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Copycat Mill Build.

Discussion in 'MACHINE BUILD LOGS' started by Blackhawk, Dec 12, 2012.

  1. Blackhawk

    Blackhawk United States Active User Active Member

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    I'm building the same mill as steve and was looking for advice from the forum members as i go. i was having problems with the electronics untill i got a link from a forum member from steves build and it proved to be the solution. here is the link to the video. <iframe width="420" height="315" src="http://www.youtube.com/embed/yvfn82KQoC0" frameborder="0" allowfullscreen></iframe>
     
  2. Blackhawk

    Blackhawk United States Active User Active Member

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    Woops, video did not show, will have to research how to upload and repost.

    rob
     
  3. alandarkdale

    alandarkdale United States Active User Active Member

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    The link works so the video is available. It just takes an extra click.

    Dale
     
  4. OakRidgeGuy

    OakRidgeGuy Active User Active Member

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    Yes.. it did work.. just gotta hit the play button on the link.
     
  5. Blackhawk

    Blackhawk United States Active User Active Member

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    success, i got the 4200 running from the smaller driver so i know it works, now i just need to find connector for the big driver. does anyone know where i might find it?

    lanham
    Picture 3.jpg

    Picture 3.jpg
     
  6. Bugsyweasel

    Bugsyweasel Active Member Active Member

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    Last edited: Dec 13, 2012
  7. Blackhawk

    Blackhawk United States Active User Active Member

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    Thanks bugsy, I'll check that out.
    lanham
     
  8. Blackhawk

    Blackhawk United States Active User Active Member

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  9. Blackhawk

    Blackhawk United States Active User Active Member

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    ybrgmountplate.jpg doing this on a manual mill is taking a long time. This pic shows steves file and the coordinates i added from emachineshop. now i need to figure out what size bolts and what holes to tap and what size

    lanhamk

    ybrgmountplate.jpg
     
  10. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    my controller came with the plug?
    if you need help i can post the connections for that controller.
    there are far more connections than needed and it is easy to connect once you have the plug.
    ( I dont seem to be getting all the threads i reply in in my email? if you have questions and i dont reply pm me I'd be glad to help you)
    steve

    yaxiswithnotes.png
     
  11. Blackhawk

    Blackhawk United States Active User Active Member

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    bracket.JPG bracket.JPG second bracket done,

    bracket.JPG
     
  12. Blackhawk

    Blackhawk United States Active User Active Member

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    Got two extra holes in previous pic, i accidently reversed coordinates, hopefully its just cosmetic
     
  13. Blackhawk

    Blackhawk United States Active User Active Member

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    clut.JPG 4oz of blood i gave up to the 4 flute end mill god

    clut.JPG
     
  14. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    should not hurt anything, did you compare my measurements to your mill
    who knows if they are all drilled the same? the alignment pin holes are drilled after assembly i guess because they are not in the same locations on my mill table. so i did not install the pins
    steve
     
  15. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    yikes
    i learned real fast spinning endmills do not push flash away they suck it in
    steve
     
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  16. 7HC

    7HC Active User Active Member

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    If you need it urgently, you can walk into Radio Shack and get a 15 or 25 pin D-Sub connector, plug, or hood for about $2 each.


    M
     
  17. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    just a thought
    once you have everything figured out you should be using shielded wire for all the low voltage connections from the breakout board to the controllers to avoid problems such as false signals.
    steve
     
  18. DMS

    DMS United States Active User Active Member

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    I made the mistake of not removing an endmill from the spindle while setting up a part in the vice. Ran my fist into (spindle was off). Cut me pretty good. They cut people even better than aluminum...

    Also, shielded cable is good, but you need to make sure you ground your shield properly, or it doesn't do you any good. Usually there is what is called a "drain wire"; a bare wire that runs through the length of the cable and sits against the metal shield. Tie this to earth ground. Don't tie it to your power supply negative, that can just make things worse.
     
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  19. Blackhawk

    Blackhawk United States Active User Active Member

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    Steve,

    I checked the measurements before i started making brackets and it looks like it will fit.

    I got 100 feet of shielded wire from the same place as you.

    Do you have the demensions for the side brackets? I did not see them in the zip file from your build?

    7HC,

    I ordered the parts i needed for the controller from online, not bad for .54 but $6.oo shipping was high.

    Dms,

    thanks for the tip on the ground wire.

    off to make more brackets.





    brack.JPG
    This is the first time i have used a rotary table and jacked it up a bit.

    brack1.JPG

    brack.JPG brack1.JPG
     
  20. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    I'm headed for the shed now
    I will measure the side brackets/standoffs and post them this morning
    there was no drawing because none of the machining was cnc
    the coupling length makes a difference in the standoff length i will post my coupling lengths also
    your moving right along
    steve
     
  21. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    as i typed that it started lightning here
    it will have to be later, i'll post as soon as possible
    steve
     
  22. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    my standoffs on X and Y are 3" long 1/2" thick and height matches bearing mount plate height
    Y height 2.375
    X height 2.0
    my couplings are 1.5" long
    the mounting holes are 1/4-20 thread and I transfer punched them to align
    steve
     
  23. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    here is my mach3 zx45mill xml file
    it is the complete setup and present calibration of my mill
    you can unzip and copy this file to your mach3 ( c:\mach3 ) directory and as long as you are using a uc100 controller, you set all drive switches to match mine, your mill will be calibrated and ready to tune and set backlash.
    when you open the mach3 loader you will see zx45mill in the list of choices
    if you have the same ballscrews you will be all set to start
    steve
     

    Attached Files:

  24. Blackhawk

    Blackhawk United States Active User Active Member

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    Thanks for the file steve.



    Time for some dirlling and tapping.

    close.JPG

    close.JPG
     
  25. Blackhawk

    Blackhawk United States Active User Active Member

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    Steve,

    I want to see if my brackets fit before going further and an having a heck of a time find a bolt to use as a jack screw to get the mill bracket off, any sugestions?

    lanham




    photo1.JPG

    photo1.JPG
     
  26. Blackhawk

    Blackhawk United States Active User Active Member

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    Steve,

    I got it, Just needed the right amount of persuasion

    lanham



    photo2.JPG

    photo2.JPG
     
  27. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    the pins are tapered and have a thread in the center. i just found a screw and used a claw hammer to pull them. once they move they slide right out.
    your coming along pretty well. did you order the same bearings as i did? if so they will need to be worked on. they did not put a shim in mine between the outer races so i could not preload the bearing. to see if yours are shimmed, press in on the inner bearings with your thumb and forefinger to preload and see if there is movement still. if there is you will have to take it apart and add a shim inbetween the outer races. i used a thin wire bent around the inside of the housing.
    steve
     
  28. Blackhawk

    Blackhawk United States Active User Active Member

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    Thanks,

    i am heading to radio shack in a few to pick up some heat shrink and look for a bus bar and a power switch or two, any suggestions?

    lanham
     
  29. Blackhawk

    Blackhawk United States Active User Active Member

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    Steve,

    doing some wiring today, what are the three aviation connectors above your breakout board for?

    lanham
     
  30. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    at the present time i dont use them
    1 is for limit switch or inputs such as touch sensors autozero z ect.
    the second is to run and external relay for coolant pump through mach3
    and the third would turn the spindle on and off through mach3
    there are other uses I just wanted to bring all the inputs and outputs to the outside of the case. you cant get to them once everything is installed in the box. there is another wire you can see taped to the harness inside marked relay also that is extra
    steve
     

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