Discussion in 'Project Logs' started by Andreas | Brodholm, 19 Aug 2016.
Excuse my ignorance, but does the base of the CNC get cut into too, and need periodically replacing?
Not really though. Its quite "dirty". But I usually wipe it down with some alcohol after a few cuts to remove all the coolant. So that help keep things a bit tidy
No worries at all! Ask away, I will answer all the questions I can!
Yes, when making a contour cut (through the whole piece) the tool cuts in the spoil board that need to be replaced after a while. I go about 0.05mm down in the work spoil board when I make cuts. So when I have lots and lots of cut in the spoil board I face it of (basically mills the whole surface) about 0.2mm. I have about 6mm of material until I need to change the spoil board. So that is about 6/0.2=30 times I can do that. And I could probably do a few chassis before you really would need to take a layer of. So I think this will last me quite a while (I hope )
Nice to see you are back modding again!
Nice explanation, thanks.
Thanks, Nice to be back!
Well! Finally got around to edit and post a video update. About 20 hours of video editing in premiere pro. First time ever using it. VERY powerful software I must say. Lots and lots of features... I just need to learn them all!
Anyway, my first attempt at a progress video
Youtube: Wing X99 | Part 1
Dont know why the youtube forum thingy does not work? Any ideas?
Several days of design and building I finally got to test the custom bending tool that I made. I will be using this for the front bends on the case. Very pleased with the results. Was a bit worried about this.
Here is a test bend I made with a left over piece I had lying around.
Holy smokes that's thick! Damn, looks like you're going to have some really loves curves in there.
Nice video Andreas !!
I look carefully at your render again, and I realize how much is clean the design...especially the lack of cooling's pipes.
Yep! 8mm EN5754 aluminium.
Also, pictures of the bending tool coming as soon as I get around to import and edit them!
Just what tool can bend 8mm aluminium like that?!?
This is what I want to know! I've seen the one Silverstone uses to bend 5mm alu for the TJs and it's a big bugger + very dependent on quality of alu to yield a good result.
I watched this more times than I should admit to. I'm not sure if this build is more tool porn or build porn.
^^^ Yeah, I need one of those. And the CNC. In fact, I need one of everything he's got!
Ohh, interesting! Do you have a picture of that machine? If not, paint me a word picture!
I need one of everything, in my own garage. Ohh and I also need a house, so I can need a garage in the first place
A simple radius bock, simple right? Wrong, this was much more complicated than I would originally have thought. I was first thinking of going with the original V-die and a upper tool to make this. But I soon realized that this would most likely cause marks on the aluminium. So I had to design a special bending machine and then build it. We also don't have a round upper die for a bending machine.
The base of the bender. No cylinder installed here.
Scale for positioning the piece on the correct distance from where the bend starts. Also an "edge" that that is perpendicular to the cylinder to insure that the bend is straight.
Changed my mind last second and decided to screw the bending machine in the CNC-router table instead of using clamps. Also added some neoprene rubber to not leave marks in the very soft EN1050 (~99% pure) aluminium spill board.
Base stationary cylinder that decides the inner radius. Made this interchangeable so I can make several size bends. Made custom washers for the M16 bolts that holds it secure.
A simple holder that screws down in the tool with a rubber surface to hold the aluminium piece in place while bending.
This is a cylinder with ball bearings that can roll so the thing actually spins instead of slide on the surface of the aluminium. This insures that bending process leaves no marks on the aluminium.
Mounted the leaver and set the correct height and aligned up everything.
Stop screws insures that no sliding occurs when the aluminium tries to push the roll up when you bend it.
Same procedure on the bottom stationary cylinder. Really do not want them to move during the bend. That would ruin the piece and you would have to start again.
Clamp that uses two M10 bolts and some rubber to not damage the pieces.
Here it is from the other angle.
Here you can see the bend when fastened down with the clamp. Put it in the middle and used piece and put that against the guide. The mark on the top side of the radius I made with upper roll when I forced it the wrong way to test how much beating it could take
Quite easy to bend. The front piece will be about 2.5 times wider than this piece so it will require some more force. But It should be okay since this thing is fairly sturdy.
Here you can see the piece bends back after the bend is made. So with this 64mm diameter roll produced a slightly bigger inner radius than 32mm that I want. So I have to take of a millimeter or so to get the desired radius.
Very pleased with the result, no marks from the actual bend. Since this piece have been in the scrap bin it have gotten some bad treatment. Did some light brushing to see if that would be ruined after the bend. But it seems to have managed fairly well. Only needing some slight touch up!
This machine took about a week (>40 hours) to design, produce, test out and work out the kinks. "Just" for some damn round corners! High radius front bends sure is a PITA, but it was well worth it in the end!
Truly impressive. I was expecting to see your standard shop press with radius dies, but I really like this design.
I was so jealous of your CNC router I finally made the decision to start designing and building my own.
some guys like me are following silently(until today) your post, with a wide open mouth and eyes full of sprinkles, and even if I wait the x99 build impatiently, the built of your CNC is completely fascinating...btw, I personaly use and love my Festool hand tools, but I haven't got the gap saw yet, and after seeing it on duty, i can't wait to have it asap... really the best hand tools ever, great are germans engineers...and really exciting thread...thanks for showing your artwork sir.
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