Tools/boxford: Difference between revisions

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{{thistoolneedsinduction}}
{{thistoolneedsinduction}}
== Introduction ==
== Introduction ==
[[File:Boxford 260vmc 02.jpg|250px|thumb|The Boxford 260 VMC Milling machine]] [[File:Boxfordworkarea.jpg|250px|thumb|The working area of the Boxford 260 VMC Milling machine]]The Boxford 260 VMC is an educational model CNC mill that is in the process of being upgraded with a modern controller and electronics. The CNC milling machine has a maximum travel of 250mm x 120mm and a vertical travel of 180mm, the spindle is speed controlled from 0-3000rpm. It's suitable for use with Aluminium, Brass, Mild steel (with caution), stainless steel (very, very slowly) and most Plastics. The Boxford mill requires [[tools/boxford/induction|induction]] before you can use it as it is a complex and challenging to use tool. The boxford is kept downstairs on the west wall between the drill press and the linisher. The lab does not keep a regular stock of milling cutters, although you might find some around the place from time to time. If you have a specific job in mind then it's recommended that you bring your own tooling, we do this because a clumsy operator can easily break hundreds of pounds worth of tools in a few minutes and it wouldn't be fair to other members for the lab to have to pay for that. At the moment we're recommending a maximum speed of 800mm/sec for travel moves and 300mm/sec for cutting moves, although the exact speed you want to use will depend on many factors (see the [[Workshops/boxford|induction]]). The boxford is protected from damage by [[Prudence|Prudence, the safety goat]].
[[File:Boxford 260vmc 02.jpg|250px|thumb|The Boxford 260 VMC Milling machine]] [[File:Boxfordworkarea.jpg|250px|thumb|The working area of the Boxford 260 VMC Milling machine]]The Boxford 260 VMC is an educational model CNC mill that is in the process of being upgraded with a modern controller and electronics. The CNC milling machine has a maximum travel of 250mm x 130mm and a vertical travel of 180mm, the spindle is speed controlled from 100-3000rpm. It's suitable for use with Aluminium, Brass, Mild steel (with caution), stainless steel (very, very slowly) and most Plastics. The Boxford mill requires [[tools/boxford/induction|induction]] before you can use it as it is a complex and challenging to use tool.


__TOC__
__TOC__

The Boxford is kept downstairs on the west wall between the drill press and the linisher. The lab does not keep a regular stock of milling cutters, although you might find some around the place from time to time. If you have a specific job in mind then it's recommended that you bring your own tooling, we do this because a clumsy operator can easily break hundreds of pounds worth of tools in a few minutes and it wouldn't be fair to other members for the lab to have to pay for that. At the moment we're recommending a maximum speed of 800mm/sec for travel moves (although speeds up to 1200mm/min are available) and 300mm/sec for cutting moves, although the exact speed you want to use will depend on many factors (see the [[Workshops/boxford|induction]]). The Boxford is protected from damage by [[Prudence|Prudence, the safety goat]]. The Fusion-360 definition file for the boxford is [[File:Boxford Smoothie.machine|here]], and the post-processor is [[File:Boxford Smoothie.cps|here]]

A quick reference guide for trained users can be found [[Tools/boxford/BoxfordQR|here]].

Steve's done a [[User:Stever/boxford/speedsnfeeds|reference guide for speeds & feeds]] that have been tested on our machine.


== Current status ==
== Current status ==
Line 12: Line 18:
! Date !! Status !! Comment
! Date !! Status !! Comment
|-
|-
| 5th May 2021 || Operating normally || Rewiring Stage-2 complete
| 30th July 2021 || Operating Normally || Spindle bearings have been replaced, normal operation can resume
|}
|}

== Specifications ==
== Specifications ==
=== Operational Specifications ===
{| class="wikitable" style="margin: auto;"
{| class="wikitable" style="margin: auto;"
|-
|-
Line 20: Line 28:
X 250mm
X 250mm


