Bridgeport CNC with Masso Controller/Clearpath

This is going to be my first CNC build and my First build log. I've decided that a build log on this forum might be a good idea for this project so the next guy to take on this project doesn't have to deal with the stupid stuff I'm already running into.

This is my Masso Controller

I will be using 3 Clearpath Stepper Killer servos model# CPM-SDSK-3432S-RLN

They are a little over 6" long...

almost 3.5"

1/2" shaft with a 3/16" keyway

I will be using Teknic's IPC-5 75VDC power supply


But before you can wire up you Masso controller you have to power up the Clearpath servos and plug them in to a PC with the ClearPath USB-B cable and it absolutely has to be their cable I've already tried 5 others, now I'm waiting for UPS to deliver a "Teknic Certified" USB cable. Very Lame....

Their program will not see my servos without the "Teknic Certified" USB cable...


Edit: Almost any USB cable will work.... lol

 

I Win....

 

Now the real fun begins I have to grind down the new gib to fit my machine......

 

The angle on the Bridgeport Gib seems to be about .8769 DEG that means me need a .0765" gauge block stack for my 5" sine plate but my gauge block set only has .050" at the smallest. Sooo now I need to start another project to complete a project to be able to continue another project..... lol

New project I need to grind a block down to exactly .0765"
The madness never ends.......

I still haven't found a way to hold the Gib on the sine plate yet.... I'm thinking of drilling some small counter bored "Oil holes" to just screw it to the sine plate....

 

New project I need to grind a block down to exactly .0765"

or make a longer sine bar ?

 

or make a longer sine bar ?

No... I'll just shim the other side of the part to make a .3765 gauge block stack work.... stop trying to add projects to my list.... lol

 

I took the table off the surface grinder cleaned the out Rack and pinion, I had a lot of dirt built up in the rack that made my table bounce at the ends of travel that made a funny pattern on the mag chuck.... After that I removed the Mag Chuck for the first time in 4 years of owning it, the table underneath the chuck was very rusty but it cleaned up nicely.... I then put the mag chuck on the table upside down on the table and took off about .005" to get the bottom flattish..... I then took the mag chuck to the surface plate to hand scrapped it to about 12 -15 Points Per Inch, then put it back on the the table and reground the top now it has a great finish.....

Finally after all that I was able to start grinding the .0765" shim for the sine plate so I can grind the Gib. I have the Gib ground within about .002" on one side and now I am hand scrapping the other side that rides against the ways.....

I forgot to take pictures.....

 

Hand scrapping is a ton of work and takes a very long time even on a small part like this.....

 

The Gib is scrapped and back in its home now, I'm reassembling the Y axis today to test the table play so I can adjust the Gib properly with an indicator......


This is the new set up for the Y axis servo, I made a nut that fits down inside of the lovejoy coupler to apply a preload to the bearing....
I had to make a tool just for this nut....

(This is the idea that was given to me from John K during the Richard King scrapping class)

 

I just finished testing and adjusting the Y axis, it's within .0009" across about 10" of travel...... Masso just added backlash support to one of the last updates and it works perfectly, I was able to get all 3 axis within .0002" of travel very easily with an indicator.....


Now I need to reassemble the way protectors and get a PC to the shop so I can make some g-code to run this beast....

 

It's working! First cuts in aluminum.... 9/16 carbide end mill 2700rpm is the max on this machine.... I need more RPM..... the stock motor was 1hp 1800rpm....

Does anyone think this machine can handle a 1.5 - 2hp motor that runs at 3450rpm???
Spindle rpm would be 5400rpm.....