I've decided I want to build computer-controlled CNC machines, like 5-axis mills - Page 1
Forum section: electronics / general

author: renzoms
author_rank: Regular Contributor
timestamp: June 29, 2021, 11:46:04 pm
content: 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 2022I just saw StuffMadeHere's [/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. ‡

author: langwadt
author_rank: Super Contributor
timestamp: June 30, 2021, 12:00:05 am
content: 90% of it is mechanical design

author: Brumby
author_rank: Unknown
timestamp: June 30, 2021, 01:29:23 am
content: ... at least.

author: renzoms
author_rank: Regular Contributor
timestamp: June 30, 2021, 01:47:04 am
content: this is a good reply:https://www.reddit.com/r/ECE/comments/oakf4p/ive_decided_i_want_to_build_computercontrolled/h3i5jkj/?context=3

author: Bud
author_rank: Super Contributor
timestamp: June 30, 2021, 02:49:47 am
content: 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.

author: rstofer
author_rank: Super Contributor
timestamp: June 30, 2021, 03:26:36 am
content: 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'

author: Cyberdragon
author_rank: Super Contributor
timestamp: June 30, 2021, 04:54:41 am
content: QuoteI'll file that right next to "ATM machine"

author: rstofer
author_rank: Super Contributor
timestamp: June 30, 2021, 01:26:51 pm
content: 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...

author: Microdoser
author_rank: Frequent Contributor
timestamp: June 30, 2021, 01:49:54 pm
content: Quote from: Cyberdragon on June 30, 2021, 04:54:41 amWhen I use one of those, I have to type in my personal PIN number.

author: PaulAm
author_rank: Frequent Contributor
timestamp: June 30, 2021, 02:46:22 pm
content: 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?

author: MadScientist
author_rank: Frequent Contributor
timestamp: June 30, 2021, 03:17:23 pm
content: I would echo the previous postEnvelope and material are two big decisionsFrom that flow cost and complexity.5 axis won’t be cheap , so I hope you have a reasonable budget along with all that timeYou will need access to a machine shop

author: Brumby
author_rank: Unknown
timestamp: June 30, 2021, 03:46:26 pm
content: Quote from: Microdoser on June 30, 2021, 01:49:54 pmExpanded form:..... I have to type in my personal PersonalIdentificationNumbernumberMade me smile.

author: rstofer
author_rank: Super Contributor
timestamp: June 30, 2021, 04:34:26 pm
content: Quote from: PaulAm on June 30, 2021, 02:46:22 pmActually, 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-ballscrewThen 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/dm542eMotion controller like this:https://warp9td.com/index.php/gettingstarted/what-is-a-smoothstepperAn 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-1000-48I 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.

author: Syed Muneeb
author_rank: Newbie
timestamp: August 22, 2021, 11:06:04 am
content: Quote from: rstofer on June 30, 2021, 04:34:26 pmThanks it really helped.

author: MarkF
author_rank: Super Contributor
timestamp: August 22, 2021, 11:32:57 am
content: Take a look at Clough42 YouTube channel:https://www.youtube.com/channel/UCeKpbMimEGgLM_0tnghfoVw/videoshttps://www.youtube.com/channel/UCeKpbMimEGgLM_0tnghfoVw/videosHe 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.

author: sokoloff
author_rank: Super Contributor
timestamp: August 22, 2021, 11:39:50 am
content: He uses Mach3.

author: jmelson
author_rank: Super Contributor
timestamp: August 23, 2021, 03:57:19 pm
content: Quote from: sokoloff on August 22, 2021, 11:39:50 amMach 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. Seehttp://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