[Khalid]

Hi all,
This is the build log of Optimus Prime 4th Generation. This time the Optimus Prime is going to transform from Sheet metal into 4x4 CNC router. This transformation might take long time as we are building Hero here that will make the rest of all Zero.

My friends CarveOne and Gerry has also started their build log and Carveone has almost completed the Steel frame router However Ger21 with hybrid ply+epoxy is coming into existence from the drawings to the real world. Both has posted fantastic build logs with lot of pictures. I started this build log to complete the "Optimus Prime" within targetted time of 60 days. probably you will find it in working condition in the last days of December. The purpose of starting this build log is to complete it within the given time frame.

What i did so far:

1- Drawings:
a- Many time changed.
b- Still on drawing board.
c- So expect no drawings from me at least this time.

Why the Drawings are late?? This is because today i visited the sheet metal bending facility and was amazed to see how accurate they bend and how align the sheets after bending.... So just scraped my old drawings which i was working for months and start building new ones.. The old drawings was amalgamate between wood, steel and Aluminum. Now the new drawings totally eliminated the wood and i am going toward lot cheaper and strong sheet metal solution.

2- Lead screw or rack and Pinion:
a- I moved toward the Rack and Pinion and for this i purchased the
Racks and pinion wheels from local market.
b- The basis for selecting R&P is because i simply inspired from ahren
R&P build. My past experience working with the lead screw is not
good in the way they are slower and having lot of other potential
problems. I want this machine accurate but fast more than 300 IPM.
c- The gear Rack came in 4ft pieces and the guy handed over me exactly
5 feets as per my requirement. I was amazed to see the welding joint
he made to join one foot piece to the remaining four feet. I placed the
two five feets gears upside down and found that all teethes meshes
perfectly.

3- Gecko G540, ahren linear carriages, cables and Steppers:
I purchased 380 Oz-in NEMA 23 steppers , cables, Z-axis 5-start
screw with anti-backlash nuts and one carriage from cncrouterparts.
He is really nice guy to deal with. This was my second deal of
purchase with him. These are in transit and i can't not wait to see
them in my hand.

4- Hot Rolled steel plates as linear guide rails:
The Hot Rolled sheet was cut on shearing press, machined on big
BORING MACHINE and accurately drilled. I have now Z-axis and X/Y
axes rails available.

5- Mach3 Screen set 2010 by Ger21:
I will use Mach3 2010 Screen set courtesy by Gerry. I really love that
screen and the functionality of auto-tool-zeroing of tools with one fixed
plate and one movable plate. He is really nice helping guy at this forum.
I am also interested in Probing which he is working on.

6- Limit Switches as per RomanLini Design:
I am currently working on making Home switches for this build based on
the great work of RomanLini.

I will soon come back with some pictures.

[DonFrambach]

It doesn't exist until you post drawings and/or pictures!

[CarveOne]

Hi Khalid,

It's great to see that you have started on your new build. I'll be watching.

CarveOne

[Khalid]

@DonFrambach:
1- My first machine(All Steel Construction) that i built in 10 days never had CAD file.
2- My second machine (All MDF construction) that i have had now has partial CAD files. I made only those parts in CAD that was required to be CNC machined on my 1st Machine. This time may be or may be not. The higher chances is that i am playing with Sheet metal bending so i will make the CAD plans as their is no chance of return neither i have too much money to do hit and trial

@CarveOne..
Keep watching my friend and guide me by posting in this thread. I do know you have bad experience with Hot rolled steel plates but unfortunately the place i live only have these Hot Rolled Plates in the shops. I will make a Lapping jig and will use CLOVER Lapping compound to make them smooth at bearing areas. The machining of these rails are 100 percent perfect and i am getting straight edges more straighter than Aluminum extrusions

Here are the pictures of machining of Hot Rolled plates. These are total 8 plates 5-feet in length for two machines. Optimus Prime-4G and its Clone.

[Paulette]

C:cheersngratulations.Can not wait to see

[RomanLini]

Yeah congrats for sure Khalid!

I bet it's going to be an awesome machine, strong and accurate!

[CarveOne]

@CarveOne..
Keep watching my friend and guide me by posting in this thread. I do know you have bad experience with Hot rolled steel plates but unfortunately the place i live only have these Hot Rolled Plates in the shops. I will make a Lapping jig and will use CLOVER Lapping compound to make them smooth at bearing areas. The machining of these rails are 100 percent perfect and i am getting straight edges more straighter than Aluminum extrusions

Here are the pictures of machining of Hot Rolled plates. These are total 8 plates 5-feet in length for two machines. Optimus Prime-4G and its Clone.

TWO machines? That's even better! Twice the entertainment.

