Hi All,
I thought that since I got inspiration from this forum I should share what I have acheived so far.
The design started 12 months ago and the actual build started 3 months ago.
Specs as follows:
38mm spindle bore using a Chinese Spindle (bought as a spare part for my manual lathe)
Spindle has a D1-4 and 5MT Chuck Interface so I can use all my Chucks and 5C Collet System from my manual Lathe.
20 x 5 x 640 Z axis ball screw and nut (Hiwin)
16 x 5 x 320 X Axis ball screw and nut (Hiwin)
20mm Linear Rails and Bearings (Hiwin)
Danfoss 0.75KW VFD (240VAC Single Phase I/P, 3 Phase 240VAC O/P, 0-200Hz) with Rototech 3 Phase Motor wired in Delta configuration.
Approx 3:1 Pulley Ratio and Powertwist Belt. (The 150mm pulley is from my old 1968 Datsun 1600 from years ago. I cut out the centre and replaced it with my own designed and manufactured Taperlock Clamp on to the spindle.)
The current spindle speed is continuously variable from 250 to 1200RPM under Mach3 PWM control.
Smoothstepper and C23 BOB. (I didn't like the PWM to Analogue tacho chip on the C23 BOB, so I built my own much simpler and linear PWM to Analogue Converter and piggybacked it on to the c23).
Spindle Speed Feedback is supplied with an OPB960 IR Opto/Schmitt Trigger through an 8mm Slot Index Pulse generator mounted on the Spindle (CSS works flawlessly).
Meanwell 500W 48VDC PSU adjusted to 42VDC for the Steppers and Stepper Drivers.
Meanwell Dual 5/12VDC PSU to power everything else.
Leadshine M542 Stepper Controllers with 430oz/in Z Stepper and 311oz/in X Stepper.
Leadshine M542 Stepper Drivers.
Most parts are machined or fabricated from Mild Steel including the 1 metre bed (200 x 75 C Section Steel). Headstock is 16mm thick Steel including a stiffening plate on the underside of the bed.
The bearing blocks are Aluminium treated with Alochrome 1200S machined on my X3 CNC Mill.
Spindle Bearings are 110mm Tapered Roller (Front) and 100mm Double Row Angular (Rear).
Axis bearings are simple Single Row Sealed on the leadscrew support end and angular contact on the motor end.
The stand is 65 x 65 x 5 RHS with adjustable levelling feet.
A slide out chip tray stainer located under the bed and below that is coolant return tray.
The cross slide has plenty of M6 threaded holes for all possible combinations of tooling. My plan is for gang tooling all designed by yet to be fabricated.
I plan to use a fishtank submersible pump located in a heavy duty plastic bucket (I fed up with the problems I have had with Chinese coolant systems in my cnc mill and cutoff saw).
Here is the first cut done with much trepidation and fear!!!
http://www.youtube.com/watch?v=0F6q95M0aGsRegards
Chrisjh
Brisbane Australia