GANTRY: Installing the moving gantry
18:46 - GANTRY: Epoxy levelling the Y axis - SUCCESS ! (2 jugs method)
22:54 - GANTRY: Lateral alignment of the 20m linear rails
24:25 - Y & Z AXIS: Installation, pre-load adjustment, MOVEMENT !
27:16 - Cable trays and drag chains
29:20 - Z AXIS fitting the steppers
30:53 - FIRST FULL MOTION CHECK !
32:31 - Proximity sensors
34:44 - Testing the sensors for home repeatability
35:58 - Spindle power cable re-fit (longer cable), basic electrical checks
40:52 - Spindle installation (1.5kW Chinese Water Cooled ER11 collet)
42:02 - Spindle to VFD connections (motor UVW, spindle & shield ground)
42:28 - Spindle run up testing 0 - 24,000 rpm
42:57 - Overview panning shots of FINISHED machine (mechanically) !
43:49 - Water temp sensor (spindle cooling system)
44:27 - Skimming the bed (get the surface in plane with the rails)
44:47 - Belt safety shields
45:21 - Squaring / homing the X axis with dual stepper motors
46:48 - Tramming the spindle (make it perpendicular to the bed surface)
49:24 - MACHINE FINISHED !
49:37 - Basic TEST CUTS, what can it do !
51:44 - How to get the free CAD download (Fusion 360 format)
NOTES:
This is probably not a first time machine and you will need a lathe and ideally a milling machine or someone with these tools to help you make the custom parts.
I don't have a cutting list, parts list, drawings, etc. but the motors, screws, rails are all standard sizes for CNC machines.
Provided as-is and I can't support modifications. Also since it was imported into F360 from another package there is no design history to roll back. Use it for ideas, inspiration, or incorporate some or all of the parts it into your DIY machine. Or just have a look around and see how I did it! I think it took about 18 months of on/off design, multiple iterations and dead ends.
Good luck with your project !

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27 июл 2024

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Комментарии : 61

@texasbowhunter2509 Год назад

What an amazing gift you have in the design and engineering feat of these projects I have watched from your CNC and the Drill conversion you developed on the tube...The attention to detail and creativeness is such a pleasure to watch...Keep up the GREAT work and those amazing projects you have created

@routercnc9517 Год назад

Thank you. It keeps me entertained . . . !

@saeedkamali2032 2 года назад

l've seen all your video (playlist making router ) you doing amazing , thanks for your sharing experience with us

@routercnc9517 2 года назад

Thank you Saeed for following along !

@daan3298 2 года назад

Finally someone made a balanced gantry, good job! I've been thinking about doing same and also add linear encoders for extra precision on actual position vs calculated position.

@routercnc9517 2 года назад

Yes if your motion controller can take feedback then why not. The other option is servos.

@daan3298 2 года назад

@@routercnc9517 Servos are less precise though, they don't account for expansion and inaccuracies in spindles. Just a thought :) Good video, watched it fully and subscribed.

@routercnc9517 2 года назад

OK yes fair point. Good luck with your project, and if you are a new subscriber I’ve been upgrading my dress press for quite a while and still going!

@nathaniellangston5130 2 года назад

Great Video! kept me interested the whole way through! I really like the Z axis in this CNC. You almost always see the spindle hanging off one side rather than centered up like this!

@routercnc9517 2 года назад

Thanks. Yes I tried to max out the stiffness.

@revtmyers1 2 года назад

Very nice build. Almost makes me want to build another one or remake my current one to stiffen it up.

@routercnc9517 2 года назад

That’s the problem. This is my 4th machine !

@mightymoaman2485 2 года назад

Love the video and project man, cool to see. Would love to watch more test cuts, maybe even trying harder materials.

@routercnc9517 2 года назад

Thanks. I actually finished this machine about 3 years ago but people asked about the CAD so I edited the episodes together so people would know how the machine was built before downloading the CAD. That means I’ve been using it for a while a d cut steel parts. See the go kart build video on the axles where I cut keyways for example,. This machine is limited for steel as the spindle is high speed so does better in aluminium and wood. Steel is limited to small cutters otherwise they spin too fast. If you want to hog steel then a low speed mill is better.

