February 4, 2016 at 7:50 pm #7017
So with these you get great strength, but lose the easy connect for the wiring. So I guess we could make a new printed model to attach to one side to allow the ability to still quick connect. I liked the idea of not having to solder everything. I haven’t started my CNC build yet, but this will be a great thing to test aluminum cutting with and get some strength back. It’s good to see how much folks are still bringing this project to new levels. Thank you Ryan!February 4, 2016 at 8:05 pm #7018
I still haven’t got a decent quote for these yet. I need to seen how long it takes me to make a set to see if its feasible to do this myself.
As for the wires, the wiring harness takes care of the ease of use. I took on that project instead of the mounts. The harness is much faster and cleaner than the solderless mounts.
Thanks for the compliment.February 4, 2016 at 8:20 pm #7021
I work for a small production company, but the only machine we have that would do these parts is a haas vf1 mill. Probably can’t offer even close to pricing that a waterjet can offer.
Someone posted about wanting a plasma cutter attachment for the MPCNC. I run a Torchmate at school and I don’t really see a reason that the MPCNC couldn’t have a plasma cutter attachment. The Torchmate uses two nema 23 steppers the x axis and two on the y. The z is jut manual adjust. Of course you need to build a base designed for plasma cutting instead of mounting it to a table, but you could make a bunch of these parts just as fast as waterjet. Even the cheapest plasma cutter should do this job just fine. If I get in some 1/8th steel plate I can make a test piece.
If the machine was mine, I would do it for a little more than material costs+shipping, but I can’t offer that since I would be putting hours on a machine that doesn’t belong to me and the consumables for plasma cutting aren’t super cheap (though better than breaking endmills). Waterjet would be a cleaner cut initially, and I would probably make the holes undersized with the plasma cutter and then drill/ream them out to size.
It could be done out of aluminum too, but you would probably want a water bed because aluminum tends to make a mess by melting to the slats holding the piece up. Plus it melts so easily that it can fly up into the torch and clog it which burns up your consumables.February 4, 2016 at 8:28 pm #7023
Last time I used a plasma the edges left a lot to be desired. I do plan on making a plasma add on when the weather gets a bit better but I doubt those 3mm holes would work. We’ll see, I just got in the production harnesses in so no more doing those by hand for 40 minutes each. I have a few projects to work on now, these mounts are one of them.February 4, 2016 at 10:14 pm #7024
The edges with aluminum will leave a lot to be desired, but it isn’t hard in a metal shop to clean them up nice with a grinder and sander. I have gotten steel to have decent edges by playing with the plasma cutter’s power and the feed rate. I have only done a few cuts with the Torchmate, waiting on more scrap to play with before actually buying good stock. People that get them dialed in can get pretty good edges. Not waterjet good, but waterjets are many times more expensive than even a large cnc plasma cutter.
As for the holes I would redo the cad drawing before importing the dxf into the software. With small holes I would just make them points to get a pilot in the right place then drill them out. You could make a jig pretty easily to gang drill them or just hold them steady for one hole, drill one of the holes in each plate, then shift it for the other hole. That would take a while though. Once you got into a grove you could still do it cheaper than water jet unless you value your time very highly.
The machine I run maxes out at 2ft by 2ft, so you could fit 6 vertically and 7 horizontally so 42 in one 2×2 sheet of material, assuming autocad isn’t giving me weird dimensions. The cut would take a few minutes, but you wouldn’t have to be totally babysitting it. You could be drilling the previous batch or cleaning up bad edges.
I will make this one of my practice cuts next time I get scrap about the right thickness and see how good I can get it to turn out. I might end up making them from steel since I haven’t printed them yet anyway.February 5, 2016 at 8:34 am #7049
What wiring harness do you speak of? I looked through the remix stuff on thingiverse, and must have missed it.February 5, 2016 at 8:42 am #7050February 5, 2016 at 12:41 pm #7075
I work for a small welding fabrication business that mostly does stainless steel and mild steel construction with some occasional aluminum work. My one job most of the time is to make CAD files from customer’s drawings on napkins or whatever and also keep our plasma table constantly running, so I see a ton of metal get torched by plasma. If a customer wants perfectly straight edges and super tight tolerances I send the drawings for milling or water jet at another shop. The kerf and arc wander of a plasma torch work best for stuff like 3/4 plate that is going to get a grinder on it anyway before it’s welded together. I know that plasma isn’t the best option for this but it’s possible.
With that said…
It’s still worth doing for other things.
I’m almost finished with my MPCNC at home and you’d better believe that I’ve already ordered a pen style plasma torch to stick on there and cut with.February 5, 2016 at 1:03 pm #7078
Congratulations Drew…You just became our resident expert on plasma!
