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Calm those horses...I didn’t slap your baby. Here is a direct link to a YouTube link that pops up when you do the search I recommend, showing what I’m talking about

https://youtu.be/YXLk0mJOwJM...

Not sure it's a great idea, but "scraping" a hardened way with a grinder is possible. Google "scraping hardened ways grinder". You will see how people have replaced a scraper with an angle grinder...

It would. You could also weld a 1/8" steel plate on the side in place of the diagonals. That would give the shear strength without local flexible points. It would also take care of your cosmetic...

On the base and z column, I would consider changing out the diagonal with a "W", there the bottom of the "W" is against the rails. The idea is that you have some longer unsupported sections, where...

Generally, you want a higher natural frequency of your structure. Higher natural frequencies result in smaller amplitude dynamic deflections, faster response, and is easier to damp out. In a very...

That's pretty interesting packaging. Where did you get the (what appears to be) raw magnetic scale so that you could make your own enclosure? I have only seen premounted scales from Ditron. Does...

What does it sound like? Clicks at the jerk points? If so, I would guess that is your acceleration feedforward (aff) doing its job. Aff causes a current (force) to be output proportional to...

Agree. If you need 7075 over 6061, you are doing it wrong - just leave more material for strength. Most of the time in machining, if it is rigid enough, it is strong enough.

0.011" per tooth? That's not messing around :) Looks like fun!

This! So many people think mass is damping, This is clearest way I have seen anyone explain what is going on when you add mass.

Don't ignore those effects. If you are going to the effort of designing, FEAing and building a machine, don't guess here. Some food for thought:

A 16 mm dia steel rod of 0.4 m length will compress...

Mostly, yes. But, most machines aren't great at moving near zero velocity, due to friction and backlash. So, lets say you are moving back and forth in the Y direction. The X will have to make very...

I had the same problem with it feeling notchy and had to try a few sizes. I was using a ground single nut and had < 0.001" backlash, so I though reballing would fix it. I was able to take it down a...

That's awesome! Now you will never wonder what would have happened if you tried to do this...

I've noticed that the diagonals are disappearing. You might want to get a diagonal brace or two in the bottom section. Even if they are bolt in items.

It depends on how much cooling you need. Water cooling can provide a massive amount of cooling, compared to air cooling.

I have purchased balls from ball-tec before. They have an amazing selection of balls.
Baltec - Home
I think chrome steel balls are the right ones for a ball screw. I used grade 25, though it's been...

"Hard milling" is the term you want to search for. Lots of info out there.

If you are truly limited in space and want the biggest machine, you could make a moving gantry mill. Lots of wood routers are made this way. Also, enormous metal mills, but not so many hobby mills....

NSK lists stiffness in the preload and rigidity table. Probably not a bad source to make rough estimates even on other manufacturers products.
...

I would get a better / bigger lathe. You don't need a lot better / bigger, but based on your spindle thread, I can see you have bigger projects in mind than this. Personally, I would consider a 12" x...

I would seriously consider not using counterweights. They are controls problems if you use servos and expense and complication in any case. There is no reason why that x axis should weigh so much you...

You sure are getting a lot done! It's impressive that you are not only doing the design, but you are actually getting to work and finishing this. Lots of people just think, but don't do. Great job!

You are correct. Any issues you have with English does not make polyester into epoxy :)

I think dropping the stiffness to weight priority is smart, unless you have some good reason for it (using it on an airplane or something like that). But I wouldn't just decide on a weight goal....

The other reason for higher power axis drives is that they aren't that much more expensive (if you negotiate price well). The drive electronics when run at 220V+ is not much of a difference at 1kW or...

Don't forget how critical proper grinding wheels are. The junk grinding wheels that come with a Dremel are just not made to grind a job like that. Your Dremel might be able to do the job faster than...

Here is the spec on the steel:
Chemical composition, Mechanical, physical and environmental properties of ASP 2080,Steel Grades,Tool Steel,

It shows 235 HB for annealed condition, which is ~22...

10 um or so would be the upper limit in my mind. Lower if you plan on using small tools.

Runout Versus Tool Life - CNCCookbook CNCCookbook

Don't forget you can grind the spindle when it is...

How does it fit? Did you blue it to check? Looking good!