Ok. Time for some further update and maybe I can get some help from folks on an issue I am seeing.
First, updates:
The watercooled spindle is operational at this point and my desire to cut aluminum took me to build an enclosure and also add flood cooling.
With this, I removed all of the connections through the terminal blocks and sealed the wires inside the enclosure.
My enclosure is just a simple 2020 rail box with plexi panels.
Now I am having some good success cutting my aluminum parts lately along with running my first facing ops.
My cut setting are as follows:
Fusion 2d adaptive: 40 ipm, .75” doc 24000rpm, .01 optimal load, 3/8” 3 flute zrn coated endmill. .05” radial stock to leave.
Followed by 2d contour with 4 .01” roughing passes and then 2 .005” finishes passes and repeat final pass.
The results are pretty good. The machine handles most of the cutting without a sweat.
The issue I am having is that it’s my y axis movement. Anytime there is y axis movement, the machine stutters a bit. This causes pretty rough surface and even some gouges. Now the light contour passes help remove these but they are still apparent while surfaces in the x axis are fantastic. X axis is along the long direction of the part, y is in the shorter direction.
I did experiment with increasing federate and that did seem to help a bit but I got to 80ipm and am not sure I want to really go much faster than that.
My spindle is pretty dang square shown by my facing op. It’s not 100% perfect but it’s really close.
I know some folks here do some pretty heavy aluminum work and could probably help me out.
I don’t think it is a MRR concern as the machine is great in the x direction. It is only in the y direction that this problem arises. But with the y axis having 2 steppers, it seems unlikely that they are bogging down.
I’m thinking it could potentiall have to do with the x axis twisting during y axis moves. But I have the single piece x and newbies z along with the axle mod for the v wheels. Although I can certainly still feel deflection about the x.
Appreciate any help or feedback on the machine progress.
Cory