Originally Posted by
b0gh0s
1) I have had several occasions where I have been able to stall the stock 1/4 hp motor using 1/4 and 3/8 EMs doing facing operations (like 5ipm feed and .03 doc in sheet aluminum). What motor upgrades work for this and where do I buy a good setup to do this? I can spend some money on this, I am looking for something reliable, and powerful. Can someone please point me to sources of stuff that has worked well? I did a search here and got a lot of stuff but nothing I feel I can go on...
Is the motor stalling, or is the belt slipping? I have never stalled the new motor. If you are stalling it then you aren't removing material fast enough so you need to reduce your DOC or your feed. Are you using lube/coolant on the work?
Originally Posted by
b0gh0s
2), I need some more backlash and tuning help, I put a dial indicator on the ways, adjusted the backlash and the gibs. I got everything pretty tight but if I really push (putting some umphf into it), I can get it to move like .0015 each way on my dial indicator, any tighter on anything, I start stalling the steppers, can anyone recommend a more directive set of steps to adjust the ways so that I can get close to holding closer to .001?
If you are pushing on it and getting a little extra backlash, chances are that's due to compression/flex. Don't worry about it so much. Cut some sample parts and see if it is coming out right. A good test is to mill a circular boss or pocket and see that it is round - don't worry about the dimensions, just that the x and y measurements are equal when you use a mic or caliper on it. You really shouldn't be trying for more than about .001" accuracy, especially if you are new to all this. Let the machine tell you how it is working.
Originally Posted by
b0gh0s
3) I have the spindle speed cranked to the highest RPM I can get, I can run like 5ipm slot milling with a 2 flute at doc of .06 with a 5/32 em, is this too aggressive?
If it works, it isn't too agressive. It's hard to go too fast in aluminum...The problem is that with smaller cutters they flex, and really can't remove that much material per revolution. Start researching proper speeds and feeds and how to calculate them (get a copy of machinery's handbook). Generally DOC should be no more than half the diameter, so .06 is ok.
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Nick Carter
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