[Gallen66]

I’m about to attempt to build a CNC Mill/Router table that can effectively cut wood and soft metals (I.e. aluminum). I plan to make the frame out of 80/20 extrusion (I’ve purchased 2 72” 1030 beams and 1 58” 3030 beam. I would like to get as much table Area & Z travel as I can without sacrificing reliability or causing flex. What are realistic dimensions I could have? (I bought NEMA 34 (607 Oz-in) for the Z and a NEMA 23 with a gearbox for the X. I will probably use 2 NEMA 23s on lead screws with ballscrews for the Y. I’m thinking linear rails for the X and supported rails for the Y and Z. Any ideas?


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[awerby]

Usually the longest axis is called "X", but it sounds like you're calling it "Y". A gear box will add backlash to whatever axis you use it on. Without seeing a picture showing how you plan to employ them, it's difficult to say anything meaningful about your selection of materials, but only the most rigid router-style machines are suitable for cutting aluminum and other metals. Any material will flex to some extent, but how much flex is tolerable depends on how it's used and what your tolerances are. If you really want to cut aluminum, then I'd suggest well-supported profile rails on all axes; round rails are too sloppy.

[ger21]

I would like to get as much table Area & Z travel as I can without sacrificing reliability or causing flex.

Everything flexes, and the longer you make it, the more it will flex. Round supported rails are not terribly rigid, and often have some play in them.

1030 extrusion is pretty flimsy stuff. Most people that build extrusion based machines use larger extrusions.

In the end, it all comes down to what your expectations are. You can cut aluminum with a dremel and a flimsy MDF machine. So the question is, how fast and what depth of cut are you looking for? And what finish quality are you looking for.

[RsDJ]

I would strongly recomend not to use SBR round rails if you want to do some real work on your router. My experience is that if you are using SBR rails, you could as well build your router out of MDF, no need for expensive extrusions then. But thats just me, others are cutting aluminum on routers made from scrap wood, I guess its all about expectations and what tolerances you are happy about.

Go through build threads and just look at other builds, materials used and ask them about speeds and tolerances, you will get the picture.

[Gallen66]

Terrific advice guys. I certainly appreciate it!


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