4th axis for milling machine

https://www.youtube.com/watch?v=qtlehiSy63Y

Hello
In this video you see the first part of the build from my 4th axis.The plan is to use this axis not only for indexing but also for cnc turning on the mill. In addition a tool changer for turning tools is planned later which will be attached to the spindle.I have deliberately chosen a closed system because I do not want to have chips on the belt or in the motor.The construction itself gives more work, however, because there are a few more plates to mill.Who wants to rebuild the axle can do this without covers but I would then recommend a thicker base plate because without the covers is lost some stability. The height of the axis including jaw chuck is 120mm and is deliberately built so low that I can drive over it with my portal milling machine, which has a portal height of 125mm.The whole parts have cost me 250 euros where I bought on Ebay for 50 euros aluminum remnants and was lucky that matching plates were there.I also use a 100mm 3 jaw chuck, a closed loop stepper motor the JMC IHSS-60-36-31, HTD-5M belt with 25mm width and 2 pulleys with 40 and 26 teeth.The gear ratio is 1:1.54 which corresponds to 4.7Nm torque and a speed of about 2000 rpm.In the first video of this series I will show you the production of the shaft on which a bearing seat is. Then the manufacturing of the shaft coupler with the 2nd bearing seat and the nut for clamping.The CAD files for the rebuild you will find in the video description of the last video when I am sure that everything fits as planned.

Part list:
JMC IHSS-60-36--31 € 70,-
Toothbelt HTD 5M-25 - 340mm. €23,58,-
Toothed belt pulley 40 5M 25 €16,60,-
Toothed belt pulley 26 5M 25 €10,80,-
100mm 3 jaw chuck €60,-
Aluminum remnants from eBay €50,-
Sets of screws €20,-
Total: €250,98

I bought a pre-cooked version of this off of fleabay a few years ago. I put an Arduino and a little LCD display on there for setting angles. Yours is more robust.

https://www.youtube.com/watch?v=EBoLlIEZP90

Hello,

in the 2nd part you can see how I made the milled parts and then assemble the main components of the axis.

Strange!!!! I know more than posted the questions below and most of the answers showed up in the original post after this posted. Not sure how that happened, might be my cell connection. In any event thanks again for the great video. Now I realize what happened, the homemadetools link took me right past the first video. I will go back to bed now.

Nice work! Will this be stepper or servo driven? I ask because I'm wondering what the top speed will be and if it will be suitable for use as a lathe. Think wood working and other relatively higher speeds.

Quote:

---

Originally Posted by wizard69

Will this be stepper or servo driven? I ask because I'm wondering what the top speed will be and if it will be suitable for use as a lathe. Think wood working and other relatively higher speeds.

---

I have one that's stepper driven. Top speed is super slow, just a few RPM. A few years ago I tried to use it as a lathe. You can badly approximate a lathe if you have it installed on a mill. Crank the speed of your end mill and slowly rotate the workpiece. It works... kinda. It takes a long time and the result is lumpy. The problem is that end mills are not actually flat on the bottom. It doesn't replace a lathe.

Hello,
At the moment it is stepper operated because I had one lying around. The top speed is not that bad at all I think that I almost come to 2000 rpm turned aluminum for the first time yesterday and the power at higher speeds is also sufficient. Sure a servo would be better, but a stepper motor is also possible. You just can't feed several mm but 0.5mm with aluminum at about 1000rpm worked well. if you are interested you can see a short video on my instagram account (_markgyver_) or you can wait if i post the next video on youtube in about 2 weeks.
Attachment 39472

Quote:

---

Originally Posted by nova_robotics

I have one that's stepper driven. Top speed is super slow, just a few RPM. A few years ago I tried to use it as a lathe. You can badly approximate a lathe if you have it installed on a mill. Crank the speed of your end mill and slowly rotate the workpiece. It works... kinda. It takes a long time and the result is lumpy. The problem is that end mills are not actually flat on the bottom. It doesn't replace a lathe.

---

Hello,

This is not true it works well as a lathe. Then you have the wrong stepper motor or wrong settings.

https://www.youtube.com/watch?v=WDr8r4oAxRc

Hello,

In part 3 you can see how I turn the flange for the jaw chuck, a runout test before and after grinding the spindle. Then I build a tool holder for turning tools and finally a turning and milling test with the axis.

Many thanks for the excellent video as well as the completeness of your design. I especially enjoyed seeing your HEM (or adaptive) machining strategies. It appears that you have a vacuum plate, however, I never saw an o-ring in your video. How are you holding down your work? Are you using the super glue & tape method or is it vacuum? I couldn’t see well enough when you created the small holes. Were you boring holes instead of drilling? And were you thread milling? Also, that was an excellent job of grinding the spindle! I am very interested in this design but need to think about the backlash issue.

Congratulations markgyver - your Milling Machine 4th Axis is the Homemade Tool of the Week!

This is a thorough build, complete with CAD files, and we're expecting that it will be used to build even more homemade tools in the future.

