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rung fu clone RF-45 ZX45 cnc conversion

Discussion in 'MACHINE BUILD LOGS' started by jumps4, Aug 22, 2012.

  1. 7HC

    7HC Active User Active Member

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    I think it would be fair to round it up to a ballpark $5K to include various nuts and bolts, wiring, and probably the sheet metal for the enclosure, which would be an absolutely fantastic price for a 4 axis CNC RF45!


    M
     
  2. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    I had already rounded up to include those materials sheet metal is only $35 a 4x8
    and i included the new usb controller for $110.00
    steve
     
  3. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    the parts for the fourth axis came today so i have my hands full with projects.
    this table is a 90 to 1 ratio and as smooth as silk with no backlash so all i'll have to build is a motor mount and coupling. ( great buy for $299.00 )
    the 90 to 1 ratio mean really hi accuracy.
    at 2000 steps per revolution from the motor and a ratio of 90 to 1 that translates to 180000 steps per revolution at the index or .002 of a degree for each step.
    thats accurate if i can keep it all a really close fit.
    steve

    DSCF0389.JPG
     
  4. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    what a unexspected surprise i just got
    because the table was setup and came with index plates the mounting for the stepper motor is going to be really simple
    three mounting holes are already drilled into the face for the index plates to mount to, i just make a mount to fit the holes and out to the motor add a coupling and i'm done. and the height of the base will let the motor clear the table so no riser is needed. this isnt going to be a long thread
    steve

    DSCF0390.JPG DSCF0391.JPG
     
  5. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    I made the first part for the 4th axis motor mount on the zx45
    steve

    DSCF0394.JPG DSCF0392.JPG
     
  6. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    I made the second part for the 4th axis and for fun i timed the entire process on this one
    I made the drawing converted to g-code and made the part including tapping the holes by hand in 58 minutes
    i have to get a faster spindle for small cutters in aluminum to get any more speed but i'm sure i could have doubled the depth. i'm running coolant because of the slow speeds
    i cut this at 1970 rpm(too slow) 3/16 endmill 10ipm at a depth of .050 per pass ramped.
    the only thing left for the 4th axis is the spacer tube, 4 long bolts to assemble and bore the coupling to size to fit. put a cable on the motor and it's ready to use after calibration.
    steve
    [video=youtube;DcsYpc4I7mY]http://www.youtube.com/watch?v=DcsYpc4I7mY[/video]

    DSCF0396.JPG DSCF0397.JPG
     
  7. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    today i made the center spacer and bored out the coupling to fit the shafts. everything fit perfect so i am down to attaching a cord and plug and running it to calibrate. calibration will be simple since i know it is a 90 to 1 ratio and how many steps per revolution i have the controller set at.
    I didnt have to modify anything on the rotary table to add the motor and it can still be used manual.

    steve

    DSCF0399.JPG DSCF0400.JPG
     
  8. MGP

    MGP United States Active User Active Member

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    Looks awesome Steve!!!
     
  9. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    mgp
    going from the sherline to this has been amazing there is no work to making anything i want now
    steve
     
  10. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    I finished wiring the 4th axis and calibrating it. I made a short video of it simulating cutting a 10 tooth gear with the axis facing you to see it better this is a demo vid and would not do anything but break a cutter lol
    well: my mill is done and i guess this thread is done
    the only other thing i may do is mount the head on an 10" rotary table for easy angle settings and tramming but that will probably stay manual...
    you never know
    to everyone who was interested
    thank you
    steve

    [video=youtube;vAadS2KV_u8]http://www.youtube.com/watch?v=vAadS2KV_u8[/video]
     
  11. 7HC

    7HC Active User Active Member

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    Looks like that imaginary gear had big teeth, maybe a rear axle ring gear?

    Seriously though, I think you've been living the dream of some of those who have been following this thread.

    At some time in the future I hope to do the same with a larger mill, but for the moment I'm slowly CNCing my little Sieg X1.


    M
     
  12. MGP

    MGP United States Active User Active Member

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    That thing is sweet! Great Job Steve
     
  13. hq308

    hq308 Australia Active User Active Member

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    Great thread Steve but I don't think you're quite ready to close it yet.
    Personally I'd like to see some of the real projects you make with it and perhaps some video of it while it's doing it. :thumbzup:
     
  14. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    ok here are 3 videos of it making the z axis parts for my 9x20 lathe cnc conversion
    i will be able to move a lot faster when i get my high speed spindle set up.
    steve

    [video=youtube;gPAmatPMHno]http://www.youtube.com/watch?v=gPAmatPMHno[/video]

    [video=youtube;5Ui4_Ia7nzY]http://www.youtube.com/watch?v=5Ui4_Ia7nzY[/video]

    [video=youtube;T_za3fXQ6uI]http://www.youtube.com/watch?v=T_za3fXQ6uI[/video]
     
  15. DMS

    DMS United States Active User Active Member

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    How are you going to do the high speed spindle? Speeder? Additional bolt-on spindle?

    A faster spindle is something that I would love on my machine, so I am curious.
     
