More parts, more progress, more problems!
I have been itching for some of those Mitee Bites Talon grips since I saw them on NYCCNC and how they securely hold the part using only .06". Unfortunately, for 2 jaws and 4 grips, it is about $200. They are relatively simple parts, so I made some. The jaws were very easy, made from aluminum and should last a very long time with the use my machine sees. The grips are scrap yard mystery steel, probably 1018 or A36. It machined nicely and didn't warp at all when I cut it down to size, so that makes me think hot roll. I started with 7 clamp blanks, then lost once since I drilled the center hole off center, and then one more was pulled from the jaws and marred up when I was cutting them to length. I ended up with 5 grips. I have not had a chance to test them yet, but I see no reason they won't work.
I made a manifold to distribute the compressed air to the machine. It takes 90 PSI from the compressor and connects to the 4 pneumatic systems the machine has (or will have) which are the mister, the power draw bar, an air gun, and ATC (when that is done...). Each line will have regulators and solenoids down stream to control the air.
I made the new mounting plate for the Nema 34 motor for the Z axis. Fusion has been being a little bit weird since the last update (as is always the case with Fusion) and has been giving me inconsistent heights with 3D adaptives. It doesn't make a lot of sense to me, since it will take a cut lighter than its maximum step down and leave extra material that it doesn't come back to cut. This is with stock to leave set to 0 and "machine shallow areas" checked. Anywho, the 2 contour for the motor face was at the right height, but the adaptive was about .02" too shallow. It should still work, but its not a good look and isn't ideal. I don't think that dimension is critical though, so I won't worry about it. I just need to either make a new coupler, or open up the current one from 1/4" to 1/2". I am not sure if it will fit, so a new one might be needed. Then I can wire it up, give it the full 7 amps the drive can handle, and the head should be zipping along.
The enclosure has had some milage put on it, and even with the back ATC section still open, and only 1 door, it catches most of the chips. I filled a 20 gallon storage container with chips contained in the enclosure, and in that time, the chips that escaped were maybe 3 inches deep in a 5 gallon bucked. If I can just figure out the door mounting, and then mount the rear panel, it should contain nearly all the mess.
I know I have mentioned a new spindle motor a few times, but I left out the details until everything was squared away. Another member here offered me a screaming deal on a servo motor and I just couldn't pass it up. I don't know if that person is ok with me crediting him for it, so for now I won't say who it was. The details were worked out and the new motor and drive are scheduled to be delivered tomorrow. The motor is a 2 HP 6000 RPM AC synchronous servo with a matching drive. The motor checked off all my boxes and then some (I wanted at least 1.5 HP, 5000 RPM, under 20 lbs, and fits on my machine). I plan to step up the spindle speed again, likely to 7500 or so. I plan to use the current pulley arrangement to see how the spindle responds to higher RPMs. With the current arrangement and faster motor, the spindle will get up to 13,200 RPM. My bearings are rated for 13,000 and 17,000 RPMs, but I don't think the spindle is nearly well made enough to handle that without excessive vibration. I would like to get it to 10,000, and maybe some balancing can make that possible. As a side note, its insane the difference in documentation between the cheaper hobby stuff and the industrial stuff. The hobby stuff comes with one 4"x4" sheet if you are lucky telling you basic dimensions and wiring. Or if you are unlucky, you can't get any information at all about the motor has a 100 page manual detailing every aspect of the motor including wiring, duty cycles, torque curves, etc. I have never used real equipment like this before so this was surprising to me. I already have the mounting plate designed and once I verify the motors dimensions, it I just need to make the one plate, wire everything, and figure out how to program and control it.
Since the new spindle motor is a servo, it can be run in both velocity and positioning mode. This opens up a number of new possibilities such as:
1. Rigid tapping
2. Indexing during tool changes
3. Holding position for using lathe tools with ATC
4. Indexing and holding for broaching corners
It would be pretty cool to be able to get the machine to hold a lathe tool in the spindle, cut a part using a lathe attachment, then use the ATC to switch to a drill or end mill and cut without me needing to do anything. I may need to add a brake to the spindle to keep it held strong if I want to make this work. But I couldn't be more excited for this thing and the things it may allow me to do. At the very least, 2 HP and 6000 RPM should let me remove a lot of material very quickly.
I also tore the Y axis way cover. When the table is close to the column, the way cover bunches up and gets caught between the vise and the Z axis way covers. I guess the rubbing wore a hole, and at some point that hole got snagged and now there is a big jagged gash in the cover. I would like to replace it either with accordion ways like the Z axis uses, or maybe some sheet metal or machined aluminum V covers.
Have some pictures!
Here are the jaws and grips. I don't have the correct screws yet, but they just need 10x32 countersink (what are the ones with an angled head called?) screws.
Pneumatic manifold/distributer/splitter/air thingy, whatever you want to call it.
Z axis motor mount. I didn't want to remake the entire Z axis motor/bearing block assembly, so the mounting plate for the larger motor also serves as an adaptor. The holes inside the circle will attach the plate to the current nema 23 mount, then the larger outside holes will attach the motor.
Here is a drawing of the new motor mounted on the head. With the air cylinder, spindle motor, and nema 34 Z axis motor, everything is a bit of a tight fit.