@hippie-io7225 2 года назад

Lovely machine!

@routercnc9517 2 года назад

Thank you I’ve been very pleased with it.

@hendrikkruger6247 2 года назад

Hi, hope you still read old video comments. Have been looking at you design for this machine. Love the attention to detail. Could you possibly make a series on how you designed this machine in fusion. Start to finish type with narration on your choices and the reasoning and perhaps show the spin of for the atc spindle and belt drive configuration. A lot of fusion videos that people are doing is small parts with a lot of the difficult commands and setup already done. (like the rigid point for movements, where to source cad files from when it's not on macmastercar, how to do the the assembly design) if you could have a look into maybe something like that would watch it. You can maybe do a poll in your next video to see if there is interest. Thanks again for the videos, they are great.

@routercnc9517 2 года назад

Hi Hendrik. I only use F360 for the CAM and gcode creation. My CAD is done in another piece of software so I'm not really an F360 CAD expert, sorry.

@diy2130 2 года назад

Whole build still looks for me kinda madness)) BUT. But the video you made is so informative ive learned A LOT from it. Thank you very much!

@routercnc9517 2 года назад

That’s fine. This is about how I approached it based on my needs, expectations and standards. So if there was something useful then great, thanks for watching!

@broglet2003 2 года назад

A really informative summary of your build. It explained everything very well and showed a fantastic attention to detail. Thank you. I wonder how long it took?

@routercnc9517 2 года назад

I think it was about 2 years to build. Plus maybe a year on and off for the design.

@zwerne42 2 года назад

Rewriting my previous comment: I made some tests with the self levelling epoxy method and personally, I didn't find it to be a very good method to create flat machine surfaces. It was just too jelly to completely level once it stops flowing around, preserving small differences in height from the pour. This added to thermal expansion considerations between metal and epoxy, raised edges from the surface tension, rigidity and other problems in the video. Though I guess this could be a reasonable way of getting very large areas close to flatness, relatively easily and without too much work. (And for who still would want to try it, a few methods could be used to improve the results. Like building wider and longer epoxy canals, stretching beyond the intended rail-mounting area. This would keep the raised borders away from the edges of the rails and be removed after the epoxy hardens.) I'd consider machining the best way all-around to make mounting surfaces, IF the machinists know what they are doing and their machinery isn't scrap. (I once had a part from a shop worse than 0.2mm in parallelism over 40cm, straight out of face milling two opposite sides. That would be way worse than the self levelling epoxy in the video) For someone who doesn't have access to a machine shop, I'd consider shimming a better way of aligning rails or a plate to be used to mount the rails. Measuring and with whatever tools are available, like precision levels, straightedges and dials or fancier stuff could allow someone to build a machine as accurate as they are patient. As if it can be measured, it can be adjusted :p And hopefully none of the shims and bolts will get loose over time and throw everything out of alignment. I got my most interesting results during tests on precision scraping. With measuring equipment, reference surfaces and a good approach to measuring, mapping and spotting a surface, an angle grinder can be used to "quickly" grind down high areas down to near flatness in a steel part, to be hand finished. I haven't tested this with parts too large to be taken to a surface plate. But while testing, in a few days I could get a 75x160mm part to read less than 0.01mm of variation over it's surface. (Thought at this level of accuracy, heat from hand-holding parts has to be considered as it can warp it. And walking around can shift the weight over the ground and throw-off level measurements if it's not solid enough.) This is a very laborious and time consuming method, but still being used to make the high-end michining centers today. Though I'd consider it too laborious to be practiacal actually. As longer and larger parts take an exponentially large amount of work and time. But It could be taken as a choice for building a very accurate machine. If time, work and measuring equipment are not a problem.

