{"id":354,"date":"2020-07-11T10:26:15","date_gmt":"2020-07-11T08:26:15","guid":{"rendered":"http:\/\/engineerlab.de\/?page_id=354"},"modified":"2023-01-22T20:43:55","modified_gmt":"2023-01-22T19:43:55","slug":"cnc-milling-machine","status":"publish","type":"page","link":"https:\/\/engineerlab.de\/?page_id=354","title":{"rendered":"CNC milling machine"},"content":{"rendered":"<div id=\"toc_container\" class=\"no_bullets\"><p class=\"toc_title\">Contents<\/p><ul class=\"toc_list\"><li><a href=\"#Last_documented_status\"><span class=\"toc_number toc_depth_1\">1<\/span> Last documented status<\/a><\/li><li><a href=\"#Preparing\"><span class=\"toc_number toc_depth_1\">2<\/span> Preparing<\/a><\/li><li><a href=\"#Technical_specification\"><span class=\"toc_number toc_depth_1\">3<\/span> Technical specification<\/a><\/li><li><a href=\"#Drawings\"><span class=\"toc_number toc_depth_1\">4<\/span> Drawings<\/a><\/li><li><a href=\"#Stepper_Motor_Driver\"><span class=\"toc_number toc_depth_1\">5<\/span> Stepper Motor Driver<\/a><\/li><li><a href=\"#3D_printed_components\"><span class=\"toc_number toc_depth_1\">6<\/span> 3D printed components<\/a><\/li><li><a href=\"#Limit_switch_and_homing\"><span class=\"toc_number toc_depth_1\">7<\/span> Limit switch and homing<\/a><\/li><li><a href=\"#Switching_cabinet\"><span class=\"toc_number toc_depth_1\">8<\/span> Switching cabinet<\/a><\/li><li><a href=\"#2_Version_of_Z_axis_with_moving_rails\"><span class=\"toc_number toc_depth_1\">9<\/span> 2. Version of Z axis with moving rails<\/a><\/li><li><a href=\"#LinuxCNC_and_Mesa_7i96\"><span class=\"toc_number toc_depth_1\">10<\/span> LinuxCNC and Mesa 7i96<\/a><\/li><li><a href=\"#Tips_and_Tricks\"><span class=\"toc_number toc_depth_1\">11<\/span> Tips and Tricks<\/a><\/li><li><a href=\"#Safety_first\"><span class=\"toc_number toc_depth_1\">12<\/span> Safety first!<\/a><\/li><li><a href=\"#Usefull_software\"><span class=\"toc_number toc_depth_1\">13<\/span> Usefull software<\/a><\/li><li><a href=\"#Usefull_Links\"><span class=\"toc_number toc_depth_1\">14<\/span> Usefull Links:<\/a><\/li><\/ul><\/div>\n<h1><span id=\"Last_documented_status\">Last documented status<\/span><\/h1>\n<p><img loading=\"lazy\" class=\"alignnone size-medium wp-image-450\" src=\"http:\/\/engineerlab.de\/wp-content\/uploads\/2021\/01\/cnc_fraese_stand_2020_12_02-e1611498998719-300x225.jpg\" alt=\"\" width=\"300\" height=\"225\" srcset=\"https:\/\/engineerlab.de\/wp-content\/uploads\/2021\/01\/cnc_fraese_stand_2020_12_02-e1611498998719-300x225.jpg 300w, https:\/\/engineerlab.de\/wp-content\/uploads\/2021\/01\/cnc_fraese_stand_2020_12_02-e1611498998719-768x576.jpg 768w, https:\/\/engineerlab.de\/wp-content\/uploads\/2021\/01\/cnc_fraese_stand_2020_12_02-e1611498998719-1024x768.jpg 1024w\" sizes=\"(max-width: 300px) 85vw, 300px\" \/><\/p>\n<h1><span id=\"Preparing\">Preparing<\/span><\/h1>\n<p>First planning a 3d model. The goal is to build a small and &#8222;cheap&#8220; milling machine for general purpose.