Some more good builds from this week:

Belt Grinder by LMMasterMariner
Tree Stump Extractor by darus627
Drill Press by Vyacheslav.Nevolya
Spot Welder by mariost
Bearing Removal Method by engineer steve
Mini Sawmill by fawabros
Bender by orioncons36
Etching Tank by editor@glue-it.com
Incline Table Saw by tado creation
Cordless Drill Wall Holster by jeremycook
Wide Angle Lens Adaptor by theeddies
Benchtop Lathe Cross Slide Sled by Claudio HG
Handheld Circular Saw by RCTURKA
Circle Cutting Jig by orioncons36
Clutch Adjustment Tool by Frank S

markgyver - we'll be adding your tool entry to our All Homemade Tool of the Week winners post. And, you'll now notice the wrench-on-pedestal award in the awards showcase in your postbit, visible beneath your username:

https://www.homemadetools.net/forum/...OfTheWeek4.pnghttps://www.homemadetools.net/forum/...eWeekIcon4.png

And, you'll be receiving a $25 online gift card, in your choice of Amazon (US-only), PayPal, or bitcoin. Please PM me your current email address and award choice and I'll get it sent over right away.

Nice work! :thumbsup:

<!-- BEGIN /var/www/html/homemadetools/protected/modules/zeus/views/tool/postUpdate.php -->
Thanks markgyver! We've added your 4th Mill Axis to our Milling category,
as well as to your builder page: markgyver's Homemade Tools. Your receipt:

<div id="blocks"> <div class="block b1 pngfix"> <div class="bimg"> <div> <a href="https://www.homemadetools.net/homemade-4th-mill-axis"> <img src="/uploads/249276/homemade-4th-mill-axis.jpeg"/> </a> </div> </div> <div class="head pngfix"></div> <div class="left pngfix"></div> <div class="right pngfix"></div> <div class="blockover b1 pngfix"> <div class="title"> <a href="https://www.homemadetools.net/homemade-4th-mill-axis">4th Mill Axis</a> <span> by <a href="https://www.homemadetools.net/builder/markgyver">markgyver</a></span> </div> <div class="tags">tags: <a href='https://www.homemadetools.net/tag/cnc'>CNC</a>, <a href='https://www.homemadetools.net/tag/mill'>mill</a> </div> </div> </div> </div>
<!-- END /var/www/html/homemadetools/protected/modules/zeus/views/tool/postUpdate.php -->

Quote:

---

Originally Posted by Saltfever

Many thanks for the excellent video as well as the completeness of your design. I especially enjoyed seeing your HEM (or adaptive) machining strategies. It appears that you have a vacuum plate, however, I never saw an o-ring in your video. How are you holding down your work? Are you using the super glue & tape method or is it vacuum? I couldn’t see well enough when you created the small holes. Were you boring holes instead of drilling? And were you thread milling? Also, that was an excellent job of grinding the spindle! I am very interested in this design but need to think about the backlash issue.

---

I'm glad you like my video.
I use a vacuum plate and a foam rubber cord to clamp the parts under vacuum.
The foam rubber cord is not visible because it sits inside the part and is completely flattened when the vacuum is created.
All the holes that could be made without reclamping (in the 1st milling pass) are milled, all the others I drilled only during assembly because of the difficulty of finding a perfect zero point and the perfect right-angled arrangement. I think that with a little effort all the holes can be milled.
I cut all the threads by hand, which was quite an effort - I think it was about 50.
I'm not quite sure where the backlash is coming from.
It could also be the software, although I have set the stepper motor to 51200 microsteps, but the resolution at mach4 is 0.1 degrees. maybe it could also be that when I only ever approach whole values such as 15 45 30 60, I could not detect any play. I still have to do a few tests to be able to say more precisely. If it is mechanical, i think i could get it under control by making only positive or only negative movements.

Thanks for answering, Mark. I couldn't see the vacuum port holes (as well as the foam ring) so that is why I was confused. Where are the holes for the vacuum? I can see the plumbing but I can't see any holes in the base-plate slots . Also, all the holes you drilled did not go completely through the part because that would have created a vacuum leak, correct?

With that 25 mm wide belt under tension, I doubt the backlash is coming from it. As you say, it could be the stepper motor software issue.
THANKS for posting your design.

Quote:

---

Originally Posted by Saltfever

Thanks for answering, Mark. I couldn't see the vacuum port holes (as well as the foam ring) so that is why I was confused. Where are the holes for the vacuum? I can see the plumbing but I can't see any holes in the base-plate slots . Also, all the holes you drilled did not go completely through the part because that would have created a vacuum leak, correct?

With that 25 mm wide belt under tension, I doubt the backlash is coming from it. As you say, it could be the stepper motor software issue.
THANKS for posting your design.

---

Sorry for the late reply. The holes for the vacuum are on the left side of the plate at the bottom. Yes, the holes and the cut do not go through, there is still 0.2mm of material at the bottom.
With the first cuts, it was always exciting whether the zero point would fit or whether the vacuum would loosen and I would mill into the vacuum plate. Fortunately everything went well :-) . In the end, I turn the plates over and mill over them again, then the holes go all the way through the plate.


I hope it's not from the belt - according to the manufacturer, the HTD 5M should have almost no play and can be neglected.

Duh ... I see it now! :lol:
I missed the holes appearing when you turned it over to finish the back side. Nice technique. Thanks again for the clarification.