Author Topic: I've decided I want to build computer-controlled CNC machines, like 5-axis mills  (Read 2012 times)

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Offline renzomsTopic starter

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I've decided I want to build computer-controlled CNC machines, like 5-axis mills, or similar "building machines" that share similar technologies, like 3D resin printers with their x-y-z motion and application of a function at a point in space. I want to be a part of a group that builds these.
What first pieces of advice do you have?

I've got all the time in the world and I'll start junior year EE next Spring 2022

I just saw StuffMadeHere's [video][/https://www.youtube.com/watch?v=SjJulcvTA7Y&t=1407s&ab_channel=StuffMadeHere ] and thought, "Yeah. Cool. I'd like to make those machines!

This would definitely involve Signal processing, Controls, Power, etc electrical engineering.

So what first recommendations do you have? What sort of technologies do these machines share. I ask so that I may pinpoint some information or knowledge that I should go out and learn! Perhaps I can find some classes on OCW about them, and pick my electives for college based on this decision. Maybe you've seen some similar arduino project sort of things that will get me into the "environment" of these machines. Maybe you've got a subreddit or forum you can recommend.

Thanks seriously.

‡ For the interested reader, my current education includes great fundamentals in linear electric circuits, c programming, MV calculus, differential eqn, kinematics, digital logic/verilog, rusty linear algebra and digital signal processing, beginner CAD and fea skils, and my resources include access to the internet, books, forums, the university and it's groups, and my small home lab. ‡
« Last Edit: June 29, 2021, 11:50:58 pm by renzoms »
 

Offline langwadt

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90% of it is mechanical design
 

Offline Brumby

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... at least.
 

Offline renzomsTopic starter

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Offline Bud

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Embedded programming is the least of you worries. As other said, this task is about mechanical design, which i understand you have no experience or knowledge of. You need to shift your focus to that if you really want to do it.

Facebook-free life and Rigol-free shack.
 

Offline rstofer

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Google is your friend, there are 5 axis projects all over the place.

The general work flow starts with CAD (I use an older free version of AutoCad) which produces a file as input to CAM (I use CAMBAM) which creates the G-codes for a stepper controller like Mach 3 which is connected to a driver controller like SmoothStepper (I use the network version).  All of the hard work is instructing CAMBAM on how to make the cuts.  You would need one of the 3D CAD programs but I don't know anything about them.

Since I only do 2.5D (two axis plus drill), I can't really help with something as complex as 5 axis.  I know about 50 years ago we had some very large 5 axis machines at the aerospace company where I worked.  The definitive test was to create a dairy cone with the usual contours.  Five axis interpolation is hard!

I would start by wandering through the Google replies to a search for '5 Axis CNC DIY'
 

Offline Cyberdragon

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Quote
computer-controlled CNC

I'll file that right next to "ATM machine"
*BZZZZZZAAAAAP*
Voltamort strikes again!
Explodingus - someone who frequently causes accidental explosions
 
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Offline rstofer

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A very popular 3 axis (plus maybe a bolt on 4th axis) is the Grizzly G0704 Mill.  Before the tariffs, it used to be quite a bit cheaper but the conversion works well.

I had a drilling job that needed very accurate positioning so I built up the Grizzly specifically for that job and any others that would follow.  It was an interesting project!  But it's a long way from 5 axis.

Google for projects...
« Last Edit: June 30, 2021, 01:32:18 pm by rstofer »
 

Offline Microdoser

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computer-controlled CNC

I'll file that right next to "ATM machine"

When I use one of those, I have to type in my personal PIN number.
 
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Offline PaulAm

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Electronics is the least of your problems.

First question: What material do you want to machine and how big is the envelope?

You could make your machine out of plexiglass and machine foam with palm size steppers, but machining aluminum or steel is another world entirely.

There's also something of the chicken and egg problem here - you need a decent machine shop to be able to make a decent CNC machine.

Even using an existing machine like the Grizzly for a base, there's still lots of fabrication involved.

Second question: how big is your wallet?  :-DD
 

Offline MadScientist

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I would echo the previous post

Envelope and material are two big decisions

From that flow cost and complexity.

5 axis won’t be cheap , so I hope you have a reasonable budget along with all that time

You will need access to a machine  shop
EE's: We use silicon to make things  smaller!
 

Offline Brumby

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..... I have to type in my personal PIN number.