<br \/>\nThe material which I want to mill will be plastic like polycarbonat, wood and thin metal plates like aluminium.<br \/>\nAnother aspect is to have the possibility to mill copper plated pcb&#8217;s for prototyping.<\/p>\n<p>Old-Version:<br \/>\n<iframe loading=\"lazy\" src=\"https:\/\/myhub.autodesk360.com\/ue2a4aeb4\/shares\/public\/SH56a43QTfd62c1cd968fcdeabc8e1856e71?mode=embed\" allowfullscreen=\"allowfullscreen\" width=\"800\" height=\"600\" frameborder=\"0\"><\/iframe><\/p>\n<p>New version (driving rails):<br \/>\n<iframe loading=\"lazy\" src=\"https:\/\/myhub.autodesk360.com\/ue2a4aeb4\/shares\/public\/SH9285eQTcf875d3c53980f67833a54b7848?mode=embed\" allowfullscreen=\"true\" webkitallowfullscreen=\"true\" mozallowfullscreen=\"true\" width=\"800\" height=\"600\" frameborder=\"0\"><\/iframe><\/p>\n<h1><span id=\"Technical_specification\">Technical specification<\/span><\/h1>\n<p>Working area:<br \/>\ny-axe: 650 mm<br \/>\nx-axe: 450 mm<br \/>\nz-axe: 125 mm<\/p>\n<p>Used mechanical components:<br \/>\nFor the y- and x-axe I used profile rails HGR20 and blocks from type HRC20-FN-V0<\/p>\n<p>portal cheeks:<br \/>\n323 mm x 392 mm x 20 mm<\/p>\n<p>Drag chain:<br \/>\nL &#8211; length of calculated drag chain<br \/>\nV &#8211; length of trace<br \/>\n<img loading=\"lazy\" class=\"alignnone size-medium wp-image-445\" src=\"http:\/\/engineerlab.de\/wp-content\/uploads\/2021\/01\/drag_chain-300x132.jpg\" alt=\"\" width=\"300\" height=\"132\" srcset=\"https:\/\/engineerlab.de\/wp-content\/uploads\/2021\/01\/drag_chain-300x132.jpg 300w, https:\/\/engineerlab.de\/wp-content\/uploads\/2021\/01\/drag_chain-768x338.jpg 768w, https:\/\/engineerlab.de\/wp-content\/uploads\/2021\/01\/drag_chain-1024x451.jpg 1024w, https:\/\/engineerlab.de\/wp-content\/uploads\/2021\/01\/drag_chain-1200x528.jpg 1200w\" sizes=\"(max-width: 300px) 85vw, 300px\" \/><br \/>\nL = V\/2+pi*R<\/p>\n<h1><span id=\"Drawings\">Drawings<\/span><\/h1>\n<p><a href=\"http:\/\/engineerlab.de\/wp-content\/uploads\/2020\/11\/montageplatte_kugelumlauf_yachse.pdf\">mounting plate y-axes (ball screw)<\/a><br \/>\n<a href=\"http:\/\/engineerlab.de\/wp-content\/uploads\/2020\/11\/portalwange_rechts.pdf\">portalwange_rechts<\/a><\/p>\n<p><a href=\"http:\/\/engineerlab.de\/wp-content\/uploads\/2020\/09\/overview.png\"><img loading=\"lazy\" class=\"aligncenter size-full wp-image-395\" src=\"http:\/\/engineerlab.de\/wp-content\/uploads\/2020\/09\/overview.png\" alt=\"\" width=\"451\" height=\"442\" srcset=\"https:\/\/engineerlab.de\/wp-content\/uploads\/2020\/09\/overview.png 451w, https:\/\/engineerlab.de\/wp-content\/uploads\/2020\/09\/overview-300x294.png 300w\" sizes=\"(max-width: 451px) 85vw, 451px\" \/><\/a><\/p>\n<p><a href=\"http:\/\/engineerlab.de\/wp-content\/uploads\/2020\/09\/rueckseite.png\"><img loading=\"lazy\" class=\"aligncenter