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Messages - SimonD

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I fly a DF4 & a Walkera 36. Nice job on the rotor core.
Thanks... My DF4 is pretty non-standard now. It even has a complete CNC'd head and 2.4Ghz receiver. The frame and main motor is original though  ;D
If you still run the plastic DF4 core and want an Ally one, give me a shout.


Yes the 4th axis is made from scratch.
It is stepper driven through a 32 - 10 belt drive.
The spindle is a genuine cheap copy of an ER20 2 Morse Taper Collet Chuck (£5 from eBay)
The bearings are Deep groove Radial 6804-2RS bearings, I didn't need a lot of preload so deep groove bearings are perfectly adequate.

I don't use it as a spindle but as a rotary indexer and so have not tried it at speed. I guess it will be limited by the kernal frequency... 200 steps * 10 microstepping * 3.2 ratio = 6400 steps per rev. at 25khz that would be 234 rpm

I have attached a pic of the axis "transparent" so you can see the inside.

Yes I have used it extensively and have not found any problems with it. The stepper is pretty weak but that is to be expected. It is fine for cutting but does not have the power to hold the collet chuck in place while you try and ram the main spindle into it (Yes, it has tried it on a particularly odd hiccup) it just freewheels which is quite nice as it saved the chuck.

In the collet is just a small fixture I use for making RC Helicopter Rotor Cores, a picture of which can be seen here along side the plastic part it replaces.... http://www.byte-sized.com/ebay/DF4_Core_Both.jpg
To give an idea of scale, it is made from 1/2" bar.

The travel on the Boxford is 190mm in X and ~125mm in Y



Yes the 4th axis is belt driven. The ratio is 32:10 Not ideal but the biggest ratio I could get in the small space.


The CoolJet is similar in concept to this patent...

The coolant and air is supplied at the same pressure to the nozzle and mixes together so you get fine dropplets in the air stream. The adjuster regulates the amount of liquid in the airstream.
I have made it also remotely adjustable using a RC servo. That way when the machine does a toolchange it can move itself out of the way of the toolchanger and return to the correct position for the specific tool.


Seeing all the other 4th axis on here, I thought I would show my rendition of one, along with the tooling plate and CoolJet I made for my Boxford 190VMC.

General Mach Discussion / Re: Boxford 160 TCL - running as is?
« on: August 22, 2008, 03:05:50 PM »
I have just converted my Boxford 160. There is a long post about it on here somewhere.
I replaced the electronics but kept the spindle drives and steppers. All I threw away was the processor board and the stepper board. These were placed with a breakout board and Geckos.

I cannot help with getting it to work using the original software or even connecting it up directly as I do not have the information, however, I have the Boxford CD with all the manuals in PDF format. So I have both the programming and User manual if you want to contact me off list. (simon at byte-sized dot com)


General Mach Discussion / Re: Boxford 160TCL
« on: August 22, 2008, 08:14:01 AM »

I used Omron, D2HW-C201H

They don't like being ignored by Mach3 and run into though, the plunger stays in! Mind you at £1.70 each they are cheap enough to replace.


General Mach Discussion / Re: Boxford 160TCL
« on: June 28, 2008, 05:48:42 PM »

Thanks. Yes I plan to make more helicopter bits, but first I have the VMC to convert. With all I have learnt from this conversion, it should be a lot easier! although the toolchanger is rather complex.


General Mach Discussion / Re: Boxford 160TCL
« on: June 28, 2008, 04:23:17 PM »
I added Home/Limit switches to both axis and used a Cubloc 220 PLC to run the front panel switches via Modbus.

General Mach Discussion / Re: Boxford 160TCL
« on: June 28, 2008, 04:21:06 PM »
I have just about finished the lathe now and I thought I would update the post to complete the information, just in case anybody is interested...

In the end I used 3 Geckos, a CNC4PC C11G breakout board, a CNC4PC relay board and CNC4PC index board.

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