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  1. #1
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    Jan 2016
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    19

    Rebuilding my 5x10 CNC Router

    After spending a few years and countless projects with my first CNC router build I have decided its time to fix the major issues I encountered.

    The main issues with the original build
    - Machine base was not big/strong enough in relation to the gantry size/weight
    • Under high acceleration/deceleration I can visually see flex in the base when the gantry stops

    - X axis motor mounts and ballscrew mounts where not properly braced for the loads
    - Epoxy leveling
    • The epoxy leveling worked to within a 5-10 thou for flatness but with no rail reference relying on clamp torque on rails not ideal for such a large gantry
    • No bearing block reference edge on the gantry feet

    - X axis rails not full length
    • Original rails purchased used to save money, without proper rail reference it is difficult to keep rails properly aligned. Blew out a bearing block when it caught on the misalignment.


    These items above can be mostly worked around by slowing the machine down considerably. Original design should have had the machine at ~2000ipm rapids with very snappy accel. I have reduced to 1000ipm for rapids and rounded off the accel considerably.

    The NEW machine
    - Base material size considerably larger than original
    - New Gantry larger legs with better feet bracing
    - Integrated vacuum hold down plenum
    - Still 5x10 machining area
    - Still 18 inches under spindle nose (no tool) when fully up
    - Small wood storage under machine (I keep my rough board stock under current machine)
    - Steel structure stress relieved
    - All linear rail and block locations machined with reference and rail lock provisions
    - All drive and motion components to be moved from current machine
    • except X axis rails, new full length 30mm rails to be purchased for new machine


    Current machine motion parts to be moved
    - X axis
    • Full length 25mm x25mm lead ballscrews
    • Dual 1 kW Servo motors
    • **New 30mm Hiwin Rails

    - Y Axis
    • 20mm x20mm lead ballscrew
    • 0.75kW servo
    • Schaeffler Linear Rails 25mm

    - Z Axis
    • Entire Z axis will be moved over to new machine
    • Current Z consists of 20mm x20mm lead ballscrew, Schaeffler 25mm rails, 0.75 kW servo, 10hp Coulombo ISO 30 Spindle
    • New Z to Y plate to be machined to account for larger Gantry


    Design
    I started designing the base and gantry over Christmas break trying to optimize strength and cost. I then came upon a deal on some large section box tubing at scrap cost so I redesigned around it. The box tubing is 10x10x3/8 inch and 8x8x5/16 inch the design below was optimized for this material.

    Photos Attached of Design - Having trouble putting them inline

  2. #2
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    Re: Rebuilding my 5x10 CNC Router

    Starting the build

    Gantry legs were laser cut out of 3/8 and 1/2 inch plate. I designed them to interlock to make assembly easier and to keep everything square.





    The gantry itself will be 12 x12x 3/8 box tubing still working on sourcing this. Also trying to decide if I need to add any internal bracing.

    The 10x10x3/8 box tubing for the main X rails were not long enough (145 inches needed 154) so I added length to each one. There will still be a 1/2 inch by 4inch wide plate added to the top of these and then machined so the welded piece needed to be "close" but didnt need to be perfect.



  3. #3
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    Re: Rebuilding my 5x10 CNC Router

    Next up was to use the current CNC and my plasma machine torch to cut holes in the tubing for wiring, x axis servo belt, anti whip devices, and such before welding. Biggest challenge was to get the roughly 600lb 10x10 tubing onto the current machine...

    ***As a note the current CNC is not setup with a water table. Precautions such as multiple fire extinguishers were on hand while cutting this tubing.***



    Notches cut in the top of the tubing for the anti whip devices for the ballscrews. I purchased the anti whip devices from Thermwood.