size-full wp-image-396\" src=\"http:\/\/engineerlab.de\/wp-content\/uploads\/2020\/09\/rueckseite.png\" alt=\"\" width=\"517\" height=\"416\" srcset=\"https:\/\/engineerlab.de\/wp-content\/uploads\/2020\/09\/rueckseite.png 517w, https:\/\/engineerlab.de\/wp-content\/uploads\/2020\/09\/rueckseite-300x241.png 300w\" sizes=\"(max-width: 517px) 85vw, 517px\" \/><\/a><\/p>\n<p><a href=\"http:\/\/engineerlab.de\/wp-content\/uploads\/2020\/09\/rechts.png\"><img loading=\"lazy\" class=\"aligncenter size-full wp-image-402\" src=\"http:\/\/engineerlab.de\/wp-content\/uploads\/2020\/09\/rechts.png\" alt=\"\" width=\"544\" height=\"338\" srcset=\"https:\/\/engineerlab.de\/wp-content\/uploads\/2020\/09\/rechts.png 544w, https:\/\/engineerlab.de\/wp-content\/uploads\/2020\/09\/rechts-300x186.png 300w\" sizes=\"(max-width: 544px) 85vw, 544px\" \/><\/a><\/p>\n<p><a href=\"http:\/\/engineerlab.de\/wp-content\/uploads\/2020\/09\/front.png\"><img loading=\"lazy\" class=\"aligncenter size-full wp-image-398\" src=\"http:\/\/engineerlab.de\/wp-content\/uploads\/2020\/09\/front.png\" alt=\"\" width=\"389\" height=\"365\" srcset=\"https:\/\/engineerlab.de\/wp-content\/uploads\/2020\/09\/front.png 389w, https:\/\/engineerlab.de\/wp-content\/uploads\/2020\/09\/front-300x281.png 300w\" sizes=\"(max-width: 389px) 85vw, 389px\" \/><\/a><\/p>\n<p><a href=\"http:\/\/engineerlab.de\/wp-content\/uploads\/2020\/09\/back.png\"><img loading=\"lazy\" class=\"aligncenter size-full wp-image-399\" src=\"http:\/\/engineerlab.de\/wp-content\/uploads\/2020\/09\/back.png\" alt=\"\" width=\"441\" height=\"406\" srcset=\"https:\/\/engineerlab.de\/wp-content\/uploads\/2020\/09\/back.png 441w, https:\/\/engineerlab.de\/wp-content\/uploads\/2020\/09\/back-300x276.png 300w\" sizes=\"(max-width: 441px) 85vw, 441px\" \/><\/a><\/p>\n<p>Sneak peek of the used components:<br \/>\nY-spindle 800 mm long<br \/>\nX-, Y- linear rails (4xHRC20-FN-V0)<br \/>\ncable chain<br \/>\nall bearings<\/p>\n<p><a href=\"http:\/\/engineerlab.de\/wp-content\/uploads\/2020\/09\/material.jpg\"><img loading=\"lazy\" class=\"aligncenter size-full wp-image-404\" src=\"http:\/\/engineerlab.de\/wp-content\/uploads\/2020\/09\/material.jpg\" alt=\"\" width=\"4160\" height=\"3120\" srcset=\"https:\/\/engineerlab.de\/wp-content\/uploads\/2020\/09\/material.jpg 4160w, https:\/\/engineerlab.de\/wp-content\/uploads\/2020\/09\/material-300x225.jpg 300w, https:\/\/engineerlab.de\/wp-content\/uploads\/2020\/09\/material-768x576.jpg 768w, https:\/\/engineerlab.de\/wp-content\/uploads\/2020\/09\/material-1024x768.jpg 1024w\" sizes=\"(max-width: 709px) 85vw, (max-width: 909px) 67vw, (max-width: 1362px) 62vw, 840px\" \/><\/a><\/p>\n<p>Resolution of my configuration with 1605 ballscrew and 1\/8 microstepping:<br \/>\n360\u00b0\/1.8\u00b0 * Microstepping * 1\/screw pitch = 360\u00b0\/1.8\u00b0 * 8 * 1\/5 mm = 320 steps\/mm<br \/>\nThis gives me a resolution of 1\/320 mm. About 0.003125 mm per step.