[Azalin]

This is the first run.

Please note this is not the final version but the very first. I've used regular ball bearings on this one but I'll change the design due to hot bearings. Got some angular contact bearings on the way for the next version.

- ER20 chuck (shaft length: 100mm, shaft dia: 20mm)
- 3kw 24v water cooled brushless motor (1050kv)
- Cheap 200A ESC
- Cheap servo tester
- I'm using series wired two server PSU units.

[H500]

Nice work. The bearings will run cooler if you replace the grease with oil.
What RPM did you run it up to?

[Azalin]

25k rpm max.

The housing is not sealed. Do I need to seal it when I use oil? Or just the seals of the bearings will do?

Thanks.

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[Tkamsker]

This is a nice Setup question do you think it can be atc able ?

[Azalin]

Atc is another story. Maybe on the next version. For now all I care about is to getting rid of my noisy Bosch colt router.

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[lixingwen1987]

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[hjl4]

Azalin, Does the ESC maintain constant torque?

[Azalin]

No, it does not gave a governor mode.

[asuratman]

Azalin,
What motor you use on this spindle?

[asuratman]

What motor you use on this spindle?

[Azalin]

This one:
Radio Control Planes, Helicopters, Cars, Boats, FPV and Quadcopters - Hobbyking

[Azalin]

Ok this is the first cut.

15k RPM (max 24k)
Feed 500
Step down .5mm
6061 aluminum
2mm 2 flute end mill



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[tony978]

Nice now I want to make one of them ! Very well done !!!

Tony

[calica]

Great build! How is the motor shaft coupled to the spindle? Which PSUs are you using?


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[Azalin]

Thank you guys.

@Calica
The best way I've found to couple two shafts together is using a quality one way bearing.

[Azalin]

Second cut with 6mm end mill.

[bluesea]

nice :cheers:

[Azalin]

Thanks BS

[Tkamsker]

Hi,
very nice design question
the er chuck did you buy that one or did you do it on an lathe or different machine ?
Or question do you think it is possible to be done on an lathe ?
Because i like your idea and i do think of building in winter also this kind of spindle
and of course i would like to know which material you used on the "hull"
thx
thomas

[Azalin]

Hi Thomas. I made the hull from stainless steel. I don't know the exact code but it is soft enough to cut on a lathe. Not so hard and not so soft.

Yes it is possible to make a collet holder on a lathe but once you are finished on the lathe you need to harden it without damaging or bending it. I bought mine from a local dealer. They are not expensive. Search on ebay for "er chuck holder". There are many types.