I am currently designing a fixed gantry router inspired by this design:
https://www.wadeodesign.com/cnc-router-build.html
My objectives are the following:
- Capable of cutting wood and aluminum
- High-quality surface finish over speed
- Automatic tool changer (10 tools)
- 30" × 20" × 10" travel
- 110V
- $25K budget for parts
One way to think about this design is as a machine that would provide capabilities similar to the Roland MDX-540SA, but with a much larger envelope and for a smaller budget ($25K instead of $36K).
https://www.rolanddga.com/products/3...illing-machine
I do not have the skills and tools to make the base and gantry myself. Instead, much like Waldeo's design, I will go for a BRUTE machine base:
https://www.americangrinding.com/req...-model300.html
My first question is this: I am planning to use the Model 300 with a bolted top plate so that I could easily change the underside table or the top plate. Will this design significantly affect rigidity and vibrations? And if so, what could I do to mitigate this?
My second question is the following: how can I build the gantry? Instead of machining a square gantry out of steel (like Waldeo did), could I use heavy duty aluminum profiles instead, with just a ground steel plate mounted on it? This steel plate could be manufactured by the American Grinding and Machine Company (the "Brute" folks) and would be used to mount the rails for the Y axis. The aluminum profiles could be oversized (240mm × 120mm) in order to get a good-enough level of rigidity, and the only thing that would be lost is squareness. How could this be addressed? I am trying to use as many off-the-shelf components as possible, and to make custom-built pieces as simple and affordable as possible so that I can afford some mistakes/redesigns along the way (think "divide and conquer strategy"). This will be my first build, and I realize that I am being quite ambitious with this project.
All axes will use linear rails and carriages with 25mm ballscrews and ballnuts, all from HIWIN. The X axis (the moving table) will use two sets of motor and ballscrew. All axes will use two rails and four carriages, and all motors will use NEMA 34 8Nm closed-loop stepper motors (Leadshine ES-MH33480 and Leadshine ES-DH2306), all directly connected to the ballscrews using shaft couplers. Any apparent problem with that design? Will HIWIN HGW carriages be sufficient, or should I go for higher-precision models?
For control, I was planning to go for a Galil DMC-4080 with support for 8 axes:
DMC-40x0 | Galil
The price difference with a 4-axis model is not that significant, and this would allow me to add a 4th axis (since X is driven by two motors, I need support for 5 axes on the controller) as well as some options in the future (automatic cover for the tools for example). This controller would be used in conjunction with Mach4. Is there any better combination that I should consider?
The one component that I am not so sure about is the spindle. The best option that I have found so far is the Mechatron ATC-8022-42-HSK:
https://static1.squarespace.com/stat...SK_-_WEB_2.pdf
I really like the HSK-E25 tool holder, the rotation speed (42,000 RPM), and the water cooling. Also, I do not think that I will need more power (2.2KW), because I favor finish over speed (I want a machine for prototyping, not production). Unfortunately, very little is available about the manufacturer. I would love to hear from people who have used their spindles, or to learn about alternative options in the $4K to $5K price range.
One critical aspect of the design is 110V (my garage does not have 220V). This is one of the reasons why I cannot install a more powerful spindle, because finding a suitable frequency inverter is a challenge. For the time being, I am planning to go with this no-brand model, but I would not mind paying a little bit more for an alternative from a more established supplier:
https://www.automationtechnologiesin...-110vac-input/
One part of the design that I have not figured out yet is pneumatics for the ATC. This introduction from Damen CNC makes a lot of sense to me, but I really do not like the idea of spending close to $5,000 for their kit. Any recommendation for a more affordable alternative?
https://www.damencnc.com/products/mi..._w_37_556_GB_1
The initial $25K budget won't cover them, but I am looking at the following optional components as well. Suggestions for better alternatives are much welcome:
# 4th Axis: Damen 4th axis with 100mm chuck — $1,493.43
https://www.damencnc.com/products/mo...w_69_1627_GB_1
# Lubrication System: Dynacut MDE-P2 — $465.53
http://www.dynacut.eu/schmiersystem_mde_p.html
# Toolsetter: Z-NANO Toolsetter — $1,458.43
https://www.blum-novotest.com/en/pro...no-series.html
# Touch Probe: 3D-finder Touch Probe — $418.86
https://www.sorotec.de/shop/3D-Finde...nsor-6411.html
Many thanks in advance for your help.