<\/p>\n<p>With 1\/16 microstepping I getting a double in resolution but the motor looses torque.<\/p>\n<h1><span id=\"Stepper_Motor_Driver\">Stepper Motor Driver<\/span><\/h1>\n<p>Three Leadshine DM542EU (original no clone!)<\/p>\n<p>Max. possible driving speed with these stepper motor driver with an maximum frequency of 200 kHz results to:<\/p>\n<p>0.003125 mm * 200,000 * 1\/s = 625 mm\/s = 37500 mm\/min = 37.5 m\/min<\/p>\n<p>Max. speed of 38 m\/min<\/p>\n<h1><span id=\"3D_printed_components\">3D printed components<\/span><\/h1>\n<p>Cover for NEMA 23 motor with GX16 connector<br \/>\n<a href=\"http:\/\/engineerlab.de\/wp-content\/uploads\/2021\/01\/3d_printed_cover_GX16.jpg\"><img loading=\"lazy\" class=\"alignleft size-full wp-image-431\" src=\"http:\/\/engineerlab.de\/wp-content\/uploads\/2021\/01\/3d_printed_cover_GX16.jpg\" alt=\"\" width=\"520\" height=\"390\" srcset=\"https:\/\/engineerlab.de\/wp-content\/uploads\/2021\/01\/3d_printed_cover_GX16.jpg 4160w, https:\/\/engineerlab.de\/wp-content\/uploads\/2021\/01\/3d_printed_cover_GX16-300x225.jpg 300w, https:\/\/engineerlab.de\/wp-content\/uploads\/2021\/01\/3d_printed_cover_GX16-768x576.jpg 768w, https:\/\/engineerlab.de\/wp-content\/uploads\/2021\/01\/3d_printed_cover_GX16-1024x768.jpg 1024w\" sizes=\"(max-width: 520px) 85vw, 520px\" \/><\/a><\/p>\n<p><a href=\"http:\/\/engineerlab.de\/wp-content\/uploads\/2021\/01\/3d_printed_cover_GX16_2.jpg\"><img loading=\"lazy\" class=\"alignleft size-full wp-image-432\" src=\"http:\/\/engineerlab.de\/wp-content\/uploads\/2021\/01\/3d_printed_cover_GX16_2.jpg\" alt=\"\" width=\"520\" height=\"390\" srcset=\"https:\/\/engineerlab.de\/wp-content\/uploads\/2021\/01\/3d_printed_cover_GX16_2.jpg 4160w, https:\/\/engineerlab.de\/wp-content\/uploads\/2021\/01\/3d_printed_cover_GX16_2-300x225.jpg 300w, https:\/\/engineerlab.de\/wp-content\/uploads\/2021\/01\/3d_printed_cover_GX16_2-768x576.jpg 768w, https:\/\/engineerlab.de\/wp-content\/uploads\/2021\/01\/3d_printed_cover_GX16_2-1024x768.jpg 1024w\" sizes=\"(max-width: 520px) 85vw, 520px\" \/><\/a><\/p>\n<h1><span id=\"Limit_switch_and_homing\">Limit switch and homing<\/span><\/h1>\n<p>LJ12A NPN normaly closed (\u00d6ffner)<br \/>\nWorks with 5V (even is specified 6V..30V)<br \/>\nPinout: black (ouput), blue (GND), brown (+Vcc)<br \/>\nhttps:\/\/www.rc-letmathe.de\/CNC-Elektrozubehoer\/Induktiver-Naeherungsschalter&#8211;Proximy-Switch?source=2&#038;refertype=1&#038;referid=177<\/p>\n<h1><span id=\"Switching_cabinet\">Switching cabinet<\/span><\/h1>\n<p>The DIN rails are mounted with sheet metal screws (DIN 7504)<\/p>\n<h1><span id=\"2_Version_of_Z_axis_with_moving_rails\">2. Version of Z axis with moving rails<\/span><\/h1>\n<p>Bezeichnung\tSchraube\tAnzahl<br \/>\nKreuzplatte<br \/>\n&#8212; Wagen HRC 20 Flansch\tM6 x 16\t16<br \/>\n&#8212; Schienen \tM5 x 16\t12<br \/>\n&#8212; KUS\tM5??