  16. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    I have not decided yet really, i'm thinking about 3 different types
    a water cooled 1.5 kw 3 phase with vfd for $245 er16
    a side mount driven off my original spindle er20
    a center mount driven off my original spindle er20
    I have put it on the back burner for now until i get the lathe done
    but i'd like to get to at least 8000 rpm
    steve
     
  17. Old Iron

    Old Iron United States Active User H-M Supporter-Premium

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    Great job Steve this has been a good threat, Even through I don't want to CNC anything I enjoyed watching your progress and movies.

    Paul
     
  18. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    thank you paul
    steve
     
  19. arvidj

    arvidj United States Active User H-M Supporter-Premium

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    Steve,

    What size rotary table is that? And the stepper ... what is the torque?

    Thanks,
    Arvid
     
  20. Analias

    Analias United States Active User Active Member

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    Steve, I'm curious how hard you would rate this conversion?

    I just completed building a CRP-4848 CNC router table. I have no prior experience with machining, in fact the only tools I had to start with were hand tools and a drill press. I have electronics and computer experience being an amateur radio operator and a systems admin/software developer for 25 years. I went on to buy the basic tools I thought I needed - radial saw, grinder, calibration tools, etc. I found the CRP-4848 pretty easy to build. I spec'd out the PMDX boards, the ESS controller, and all the electrical for the shop and the 220V spindle/VFD myself. It was challenging because I hadn't done it before, but it worked pretty much the first time I powered it up.

    How would that compare to converting the ZX45 to CNC?

    The biggest challenge I see is that most folks tackling conversions already have at least a manual mill or lathe. They can cut the parts they need for a conversion like this. The best I can do is cut aluminum, not steel. Once I had a mill, then I would expect I could pretty much tackle any project. I guess a lathe would be next :) I see myself being very cash poor for the next few years.

    -Freeman (Analias)
     
  21. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    the table is a 6" from wholesale tools it came with the plates and a tail stock for $299
    it is really well built and completely adjustable for backlash and be disengaged to free wheel
    the stepper motor is a 880 oz/in nema34
    there was nothing to adapting this table it was really easy.
    and i did not have to modify the table so i can convert it back to manual
    steve
     
  22. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    this version of the zx45 was really a lot easier than i expected but there are a lot of different versions of this mill all different. I'm sure that is why kits are available by brand only and may not always fix even though you bought that brand. wholesale tools told me they had no idea what was in my crate but it will meet the min requirements. my mill was a lot nicer than the add and was 2hp not the adds 1.5hp.
    not one conversion i had read about was much help because my mill was different than theirs and easier to do.
    there is no steel in the conversion except the ballscrews i had to cut and grind to fit a end bearing on the x axis. and you can order them to the length and specs you need if you dont mind the wait.
    steve
     
  23. Analias

    Analias United States Active User Active Member

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    So far my searches have shown that WT has the cheapest prices on RF-45 style mills. Everyone else is very proud of their products and charges anywhere from $3500 to $6600 for something matching the ZX45.

    If you don't mind me asking, what did you pay in shipping? I know it will vary for location, but I'm looking for a ball park figure.
     
  24. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    they are 35 miles from my house i picked it up. if you call the 1-800 number you can talk to them. you might even ask if they have any lease returns. when i was at the local warehouse they had 2 big lathes i believe were lease returns but i didnt ask because i know me i would have brought one home.
    steve
     
  25. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    i am planning on making some involute gear cutters on the 9x20 cnc lathe when finished and milling the teeth into them and making a set of gears as a thread when i get all this done but it is going to be a while. i have to also learn how to edit the videos to post them or they will be boring to watch full length.
    steve
     
  26. DaveSohlstrom

    DaveSohlstrom United States Good bye Active Member

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    Steave

    Take a look at this program. It lets you make gears using end mills and your rotary table. Can also make helic gears.

    Dave

    http://gearotic.com/ I have no connection to this program.
     
  27. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    thanks i have looked at that before and if i had a use it would be an option i might concider, but i do enjoy making the tools as much as the gears so until i need anything but spur gears it's on the back burner for now.
    steve
     
  28. cjsamples

    cjsamples United States Active User Active Member

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    New project for you?

    Steve,
    Great work on this mill. This thread tells me to get off my butt and just do it. I think I found a project you might love. This 4th axis is one of the things that really gets your mind going with ideas.

    https://www.youtube.com/watch?v=HvjnDQoh-7I&feature=plcp

    and this video shows just how far you can go with it.

    https://www.youtube.com/watch?v=Y3PIdnNwsAg&feature=channel&list=UL

    Maybe this will give you a few ideas for your trunnion table.

    https://www.youtube.com/watch?v=itJqDwl7X2o&feature=channel&list=UL

    Chris
     
  29. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    those were pretty interesting i liked the endmill one the best
    that is how i grind my involute cutters i make but this mill probably does not have the rpms required
    steve
     
  30. arvidj

    arvidj United States Active User H-M Supporter-Premium

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    Thanks for the details. I have an 8 inch that I want to CNC and was looking for some experienced installations before committing to the components.
     

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