Expanded form:
..... I have to type in my personal Personal Identification Number number


Made me smile.   ;D
 

Offline rstofer

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There's also something of the chicken and egg problem here - you need a decent machine shop to be able to make a decent CNC machine.

Even using an existing machine like the Grizzly for a base, there's still lots of fabrication involved.

Second question: how big is your wallet?  :-DD

Actually, I just bought a ball screw conversion kit and bolted it in place.  It already had the hubs necessary to mount the stepper motors.  No machining required.

Something like this:

https://www.automationtechnologiesinc.com/products-page/g0704-bf20-pm25mv-x2-x3-kit/g0704-with-duf-ballscrew

Then I added steppers, drivers, controller, PC and all the usual suspects.

Drivers like this:

https://www.automationdirect.com/adc/shopping/catalog/motion_control/stepper_systems/stepper_drives/dm542e

Motion controller like this:

https://warp9td.com/index.php/gettingstarted/what-is-a-smoothstepper

An industrial computer like this but much earlier version.  It's running Win 7 I believe (haven't played with it much lately:

https://www.onlogic.com/ml350g-10/

A 48VDC power supply like this:

https://www.automationtechnologiesinc.com/products-page/switching-power-supply/48v-20a-switching-cnc-power-supplykl-1000-48

I put all of the electronics in a PC mid-size tower case.  I had to add a swing-out panel to hold the PC because the driver stuff took all of the internal space.

All of the links above point to things 'like' what I used but I'm too lazy to open the case to see the actual part numbers.  If you go this way, do your own research.

Bottom line:  Everything was off the shelf and a simple bolt-on operation.

Another bottom line:  Pick a mill for which kits are already available.

But... It's only 3 axis and 5 axis is a whole different thing.
 

Offline Syed Muneeb

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There's also something of the chicken and egg problem here - you need a decent machine shop to be able to make a decent CNC machine.

Even using an existing machine like the Grizzly for a base, there's still lots of fabrication involved.

Second question: how big is your wallet?  :-DD

Actually, I just bought a ball screw conversion kit and bolted it in place.  It already had the hubs necessary to mount the stepper motors.  No machining required.

Something like this:

https://cncrouterhub.com/
https://www.automationtechnologiesinc.com/products-page/g0704-bf20-pm25mv-x2-x3-kit/g0704-with-duf-ballscrew

Then I added steppers, drivers, controller, PC and all the usual suspects.

Drivers like this:

https://www.automationdirect.com/adc/shopping/catalog/motion_control/stepper_systems/stepper_drives/dm542e

Motion controller like this:

https://warp9td.com/index.php/gettingstarted/what-is-a-smoothstepper

An industrial computer like this but much earlier version.  It's running Win 7 I believe (haven't played with it much lately:

https://www.onlogic.com/ml350g-10/

A 48VDC power supply like this:

https://www.automationtechnologiesinc.com/products-page/switching-power-supply/48v-20a-switching-cnc-power-supplykl-1000-48

I put all of the electronics in a PC mid-size tower case.  I had to add a swing-out panel to hold the PC because the driver stuff took all of the internal space.

All of the links above point to things 'like' what I used but I'm too lazy to open the case to see the actual part numbers.  If you go this way, do your own research.

Bottom line:  Everything was off the shelf and a simple bolt-on operation.

Another bottom line:  Pick a mill for which kits are already available.

But... It's only 3 axis and 5 axis is a whole different thing.

Thanks it really helped.
 

Offline MarkF

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Take a look at Clough42 YouTube channel:
   https://www.youtube.com/channel/UCeKpbMimEGgLM_0tnghfoVw/videoshttps://www.youtube.com/channel/UCeKpbMimEGgLM_0tnghfoVw/videos
He automated his Grizzly mill.

He uses Fusion 360 to do his design work.
You can search the videos for a instance where he states what software package he uses to drive the mill. 
I know he mentions it several times (and also describes doing calibration for each tool) but; I don't have time to look for it.

It will give you a starting point at least.
I don't think you want to attempt to write you're own software package.
 

Offline sokoloff

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He uses Mach3.
 

Offline jmelson

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He uses Mach3.
Mach 3 is pretty obsolete, it hasn't been actively developed in over a decade.  It also is fairly limited.  You might take a look at LinuxCNC, which is still actively developed.  It also handles non-Cartesian machines and 4- and 5-axis machines.  See http://www.linuxcnc.org/
for more info.  You can download it for free and burn to a DVD, and then try running it without installing on the PC hard drive.

Jon
 


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