\t8<br \/>\n&#8212; Winkel\tM8 x 10\t10<br \/>\nMontageplatte Spindel<br \/>\n&#8212; Versteifungen\tM6 x 10\t26<br \/>\n&#8212; Spindel-Geh\u00e4use\tM6 x 10\t8<\/p>\n<p>Aktueller Designstand<br \/>\nKreuzplatte \t275 x 153 x 35 mm\u00b3\t1<br \/>\nMontageplatte Spindel\t351 x 153 x 15 mm\u00b3\t1\t351 x 153 x 18 mm\u00b3<br \/>\nVersteifungen Z-Platte\t337 x 73 x 15 mm\u00b3\t2<br \/>\nZ-Platte-Festlager\t121 x 153 x 15 mm\u00b2\t1<br \/>\nMontageplatte Y-Achse Wagen\t200 x 223 x 15 mm\u00b2\t1<\/p>\n<h1><span id=\"LinuxCNC_and_Mesa_7i96\">LinuxCNC and Mesa 7i96<\/span><\/h1>\n<p>Custom keyfiles in LinuxCNC:<br \/>\ncd ~\/.<br \/>\nls -a<br \/>\nsudo nano .axisrc<br \/>\n.axisrc &#8211; file:<\/p>\n<p>Howto using the pwm output on step 4 of the mesa card:<br \/>\nFlashing the right bit-file<br \/>\nhttps:\/\/forum.linuxcnc.org\/27-driver-boards\/39823-flashing-7i96-to-support-pwm-outputs<\/p>\n<h1><span id=\"Tips_and_Tricks\">Tips and Tricks<\/span><\/h1>\n<p>Remap short key&#8217;s:<br \/>\n1. Open Termin in Linux und type in &#8222;sudo nano .axisrc&#8220;<br \/>\n2. Type in your custom bindings<br \/>\n#choose 0=for x-axis, 1=for y-axis, 2=for Z-axis, 3=A, 4=B, &#8230;)<br \/>\nroot_window.bind(&#8222;&lt;Up&gt;&#8220;, lambda e: jog_on(0, get_jog_speed(0)))<br \/>\nroot_window.bind(&#8222;&lt;Down&gt;&#8220;, lambda e: jog_on(0, -get_jog_speed(0)))<br \/>\nroot_window.bind(&#8222;&lt;KeyRelease-Up&gt;&#8220;, lambda e: jog_off(0))<br \/>\nroot_window.bind(&#8222;&lt;KeyRelease-Down&gt;&#8220;, lambda e: jog_off(0))<br \/>\nYou need Keyrelease to stop jogging if releasing the key otherwise, the axis jog permanently<\/p>\n<h1><span id=\"Safety_first\">Safety first!<\/span><\/h1>\n<p>In case of an failure of the VFD it is possible that a dc current flows in the protective ground conductor which can exceed a dangerous current. Therefore all VFD manufacturer recommending to use the following RCD type for protection against direct or indirect contact. The RCD has to be installed between the mains supply and VFD input, not the output side of the vfd!<\/p>\n<p>For 1-phase VFD&#8217;s: RCD Type F (in german: pulsstromsensitiv Type F)<br \/>\nFor 3-pase VFD&#8217;s: RCD Type B (in german: allstromsensitiv Type B)<\/p>\n<p>The tripping current should be at least &lt;= 30mA!! Dont use the EV charger RCD&#8217;s they are not suitable for this!!!<\/p>\n<p>You can read more about this in the LENZE VFD system manual (like the E82EV222-2C)<\/p>\n<h1><span id=\"Usefull_software\">Usefull software<\/span><\/h1>\n<p>CAM-Software:<br \/>\nhttp:\/\/www.cambam.info\/<br \/>\n3D Cam Simulator which can be integrated in CamBam:<br \/>\nhttps:\/\/camotics.org\/<\/p>\n<h1><span id=\"Usefull_Links\">Usefull Links:<\/span><\/h1>\n<p><a href=\"https:\/\/www.mcmaster.com\/\" target=\"_blank\" rel=\"noopener\">3d models of all screws<\/a><br \/>\n<a