Discussion in 'Project Logs' started by Mr3D, 22 Mar 2015.
This is getting the cogs in my head turning, they've been standing still for a while.
First of all, sorry for my late reply. Was really tired after work yesterday.
Anyways. All your comments are much appreciated! Thanks guys!
I do get your point and could partally agree with you(only on the chips, not the power consumtion, see below). But if you think the stuff I did is much waste, you're kinda wrong(I do agree that it seems much tho). All the chips are sold to a recycling company, so no waste there(through the company i work for ofc!)
I have a friend that works as a CNC-operator for another company, he machines much aluminum and there were one job that had to be milled from a HUGE block of aluminum. A few hundreds of kilos waste for just one part(which of course will be recycled).
About the power, for a modern CNC(the mill I run is modern enough), the servo motors used only consume as much power that's actually needed. And machining aluminum don't require that much power(in my case) Both in terms of spindle power and axis power. I don't know if my quick estimation is correct but I would guess 1kw/h of power...
...Spindle got a 7.5kw motor, when I milled aluminum the spindle load was around ~5%(375w), I don't know the size of the axises motors, but they are smaller. Probably 2kw or so. I can't see the load on the axis but let's say 10%(200w) there. Not all axises ran at the same time, and at load that is. Let's say 400w of total axis power. 400w + 375w = 775w, and maybe some extra stuff(or me calculating wrong). So let's say 1kw/h(that's with the heavy cuts, lots less with the finishing cuts and it's the finishing cuts that takes time, in my case).
That's comparable to a more powerful gaming rig running a heavy game... Soooo... No, I wouldn't say that milling is consuming much electricity.
Modding is not about what you need, but about what you can. There are no limits (no no, no no-no no...).
I'd agree with this, if you got access to awesome tools it would be mad to not use them.
I look at seemingly impossible pieces to make by hand & just think in layers, then it's doable as long as it doesn't have to be water tight.
If you want to play with numbers let's play: to produce 1kg of Alu you need 15Kw so 525 kwh
plus recycle (the magic word RECYCLE let's do a bad design I can RECYCLE!!!(0,9kwh x 30kg.= 27 kwh plus 525) 552kvh plus a MOUNTAIN of bauxite Your figure of 1kwh to mill 30 kg. of alu is a quick estimation but I think it applies on milling butter, maybe peanut butter.
Dare I ask what you are doing in this thread other than stirring the pot, and generally being a dick? I would love to help stirring, but it would be a waste of time.
Daniel, you are doing something awesome. Please don't feed the trolls further, but focus on the mod so we can see some awesomeness
PS, you should see some of the alu blocks we work with where i work.
We normally use around 4 of these for one project:
And often 2-400 kilo is taken away, and sometimes WAY more (Okay, maybe I am stirring the pot a LITTLE)
You don't seem to get the subtractive manufacturing process, do you? Milling 30kg(more like 15-20kg in my case, because the raw material for the shrouds were sawn to a smaller size and the material is saved) is nothing. Other parts need material removal of a few hundreds of kilos, like the pic p0pe showed. I don't see you complaining about a "bad design" there.
About my calculation. I said 1kw/hour, I never said the time. Just compare it to the amount of power/hour to a powerful gaming pc.
And yes, cutting aluminum is like cutting butter.
Heh, thanks man!
You should totally mill a computer case from that solid block!
More like cutting chewing gum, I find. If I don't watch the RPM it clogs up my end mills. I much prefer brass to work with, but aluminium being cheaper and lighter often makes a more appropriate material for large pieces.
Well, if you don't use a lot of coolant, you're doomed... It's also based on the alloy your cutting. EN AW-60** got great machinability. You should also use a end-mill with a small amount of flutes and with super-positive cutting-edges(super sharp).
One thing is having proper tools, another is creating something functional and aesthetically pleasing with those tools. I could have all the CNC machinery in the world, and not come up with something as awesome as this. Love the design! Subbed.
I don't know what "sinker EDM" means, but I'm guessing it's a good thing, and very cool. I'm looking forward to this one!!
I may experiment with cutting fluid (WD-40 also appears to be really useful). I use two-flute end mills which have pretty sharp cutting edges, but they are generic model engineering ones, not specialist super positive ones. Large mills work fine, but the small ones clog easily. My aluminium comes from a base metal merchant, so it's kind of pot luck on the exact alloy.
Yeah two flute endmills are best fore Brass and Aluminium I use a proper cutting fluid that you water down according to what metal you're cutting, got it from ebay pretty cheap too certainly cheaper than WD-40.
Aluminium is the third most abundant element on earth.
I don't know the exact name in english, but some kind of alcohol/ethanol works great for aluminum!
Time for a small update what I did this Wednesday.
Improved the looks of the fans!
The original sticker on the fan is kinda ugly, so let's remove that. Instead, let's put a matte black vinyl piece there! (A friend of mine got a vinyl plotter, so he cut them for me)
Noctua! How did you forget to integrate the wiring?
@Mr3D - Keep doing what you do. Over the top is welcome here. If you could do a final photo shoot with explosions in the background it would appreciated.
@Pope - Mail me one of those paperweights. I'll give you some stamps.
100% awesomeness here, great thoughts and execution. As a guy that has spent hundreds of hours grinding away on a sinker EDM, I approve
Cool, but needs more metal action:
Although I suspect you may not have room for that. But some flat aluminium hubs would work.
Thanks man! Yeah, go extreme or go home...
I'll keep that in mind for the final photoshoot. If you got some C4 laying around, send them my way. Might be needed for the shoot...
Thanks! Yeah, I too have been doing many hours in front of the sinker EDM, tho in steel and beryllium copper. Now when I machined aluminum, DAMMMMN THAT'S FAST!
Yeah, I saw that in your worklog. Nice work man! But as you say, won't fit this build. In my application vinyl looks great imo!
Anyways, UPDATE TIME!
This weekend was mostly a "fix the ****ups" weekend. The mistakes I did was at the design-level.
Milled a cap for the integrated 230V connector.
Finishing tool-path for the pocket.
But here we have it, my design flaws.
1. Bad aligning with the cap and frame(should be 0.5mm longer).
2. chamfer on the frame not ending where the cap is.
A few hours of milling later...
Updated the 3D model and milled both a new cap and frame-piece. Looking muuuuch better now!
Another part that i finished, tho. The PSU bracker/holder thingy.
Next up is another test assembly!
You might wonder why I duct-taped the PSU. Well, I ordered some UNC 6-32 screws, but they are still in-transit. Haven't received them yet.
Your hands are so dry, you don't need Nvidia, you need Nivea Seriously though, that's some really sleek work, nice one!
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