This project consists in developing a Public Domain design for a high-precision 6-axis machine that could be used for educational purposes. This is *not* a design for a production machine, but lessons learned through its design and development could be applied to the design of future production platforms.

The main characteristics of the design are:

- 6-axis Horizontal Machining Center targeted at aluminum
- 60" x 60" x 60" footprint
- 30" x 20" x 20" envelope
- 30" x 20" X-Y table
- 20" C rotary table
- A-B two-axis HSK-E40 36,000rpm 7.8kW spindle
- Granite stone monobloc base
- Granite stone monobloc column
- Iron casting for table carriage
- Iron casting for head carriage
- Dual servo motors on all linear axes
- Direct drive torque motors on all rotary axes
- Absolute linear encoders on all linear axes
- Absolute rotary encoders on all rotary axes
- Precision ground ball screws
- Precision ground linear rails
- Dual hydraulic Z-axis counterbalance
- 30-tools automatic tool changer
- Spindle water chiller
- Minimum quantity lubrication system
- Production-grade controller

The machine is designed as a kit that can be assembled by students and faculty over the course of a few weeks. The kit will be made of two main pre-assembled components (base+column assembly and control system) and all other parts required to build a fully-functional machine. The base and column are made of granite (stone, not epoxy granite) supplied by this company in the US:

Precision Granite Machine Bases - Pyramid Granite & Metals

Similar suppliers can be found in Europe and China. The base and column will come already assembled and squared, including the two pairs of linear rails for the X and Z axes. Similarly, the pair of linear rails for the Y axis will come already assembled on the table carriage casting.

Because the machine is designed for educational purposes and is not intended for production, it will not concern itself with the collection of chips. Along the same lines, the addition of a Minimum Quantity Lubrication System and the focus on aluminum makes it possible to avoid the use of traditional spray coolant. As a result, this makes possible the use of granite for the base, thereby providing a more affordable alternative to weldments, iron castings, or granite epoxy composites.

For reference purposes, the following components will be used:

# Spindle: HSD HST310 two-axis spindle
- ES368 HSK E40 Asynch
- Power S1-S6 6,5kW / 7,8kW Asynch
- Torque S1-S6 3,4Nm / 4,1Nm Asynch
- Max RPM 36.000 grease
- Rated Speed RPM: 18.000
- Spindle Encoder: no

# Controller: Siemens SINUMERIK 840D sl

# Servo Motors: Siemens SIMOTICS S-1FK7

# Linear Motion: THK
THK HSR Ground Linear Rails
THK HSR Linear Guide Blocks
THK BIF Ground Ball Screws

# Linear Encoders: Heidenhain LC 495 S

# Minimum Quantity Lubrication System: Unist Quantum

The goal of the project is to build and demonstrate a complete prototype for less than $150k in parts, while delivering a design which parts could cost less than $100k when purchased in relatively small volumes (25 to 50 units for the first batch).

The following benefits of the machine are expected:

- Relatively low cost (when compared to other 5-axis HMC platforms)
- Very small footprint (educational institutions are space sensitive)
- DIY kit (great for educational purposes)
- Simple design for self maintenance (a must for educational institutions)
- True 6-axis design (great for experimentation and research)
- High-precision (this is intended to be a real machine, not a toy)
- Production-grade controller (great for training)

PS: This thread is a follow-up to an earlier thread from which it originated. The original thread evolved very rapidly over the course of two weeks and 150 posts, making it difficult or onerous for new readers to get up to speed. Therefore, once the goals and objectives for the project were settled, this new thread was published. The original thread can be found there (you've been warned):

https://www.cnczone.com/forums/diy-c...62576-cnc.html

PPS: This project is lead y an over-zealous novice. Please try to be patient and supportive, or ignore the thread altogether. Thank you! (^_^)