href=\"https:\/\/schraube-mutter.de\/bohrtabelle-fuer-zylinderschrauben\/\" target=\"_blank\" rel=\"noopener\">lowering of cylinderhead srew<\/a><br \/>\n<a href=\"https:\/\/www.cenon.de\/cgi-bin\/ToolCalc?lng=de\" target=\"_blank\" rel=\"noopener\">Online calculator<\/a><br \/>\n<a href=\"https:\/\/www.anzugsmoment.de\/metrische-gewinde\/blechschrauben-kernloch\/\">Sheet metal screws (Blechschrauben D 7504<\/a><br \/>\n<a href=\"http:\/\/www.b-pahl.de\/bastel\/notstop\/sss.html\" target=\"_blank\" rel=\"noopener\">Spindel-Sicher-schalten<\/a><br \/>\n<a href=\"https:\/\/de.wikipedia.org\/wiki\/Selbsthaltefunktion\" target=\"_blank\" rel=\"noopener\">Selbsthaltefunktion<\/a><br \/>\n<a href=\"https:\/\/gist.github.com\/Bouni\/803492ed0aab3f944066\" target=\"_blank\" rel=\"noopener\">Huanyand Modbus Command<\/a><br \/>\n<a href=\"https:\/\/www.youtube.com\/watch?v=VftazY1AHgo\" target=\"_blank\" rel=\"noopener\">Fusion 360 CAM Example<\/a><br \/>\n<a href=\"https:\/\/www.youtube.com\/watch?v=oRTcqNxsM4k\" target=\"_blank\" rel=\"noopener\">Fusion 360 Generating Gcode LinuxCNC Postprocessor<\/a><br \/>\n<a href=\"https:\/\/mcdcad.eu\/2018\/01\/23\/fusion-360-cnc-schnittdaten-fuer-ihre-fraeser-und-materialien-ermitteln\/\" target=\"_blank\" rel=\"noopener\">Fusion 360 Calculating Cutting Parameter<\/a><\/p>\n","protected":false},"excerpt":{"rendered":"<p>Contents1 Last documented status2 Preparing3 Technical specification4 Drawings5 Stepper Motor Driver6 3D printed components7 Limit switch and homing8 Switching cabinet9 2. Version of Z axis with moving rails10 LinuxCNC and Mesa 7i9611 Tips and Tricks12 Safety first!13 Usefull software14 Usefull Links: Last documented status Preparing First planning a 3d model. The goal is to build &hellip; <a href=\"https:\/\/engineerlab.de\/?page_id=354\" class=\"more-link\"><span class=\"screen-reader-text\">&#8222;CNC milling machine&#8220; <\/span>weiterlesen<\/a><\/p>\n","protected":false},"author":1,"featured_media":0,"parent":0,"menu_order":0,"comment_status":"closed","ping_status":"closed","template":"","meta":[],"_links":{"self":[{"href":"https:\/\/engineerlab.de\/index.php?rest_route=\/wp\/v2\/pages\/354"}],"collection":[{"href":"https:\/\/engineerlab.de\/index.php?rest_route=\/wp\/v2\/pages"}],"about":[{"href":"https:\/\/engineerlab.de\/index.php?rest_route=\/wp\/v2\/types\/page"}],"author":[{"embeddable":true,"href":"https:\/\/engineerlab.de\/index.php?rest_route=\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/engineerlab.de\/index.php?rest_route=%2Fwp%2Fv2%2Fcomments&post=354"}],"version-history":[{"count":87,"href":"https:\/\/engineerlab.de\/index.php?rest_route=\/wp\/v2\/pages\/354\/revisions"}],"predecessor-version":[{"id":551,"href":"https:\/\/engineerlab.de\/index.php?rest_route=\/wp\/v2\/pages\/354\/revisions\/551"}],"wp:attachment":[{"href":"https:\/\/engineerlab.de\/index.php?rest_route=%2Fwp%2Fv2%2Fmedia&parent=354"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}