The hot rolled rails did work after cleaning them up, but they were noisy because I did not try having the edges surface ground. I only removed the black foundry scale that was on the surface of the steel. I abandoned those rails and purchased the better cold rolled material at higher expense. Even they were not perfect.

Since cold rolled steel is not available to you, and it was cut from sheet steel, it may be a little better material than what I purchased. I am hoping that will be the case. Make them as smooth as you can on the sides and edges where the bearings roll. I am familiar with the Clover grinding compound. The plates in your photo do not appear to have the black foundry scale on them that mine had.

CarveOne

[Shoukat Ali]

i hope you will develop a great machine. i think i am the most one who is anxiously waiting for completion of machine.

[Khalid]

TWO machines? That's even better! Twice the entertainment.

Yes two Optimus-4G one for me and one for my brother Shoukat Ali. This will be really very very great experience for all of us especially working with 3mm sheet metal bending parts.. Lot of drilling and tapping and i was very worried about the warping/distortion during the drilling of thin sheet. But one of my machinist friend told me do not worry he will do the work for me with great care and precision.

The hot rolled rails did work after cleaning them up, but they were noisy because I did not try having the edges surface ground. I only removed the black foundry scale that was on the surface of the steel. I abandoned those rails and purchased the better cold rolled material at higher expense. Even they were not perfect.

My sheets has no black scale on them i don't know how they made it and furthermore you can see in the above posted picture that i have machined the top and bottom edges of the sheets so i am getting full thickness at the edges (6mm)...
I will apply the clover compound where the Bearings will roll to smoothen them out although these surface are good enough for rolling the bearings...

Since cold rolled steel is not available to you, and it was cut from sheet steel, it may be a little better material than what I purchased. I am hoping that will be the case. Make them as smooth as you can on the sides and edges where the bearings roll. I am familiar with the Clover grinding compound. The plates in your photo do not appear to have the black foundry scale on them that mine had.

CarveOne

I will soon show you the close up pictures and will suggest you to look the sheets available at your nearby store. Also locate the sharing press around you , you will be astonished to see the quality of cutting and straighness after shearing.

[Khalid]

i hope you will develop a great machine. i think i am the most one who is anxiously waiting for completion of machine.

Welcome brother... I know you are one of the victim who suffered lot due to me (chair)..but this time you will definitely get one very soon Keep posting...

[Khalid]

Yeah congrats for sure Khalid!

I bet it's going to be an awesome machine, strong and accurate!

Hi roman,
thank you for posting and greetings from you ... I think i shall need SuperPID at the right time ....You are the one inspiring personality for all of us..

[DonFrambach]

@DonFrambach:
1- My first machine(All Steel Construction) that i built in 10 days never had CAD file.
2- My second machine (All MDF construction) that i have had now has partial CAD files. I made only those parts in CAD that was required to be CNC machined on my 1st Machine. This time may be or may be not. The higher chances is that i am playing with Sheet metal bending so i will make the CAD plans as their is no chance of return neither i have too much money to do hit and trial

Did not mean in any way to offend. Just that I'm looking forward to following your build!

Don Frambach

[Khalid]

Hi Don,
I never offend I love critisim(chair) this always improve my work...
Here is the sheet metal bending profiles for X-axis only. The thickness of the profile is 2.75mm.

[Shoukat Ali]

i dont think so i was suffered due to you. That time had to pass in the same way and it is passed. i think bad time passed and good time has started.

[rocketflier]

Hi Don,
I never offend I love critisim(chair) this always improve my work...
Here is the sheet metal bending profiles for X-axis only. The thickness of the profile is 2.75mm.

Curious. How does the price compare to square tubing?

[Khalid]

@ Shoukat:
Please pray we can get it working within the specified time period else suffering days might continue...Actually assembling two machines in one small room will be tricky.. perhapes i shall need your help in near future so that you learn assembling and alignment...

Curious. How does the price compare to square tubing?

Hi,
The price of the customized bended sheet is 1.27 US dollar per Kg ... Actually i have visited all the big stores with structural steel and tubing.. I never found one exactly straight, normally the structural steel seems straight but when you measure the straightness you always find 1mm or 2mm difference and warping.This warping/distortion normally comes during the transportation/handling etc.

The bending of straight sheets gives you perfect results Just check around any bending press in your locality....

[Khalid]

Here is the CAD model of the X-axis beam with Rail.

[CarveOne]

This is an interesting construction method Khalid. I think you will have good success with it. Will you be doing any welding of joints or will it be a completely bolt together construction?

CarveOne

[Khalid]

Hi CarveOne,
It will be almost totally bolted construction. However for perfect Alignment i will place DOWELS at specific locations.Only the end caps shall be tack-welded so that bolted joints can be made with X and Y axes members.

[CarveOne]

Ok, that is good. I was just curious. I am sure that someone without ability to weld would be asking about it if I did not ask first.

CarveOne