Y 120mm
Y 130mm


Z 180mm
Z 180mm
|-
|-
| Maximum load on table || 25Kg
| Spindle Speeds || 100-3000rpm (500-3000rpm recommended)
|-
|-
| Spindle power || Probably around 250W
| Spindle Speeds || 100-3000rpm (500-2500rpm recommended)
|-
|-
| Spindle power || Originally 500W, now limited to more like 250W
⚫
| Maximum travel speed || 800mm/min (under review)
⚫
|-
⚫
| Maximum travel speed || 800mm/min recommended, 1200mm/min allowed
|-
|-
| Maximum recommended cutting speed || 300mm/min
| Maximum recommended cutting speed || 300mm/min
Line 34: Line 44:
| Maximum tool size || 16mm in ER25 collet, a larger carbide insert face mill is available
| Maximum tool size || 16mm in ER25 collet, a larger carbide insert face mill is available
|-
|-
| Maximum recommended drill size || 6mm (8mmm possible if feed is slow enough, holes over 6mm should be milled where practical)
| Maximum recommended drill size || 6mm (8mm possible if feed is slow enough, holes over 6mm should be milled where practical)
|-
|-
| Cooling system || Minimum Quantity Lubrication via oil mister
| Cooling system || Minimum Quantity Lubrication via oil mister
⚫
|-
| Maximum run time per program || 1 hr, limited by thermals, programs can be divided into <1hr sections will cool-down times between
|-
|-
| Electrical requirement || 10A 240V single-phase
| Electrical requirement || 10A 240V single-phase
Line 45: Line 53:
|}
|}


=== Technical and maintenance specifications ===
== Machine Details ==
{| class="wikitable" style="margin: auto;"
* Controller: Custom built smoothieboard made by Richard-I connected to a micro-PC
⚫
|-
⚫
* Spindle motor: Lenke 180V DC permanent magnet motor
| Spindle Bearings || 45 x 75 x 16 mm bearings (2 required), Originally 6009-2Z-C3 Deep groove
⚫
* Spindle Driver: Parker Controls 508/00/20/00 12A 180V motor driver
Replaced with 7009B-P4 Angular contact bearings
⚫
* Limit Switches: SIP10-C2 NPN NO AECO V3 Shielded inductive sensors
⚫
|-
⚫
* Stepper PSU: 60V DC 1500W switch mode power supply
⚫
| Spindle Motor || Lenke 180V DC permanent magnet motor
⚫
* Stepper drivers : DM860H 7.2A fan-cooled stepper drivers, set for 4.3A continuous, 5.2A peak, no idle current reduction
|-
⚫
* Stepper Motors: NEMA34 8-wire steppers that are about 80mm deep, The X and Y Axis motors are unknown, the Z-axis motor is RS part number 180-5291
⚫
| Spindle Driver || Parker Controls 508/00/20/00 12A 180V motor driver
|-
⚫
| Limit Switches || SIP10-C2 NPN NO AECO V3 Shielded inductive sensors
|-
⚫
| Stepper PSU || 60V DC 1500W switch mode power supply
|-
| Air system PSU || RS components 24V 2A DIN rail PSU
|-
| Logic PSU || RS components 12V 2A DIN rail PSU
|-
⚫
| Stepper drivers || DM860H 7.2A fan-cooled stepper drivers, set for 4.3A continuous, 5.2A peak, no idle current reduction
|-
⚫
| Stepper Motors|| NEMA34 8-wire steppers that are about 80mm deep, The X and Y Axis motors are unknown, the Z-axis motor is RS part number 180-5291
|}


== Planned Upgrades ==
== Planned Upgrades ==
Line 59: Line 81:
* Replace controller with MESA 7i76E
* Replace controller with MESA 7i76E
* Install LinuxCNC option
* Install LinuxCNC option
* Rebuild spindle - Bearings need replacement to reduce noise and heating
* New spindle motor and driver - To possibly increase max spindle speed
* New spindle motor and driver - To possibly increase max spindle speed


=== Known Issues ===
=== Known Issues ===
* Door interlock switch disconnected (might not want to reconnect)
* Door interlock switch disconnected (might not want to reconnect)
* Spindle resumes automatically when E-stop is released, proper re-start procedure can deal with this safely but it still shouldn't happen
* Spindle bearings need replacement, killed by too much exposure to sawdust
* Head needs tramming
* Head needs tramming


Line 75: Line 94:
|-
|-
! Name/Contact !! Notes
! Name/Contact !! Notes
⚫
|-
| Steve-R ||
|}
|}