    Holes in legs for routing cables and air lines

    Holes in bottom of main for routing

    I was then able to assemble the right side of the main frame



    Here is a video of the plasma running. I dont have a touch off setup so I just zero the z at the top of the tubing.

    https://youtu.be/NlsQXWiEFPU

    Next up is to finish plasma cutting the Left main tubing and all of the left frame parts then assemble. Then I will have some work to do to get everything on the same plane before welding in the cross members. Would be very nice to have a bedplate to work off of for this process. Open to suggestions on this but my plan is to use my precision levels to set one side flat. Then using a straight edge transfer that plane to the other side. Then level the other side, this should put everything on the same plane, at least close enough since it will be machined.

  4. #4
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    Re: Rebuilding my 5x10 CNC Router

    Cool!

  5. #5
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    Re: Rebuilding my 5x10 CNC Router

    Small update I got the other side of the frame plasma cut and welded up.

    I then used a couple starrett precision levels to set the frame level in both directions. Then I brought the 2nd frame in and transferred the level to the 2nd frame side. Using lots of clamps and straps to hold everything together. After all the welding the frame is within the ~0.030 on the same plane according to the levels. Well within acceptable limits for a frame that will get stress relieved and machined.

    Pictures are tough to get of the full frame with the space I have in the garage.


    Sent from my SM-G950U using Tapatalk

  6. #6

    Re: Rebuilding my 5x10 CNC Router

    Nice work. Looks like a heavy duty machine. :cheers:
    Jim Dawson
    Sandy, Oregon, USA

  7. #7
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    Re: Rebuilding my 5x10 CNC Router

    Quote Originally Posted by Jim Dawson View Post
    Nice work. Looks like a heavy duty machine. :cheers:
    Thanks going to be pretty sturdy machine. Wasn't going to be this heavy but couldn't pass up the great deal on the box tubing. I hope to get the rest of the steel next week and off to machining in a few weeks.

    Sent from my SM-G950U using Tapatalk

  8. #8
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    Mar 2014
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    Re: Rebuilding my 5x10 CNC Router

    That's a BIG machine! Post some pics of the machining and stress relieving when you have it done.

  9. #9
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    Re: Rebuilding my 5x10 CNC Router

    Sorry for the long delay updating this thread regular life got in the way...

    Made great progress on the main frame and finished the gantry. Gantry is off to to machining and I hope to get main frame out the door early next week. Still need to figure out how to get the beast onto my trailer.

    For the main frame I need to add the ballscrew supports (which will get machined down) and the little triangle feet supports. I welded the 3/4 plate to the top of the box tubing and to the gantry every 6 inches with a 2 inch bead.

    For the main surface area its 3/4 inch by 8 inch wide flat plate. I currently have them welded down at each vertical support. I started to weld underneath and really struggled to lay a good bead, most welding positions I can make a adequate bead but overhead is just not my thing at the moment.

    Thoughts on if the plate welded at each vertical piece and good welds on the top of the 8x8 box tubing they lay on is sufficient? The whole thing will be surfaced and used to mount the vacuum table and spoil board etc. Gut feel says its enough, one concern is when its machined it may chatter a bit, but Im thinking thats a non issue since its 3/4inch thick.

    I will add some more photos in another post

  10. #10
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    Re: Rebuilding my 5x10 CNC Router

    Some more photos. I used my precision level to set the gantry level before welding the legs on. I then was able to transfer that level to the foot so they are as close to planer as can. These will be machined so close was close enough...

  11. #11
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    Re: Rebuilding my 5x10 CNC Router

    Quote Originally Posted by 1Jumper10 View Post
    That's a BIG machine! Post some pics of the machining and stress relieving when you have it done.
    Im going to try to go and watch some of the machining operation, I will defiantly take photos and video of it getting machined if I can and post here.

  12. #12
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    Re: Rebuilding my 5x10 CNC Router

    A small update, got the frame and gantry over to the machinist. They were kind enough to snap some pictures for me as I wasnt able to get over to see it on the mill. The machinist told me the the surface was within 0.060inch over the entire surface. I couldnt believe it, I was expecting to have to take 0.125-0.2 off the surface. They should get the gantry on the mill early next week. My new 30mm linear rails for the x axis are scheduled to arrive to the shipping terminal early next week as well. Enjoy the photos for now, more to come.





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