[Ivan_1966]

Hi All,
first exuse me for my bad Englsh. There will be a lot of mistakes and poor expression.
At the beginning, I want to thank to Peter(peteeng) for the help he gave me over the years with calculations, information and valuable advice.

It's time to implement an old hobby cnc machine project. Mainly for aluminum and wood.
But I think it might handle mild steel if used carefully with slow feeds.

It all started from this thread:
https://www.cnczone.com/forums/mecha...92570-cnc.html

Working area: 900x600x185mm (35.4" x 23.6" x 7.3"). Z axis travel: 160mm (6.3").
Spindle can be moved along Z plate.

Here are the parts purchased years ago:

steppers and drivers
---------------------
LinuxCNC MESA 7I76E ethernet card

Xinlichuan Electrical Co
LCDA2260H Digital hybrid servo driver
LC86H3114 3 Phase Nema34 closed loop stepper motor 6.8NM,
encoder 1000PPR(changed with new encoders with index by me), 7mH inductance

bracket for stepers:
--------------------
HM15-86 steel bracket angular contact bearing P5(C5) precision - pairing DF

Spindle:
--------
RTM110-24Z-3.0
(constant torque, ceramic bearings)
ER20 380V 6.7A
200-400Hz 12000-24000rpm
2.4-3.4Nm 3.0KW(S1) 4.2KW(S6)

Linear guide
-------------
original HIWIN HGR25R rails and HGH25CAZ0H, HGW25CCZ0H Linear blocks
SFU2005 ballscrew for all axis with separate double nuts for anti backlash

igus chainflex® TPE cables
----------------------------
CF35.UL.25.04 motor cable
CF10.10.04 control cable
CF11.02.03.02 data transmission cable
CF11.02.04.02 data transmission cable

igus® Energy Chain®
-------------------
Series R58 and R158 "E2 tubes"

igus chainflex® Clean Air pneumatic hoses
-----------------------------------------
CAPE.A.06.0, CAPE.A.08.0, CAPE.A.10.0

UHPC base and gantry:
---------------------
TEGNO® special cement (NANODUR Compound 5941)
aggregate - quartz different sizes (I will post the exact recipe later when it is refined)
FLUP® - PCE-375 liquid superplasticizer
ECLIPSE® FLOOR shrinkage reducer
Straight Copper Plated Micro Steel Fibre 0.2x13mm (1.5% of Volume)

After many revisions, I am publishing the final version (for now).
I want to start making the formwork for casting uhpc base and portal.
I received the cement soon and am just waiting for the stee fiber from China
So I'm asking for advice if you don't like something or it's wrong.

I would like the base to be thicker and without a beam structure, but the requirement is that it can be lifted and moved without special equipment.
That's why it's this complicated shape - to optimize the weight. Base: 135 kg. Gantry - 102 kg.
For this reason, the base is reinforced from above with 50x50mm dense calibrated steel C45 beams .
Bottom - 60x80x5mm rectangular profiles.

On the back of the portal I will install a 10mm steel plate.
Perhaps it is not needed, but I have such excess material and it will additionally strengthen the portal.

There is no steel in the castings (except for a few thread insert at the base of the gantry). All connections are bolted through the concrete.
Any small irregularities in the common surfaces between concrete and steel (slabs, profiles, etc.) will be leveled with
liquid metal Loctite EA 3478 A+B (Compressive Strength 134 N/mm2, @65ºC, ISO 604).

The stand will made of IPE 200 profiles. I gave up on welded structures because of continuous deformations over time.

IPE profiles make for the easiest bolt connections (again with Loctite EA 3478 between them)

First I have to prepare the forms for casting the concrete.
I will post pictures of the progress of the project.

Happy Holidays !
I wish everyone good health!
And good luck too!

[Ivan_1966]

continue....