I will be getting mine going with some tax money, if there is some. We can play 1000 questions as soon as I have it running. I have only used a plasma in a body shop a long time ago on a handful of cars so you are the new go to expert. 🙂February 5, 2016 at 1:40 pm #7088
I’ll be glad to help in any way that I can. I’ve been lurking here for quite a while 🙂 I like this project and it makes my head spin just thinking about possibilities with a modular system like this.February 5, 2016 at 8:53 pm #7111
Ryan, I didn’t see those wiring harnesses yet. See, you’re always updating to better things. Thanks for the info…and the link.
How thick of aluminum do you think you can cut holes out of with the DW660? You think 1/2″ is too much? I know that size of CNC matters as well. Still trying to decide how big to make mine.February 6, 2016 at 2:05 pm #7128
If a thread get started on that, I will probably jump in too. I am just playing around with the one in the shop at school guessing feed rates and noting how well they work. I found a few documents that have example feed rates that have been the best of my tests so far. I also need to play with the settings on the plasma cutter a little bit too.
Milling these would definitely be the way to go without a waterjet, but milling is slower and more expensive. If I drag this project on long enough to last until I get back to work this summer I might use these as one of my pieces for learning HSMworks. Low volume part that would be cheap enough for me to order my own stock for.February 6, 2016 at 4:35 pm #7134
The first few videos I put up were 3D milling aluminum about 1/2″ deep. That was before the rigid middle Z and with the weak flex shaft grinder. Should be fine now, just use shallow passes.February 6, 2016 at 8:33 pm #7143
How deep of a pass have you managed to do? Shallow passes allow for a much faster feed rate but only put wear on the bottom section of the endmill leaving a lot of life left in the tool above the depth of your passes but quickly wearing down the lower parts making the endmill essentially useless because you can’t cut using the lower area.February 6, 2016 at 8:40 pm #7144
Whole new ballgame now for just the reason you stated.February 6, 2016 at 10:17 pm #7150
I would not have thought of that, but I am also not in school for machining. Looking forward to finishing my machine and playing around with this. I would like to use HSM inside of inventor or solidworks, but I think that video just convinced me to cave and buy ESTLCAM. Plus there is already so much documentation on the forum about it.February 7, 2016 at 9:29 am #7161
OK Im in. pcflyer has been pushing me to make one of these for about 6 months now, but I couldnt see a reason for me to have one since I already have a cnc mill. Then last week it hit me – I need a plasma table. So parts are printing and I already ordered the parts kit.
On another note. I may be able to assist with the aluminum motor mounts. I have two options for cutting them. We can mill them in my shop or I can have a friend of mine laser cut them at his shop. What grade and thickness of aluminum are you looking to use? I know you used .085 for yours but you also said you wanted them a bit thicker.February 7, 2016 at 1:38 pm #7177
That would be cool, I don’t think grade matters too much for this part so cheap is better, but whatever the next thickness up is would be fine. The last ones worked great, but a little more would be perfect. I have been getting quotes for full sheet quantities, and the prices are all over the place.
I just got the wiring harnesses in so now I don’t need the solderless stuff. Now I am very interested in getting these made and just including them in the kits. I found another shop locally to try and get a quote from, or I was just going to build a smaller dedicated mill for these. I can get strips so I could just feed them in probably 3-4 in a line and keep the mill small and rigid and cut much faster than the last ones.February 7, 2016 at 5:03 pm #7191
That would be pretty cool. A small but super rigid MPCNC for cutting these out. Not even close to as fast as a waterjet, but costs would be much much lower. If you do that, please post pictures/videos to show what a small machine can do.February 7, 2016 at 5:40 pm #7197
Sounds like a valid
excuseI mean reason to build a 3rd machine…February 11, 2016 at 11:02 am #7400
Another reason I am taking the leap into Fusion 360 https://www.youtube.com/watch?v=_N5VaTchhys
And it is free…February 11, 2016 at 9:37 pm #7420
Fusion 360 is cool, but I have student versions of Inventor Pro HSM and Solidworks with HSMexpress installed on my main laptop. I love being a student, I just wish the student license for solidworks for a year wasn’t $150. I got it for free through a design RSO that I do some 3d printing for.
There isn’t actually anything that keeps anyone from downloading a student version of Inventor pro but you can not use it to make money and it may embed something in the files that says, “Student Version” or “Not for professional use”. I wish they had a personal use license but I think that is what they are trying to do with fusion 360.
You must be logged in to reply to this topic.