@routercnc9517 2 года назад

The epoxy cost me about £80 so was worth a go as some people had seen some success with it. The epoxy method has been discussed at length on the mycncuk forum and all those points were raised. Having tried the epoxy method (and failed/learned from the first attempt) I agree with you and would go with machining and shimming next time. But I don’t have a machine large enough so I would have to find a machine shop (£800? to machine a completed bed or gantry assembly), or perhaps find a friend to machine just the raw stock and then with one surface flat adjust and shim it into the assembly, then finally shim or scrape the rail surface. I’m sure, as you describe, it can be done. So for anyone reading this and considering a build those are your options. I did have a comment from someone that they just built the machine without any leveling or consideration so it depends on the level of accuracy you are aiming for!

@oldestnerd 2 года назад

Very, very nice.

@routercnc9517 2 года назад

Thank you!

@DelisonJunio 2 года назад

Do you work in a mechanical engineering or related field? I'm really amazed at all of this and have been learning a ton!

@routercnc9517 2 года назад

Yes my background is engineering so CAD, design, and analysis is familiar to me. But I’ve also learned a lot having built 3 previous machines and been a member of the mycncuk forum since around 2009. Thanks.

@TheJuicyBurger 2 года назад

Hello! Beautiful machine. I am so glad to see someone have a go at the balanced gantry design. I am extremely curious though, with your level of attention to detail and patience, why make this out of aluminum? I understand that it's cheap, readily available and easy to work with, but on a list of materials to make a cnc router/mill out of it's probably at the bottom. With your level of attention to detail you could have used any number of better materials for similar or less cost that would function much better, specifically at vibration damping. Very eager to hear your thoughts because you clearly have an above average understanding of the fundamentals on all other aspects of machine design.

@routercnc9517 2 года назад

Because I can buy ecocast aluminium tool plate which has the surface ground flat in custom blank stock sizes. Then minimal machining to make the parts. I used thicker parts to add stiffness which would more than compensate for the higher inherent damping in cast iron by pushing resonances higher in frequency where the excitation levels are lower.

@flikflak24 2 года назад

i hope you also filled the non moveing extrusion with sand or concreat or epoxt granit ( more waight and / vibration absorbing in non moveing parts is always your friend )

@routercnc9517 2 года назад

I thought about it during the build but it blocked access to some of the fixings inside the section so I didn’t do it in the end. Machine performs well, but it would have helped a bit more. Thanks

@flikflak24 2 года назад

@@routercnc9517 also the bed and the ones going up to where the gantory/beam that the liniar ways are mounted to ?

@routercnc9517 2 года назад

I thought about it there too but did not do it in the end. I think it took 2 years to build so was keen to actually finish it. If I built it again I would have put something in the bed at least. Thanks

@flikflak24 2 года назад

@@routercnc9517 good to hear and tanks for the reply i like the dual screws for the Z axis and support / rails on both sides on the spindle and not just one side as most do ( technically is good enough for huby to only have on one side but its good practis to have on both sides like you have ( less tilt. more support on the spindle and also way less pulling away force in that rails since it then just push into the ones on the other side ) if i may recomend a endmill for finishing in alu i would recomend the yg1 alupower 3 flut ( though the 2 flut is also really good after my own experiance ) at pretty much full rpm and 0.005-0.007 feed pr tooth taketing about 0.2 mm off the wall and 0.01-0.005 off the floor ( floor only still pretty much max rpg and 0.005-0.007 feed pr. tooth and 0.1-0.05 depth and about 93% sttepover and same stepover with a faceing tool so you have pretty much full contakt over the whole tool and and just one side where it can micro tilt a little to the side ( witch every machine does no matter what. all we can do is use cutting strategys to minimise that like going 93% stepover when we can. done that myself alot when i programed machines and ran them( way better surface. faster and easier on the machine structure. though a little harder on the spindle. witch you can ajust by feed or doc ( just never go less then what the tool is designed fore for a given material witch reminds me the longest af tool last is in the box not getting used xD and secend longest is being run as it should. not pushing it enough actually breaks the tool faster then pushing it had enough

@farhanchoudhre6962 Год назад

Hi. Its a cool Project. I am planning to make gantry cnc as your`s but all parts will be iron casted insted of aluminium 15mm thickness with aerospace ribs. i just want to know How did you wire up two z axis

@routercnc9517 Год назад

The Z steps output on the AXBB pin has 2 cables connected, one to each driver. I checked with the AXBB manufacturer and they said it would be OK with the current draw to control 2 drivers from one pin. Been running fine for years.

