I've been a long time lurker and this is my first post. My posts tend to get very 'wordy' on forums so I am trying hard to keep descriptions succinct and use pictures instead. And let me first say Thank You to all the regular members who post on here. I really look forward to hearing your comments/suggestions/criticism on this idea.
Overview: 3D Router; Steel and aluminum construction. Full 48" x 48" x 10"cutting envelope
Purpose: I need a 3D router for cutting foundry patterns. These are typically routed from polyurethane tooling board ( Alro Plastics Polyurethane Tooling Board). A casting pattern can have a lot of complex 3D contours and always has draft to release the sand from the pattern. I need something that is capable of Large and Fast Z axis movement to follow the bounding surface. Tooling board is roughly 80lb/ft^3 / 10,000psi tensile strength / 85 Shore D, so maybe a little harder to cut than wood but much easier than aluminum. Rough speed 1500RPM @70IPM and Finish at 10,000RPM @100IPM I would also like to be able to cut aluminum - mainly 2.5D motion (flanges, pockets, bolt holes).
Y-Axis 52.00" maximum travel. SBR25 Rail with 2 trucks per side (chinese rail/trucks). Motion using 2x CNC Router Parts Pro Rack and Pinion. Motors: 2 x Nema 23 unknown size
X-Axis 50.20" maximum travel. SBR20 Rail with 2 trucks per edge (chinese rail/trucks). Motion using 1x CNC Router Parts Pro Rack and Pinion. Motor: 1 x Nema 23 unknown size
Z-Axis 12.24" maximum travel. Hiwin 15mm profile rail with 2 flanged trucks per edge. Motion using 1x 2510 ballscrew (chinese ballscrew, bearings, anti-backlash ballnut) Motor: Offset mounted Nema 23 with timing belt. Counterbalanced using pneumatic cylinder. Spindle 2.2kw water cooled spindle ER20 collets
Construction: Box tubing for table 3" x 3" x 0.120". Gantry from 0.25" hot rolled steel using tab and slot for assembly. Fully TIG welded. Z -axis components from 1.0" and 0.5" 6061 Aluminum or MIC6 cast plate. Spindle tube is aluminum 4.0" OD with ~0.5" wall thickness.
Electronics/Software: MACH4 (although I'm weary of being a guinea pig and also no plugins seem to have been developed). PMDX 140 (PMDX.COM - Products for CNC and motion control applications) coupled with a PMDX 126 (PMDX.COM - Products for CNC and motion control applications) and PMDX 407 (PMDX.COM - Products for CNC and motion control applications) for spindle speed control. Geckodrive G540. I'm also open to suggestions. Something with ethernet and a ton of I/O would be great. Something with feedback or closed loop motion would be even better, but I think these are too expensive for my budget.
Concerns: Budget like everyone else. Other wise this would be 5' x 10' with linear profile rail for each axis. I'm also worried about the crane weight (over 300lbs with Z carriage and spindle) and whether that's too heavy? What motors I should run? Box tubing wall thickness @ 0.120"? The location of the X-axis rack and pinion and racking concerns? SPEED of Z axis with motor and 2510?
Not all hardware (nuts, bolts) has been modeled yet. Still to be modeled: axis limits/stops and homing switches, cable trays, table legs. I will update and upload pictures as I make the changes you guys suggest. Thanks again guys.
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