[peteeng]

HNY for 2024 Ivan - Great to see your design. Look fwd to seeing it materiaise into reality. Add generous radii to the inside corners of the base to prevent cracking and wax those moulds well!! I see you have speced Z0 preload cars. This is not recommended for this type of machine. Best is ZB but ZA is better then Z0 if you can't get ZA.... Peter

edit - Ivan your English is perfect!

[Ivan_1966]

Happy New Year !
Yes Peter, I wanted to buy blocks with ZA preload, but in Bulgaria, the HIWIN distributor offered a only Z0. They are mass bought . They told me that for a router preload Z0 is enough. They also told that the ZB move quite hard and wear out quickly. My blocks are already bought anyway and I can't return them.
The only way is - I to buy quality steel balls with the required diameter for ZA or ZB and replace them.
I will look for information on ball sizes for the different preload.
Maybe it will be difficult to assemble bloks with balls for ZB preload !.
So, ZA or ZB?

[Ivan_1966]

....Add generous radii to the inside corners of the base to prevent cracking and wax those moulds well!!....

Ok. I will do that. Thank you !

[catahoula]

I also tried to buy HGH-20-HA blocks with ZB preload and was told by the distributor (an aliexpress store in this case) that Hiwin does not recommend ZB preload for smaller size rails. So I got ZA preload. Hopefully and probably they will be fine, I will find out soon.

[Ivan_1966]

Thank you so much catahoula for this info. Ok, I will want steel balls for ZA preload.

P.S. I'm impressed with the very stiffness machine you've made.

[Ivan_1966]

So far I can't find any information about the diameter of the balls for HIWIN HGH25.
I found only about some Chinese brand SNWNYN in which they write about their HGH25 - ball diameter 4.763mm.
I have a precision micrometer and I will measure balls of my blocks. But they for preload Z0 !
And what should they be for ZA preload?

[peteeng]

Hi Ivan - The med preload cars easily slip onto the rails by hand. Send a note to Hiwin direct with your questions they will answer. Peter

[Ivan_1966]

Hi Ivan - The med preload cars easily slip onto the rails by hand. Send a note to Hiwin direct with your questions they will answer. Peter

OK Peter.

HGH25CAZ0H ball diameter - 4.748mm at temperature about 22 degree celsius.
Only one ball was measured - several times. The value does not change.

[Ivan_1966]

These are the casting molds. There is a lot of work on them. Lots of steel tubes (10x1mm) for the through bolts. They will remain in the cast concrete. Today I start making the molds.

[peteeng]

Hi Ivan - Ambitious - I like it. Peter

[Ivan_1966]

Thanks Peter !
Here are the molds for internal castings (X base).
From three pieces glued together to achieve the required thickness (95mm and 75mm).
XPS Fibran and chipboard. This was necessary because I have nothing to cut more than 4.5 cm thick with.
Then I will fill the chipboard cuts with wood putty, round the edges with sandpaper and paint them.

[peteeng]

Hi Ivan - Typically for fillets we use automotive body filler. Wood filler may go soft or dissolve. Better do a test or read the tech sheet on your proposed filler. Peter

[Ivan_1966]

Peter, I took your advice and bought polyester body filler

[Ivan_1966]

The mold for X is almost ready.

[Ivan_1966]

The bases for the x and y rails arrived today. Processed on a flat grinder (I don't know if this is the correct name in English)
Since the working length of the grinder is up to 1000 mm, but X is 1500, first 1000 mm were processed, then by sliding the workpiece - the remaining 500 mm. Since there is no way to get an exact fit this 500mm are left about a few microns higher.
I'll hand-finish them with a new russian bridge straight line, painting and hand scraping.

[catahoula]

Looks like you're off to a great start. I hope you can get the base out of the mold without any damage!

[Ivan_1966]

Catahoula, I will try to be very careful . I will use PLOPP mould release agent.
But there will probably be some minor chipping along the edges that will be fixed later. Today I'm going to do some rounding on all the edges with acrylic silicone.

[catahoula]

Maybe you could attach the steel bar that goes onto the open side before de-molding, to reinforce it?