@TheRainHarvester 2 года назад

Did you slow rpm on your chop saw to cut aluminium?

@routercnc9517 2 года назад

The chopsaw only has one speed but cuts aluminium fairly well. My bandsaw had a variable speed so I can vary it for steel or aluminium. Thanks

@zwerne42 2 года назад

Hi again! First :p Btw. Have you covered linear rail/ballscrew maintenance at some point?

@routercnc9517 2 года назад

Hello again. No, I've only showed how to grease them. I wouldn't claim to be an expert there and for my DIY use once they are greased up I've not gone back other than cleaning off obvious clips etc. and all has been well for many years. If someone knows what the recommended service interval and process is then by all means post it here . . .

@routercnc9517 2 года назад

RU-vid being weird again. I can see your epoxy comment in my email but not in the comments section - yes it’s a bit tedious but I did get it to work. I think machining surfaces flat would be preferable if you have access to the equipment then shimming anything minor.

@zwerne42 2 года назад

@@routercnc9517 Yea I deleted it. After posting It just didn't feel as useful as I wanted it to be. I could rewrite it better.

@routercnc9517 2 года назад

Ok no problem. I’ve had RU-vid not show a post that was in my email many times. I can’t reply and it makes me look rude!

@user-zb5vp3km2i 2 года назад

훌륭합니다 당신의 기술이 참 좋아보이내요

@user-zb5vp3km2i 2 года назад

전기 전자 기계에 대한 이해도가ᆢ있어야

@user-zb5vp3km2i 2 года назад

시쓰템이 ᆢ

@routercnc9517 2 года назад

“ that's great Your skills look great”. Thanks

@routercnc9517 2 года назад

“ Must have an understanding of electrical and electronic machinery”. Yes, just enough !

@routercnc9517 2 года назад

Second . . .too slow :(

@sjefkepoulussen2264 2 года назад

Beefy looking machine! what material were those test cuts, alu or steel?

@routercnc9517 2 года назад

Aluminium. The spindle is only 1.5 KW and is the limiting factor. It is basically a router motor not a milling spindle.

@LeeRobertsMe 2 года назад

Bravo 👏 :)...3rd

@routercnc9517 2 года назад

Thanks Lee!

@i.bcraftsman5977 2 года назад

Sorry I was far away from m phone

@routercnc9517 2 года назад

No problem. Good to see you back again.

@user-yx3my1tr5o 2 года назад

as beautiful as it is useless. Reinforced where not needed, weakened where needed. A classic portal needs only a little reinforcement so that it surpasses your design in terms of rigidity. But still, the classic portal will not surpass a simple movable table-rigid spindle, where the cutting load is always located in the center of the guide-carriage system. Including the choice of materials, their fastening methods, the design geometry, it is possible for you and gives you the ability to adjust for increased accuracy of the processing geometry, but the rigidity at the same time turns out to be terrible for such a massive machine, which is what we see.

@routercnc9517 2 года назад

I needed a very large cutting area to cut wooden panels so a moving gantry was the best option for me. A moving table design would be too large for my workshop as it needs a lot of space. Because I wanted to also cut aluminium I built it as stiff as I could. I’ve been using it for many years and made lots of things with it. I’m pleased with it and it fits my needs. Thanks

@user-yx3my1tr5o 2 года назад

@@routercnc9517 I just wanted to say that it was possible to make a mobile portal much cheaper and easier to maintain, but if you like it, that's good -)