Line 88: Line 105:
|-
|-
! Name/Contact !! Notes
! Name/Contact !! Notes
⚫
|-
| Steve-R ||
|}
|}


== Recent Changes ==
== Recent Changes ==


⚫
* Fit spindle current gauge and readjust the spindle controller for better response and stability [[User:Stever|Stever]] ([[User talk:Stever|talk]]) 17:55, 26 January 2022 (UTC)
* Tighten play on spindle bearings slightly. Seems to be settling down and wearing in OK, Easy-change chuck still performing poorly [[User:Stever|Stever]] ([[User talk:Stever|talk]]) 22:28, 20 September 2021 (BST)
⚫
* Increase rapid G0 speed limit to 1200mm/sec on X and Y, increase travel limit on Y to 130mm [[User:Stever|Stever]] ([[User talk:Stever|talk]]) 18:08, 12 September 2021 (BST)
* Added Script to allow Rapid G0, even on Fusion360 Personal accounts. For more ask Steve. [[User:Ruperte|Ruperte]] ([[User talk:Ruperte|talk]]) 17:34, 12 September 2021 (BST)
⚫
* Fit non-return valve on MQL system, priming should no longer be needed and valve should not be adjusted [[User:Stever|Stever]] ([[User talk:Stever|talk]]) 17:04, 11 September 2021 (BST)
* Readjust Y and Z axis gibs for best balance between backlash and slop, screws on order to adjust X-axis [[User:Stever|Stever]] ([[User talk:Stever|talk]]) 22:48, 6 September 2021 (BST)
* Replace spindle bearings, re-manufacture pre-load shim and retaining washer, set up and run in, replace spindle cooling fan. [[User:Stever|Stever]] ([[User talk:Stever|talk]]) 10:35, 30 July 2021 (BST)
* Clean and lubricate spindle, bearings continue to give concern. Clean and relube the EZ change chuck, replace damaged release pin [[User:Stever|Stever]] ([[User talk:Stever|talk]]) 16:50, 12 July 2021 (BST)
* Implement proper spindle shut-down on E-stop, increase maximum allowed travel speeds to 1000mm/min [[User:Stever|Stever]] ([[User talk:Stever|talk]]) 15:48, 5 July 2021 (BST)
* 2A slow-blow fuses do not work in the controller circuit, decision made to rate the circuit at 4A regular speed fuses [[User:Stever|Stever]] ([[User talk:Stever|talk]]) 08:15, 22 May 2021 (BST)
* 2A slow-blow fuses do not work in the controller circuit, decision made to rate the circuit at 4A regular speed fuses [[User:Stever|Stever]] ([[User talk:Stever|talk]]) 08:15, 22 May 2021 (BST)
* Phase-2 rewire finished [[User:Stever|Stever]] ([[User talk:Stever|talk]]) 18:13, 5 May 2021 (BST)
* Phase-2 rewire finished [[User:Stever|Stever]] ([[User talk:Stever|talk]]) 18:13, 5 May 2021 (BST)
Line 105: Line 129:
* Fitted new drivers, wiring is a mess that needs redoing. [[User:Stever|Stever]] ([[User talk:Stever|talk]]) 22:01, 27 February 2021 (UTC)
* Fitted new drivers, wiring is a mess that needs redoing. [[User:Stever|Stever]] ([[User talk:Stever|talk]]) 22:01, 27 February 2021 (UTC)
* Adjust gibs on all axis, neaten up wiring and improve star-grounding, re-connect spindle cooling fan. [[User:Stever|Stever]] ([[User talk:Stever|talk]]) 22:30, 21 February 2021 (UTC)
* Adjust gibs on all axis, neaten up wiring and improve star-grounding, re-connect spindle cooling fan. [[User:Stever|Stever]] ([[User talk:Stever|talk]]) 22:30, 21 February 2021 (UTC)
* Phase-1 rewire completed, boxford returned to service. [[User:Stever|Stever]] ([[User talk:Stever|talk]]) 02:12, 25 August 2019 (UTC)
⚫
* Rewire continues but we lost a driver and the bridge rectifier to an unexpected ground-return loop. [[User:Stever|Stever]] ([[User talk:Stever|talk]]) 02:58, 19 August 2019 (UTC)
⚫
* The stepper driver has been repaired, boxford is functional again. [[User:Stever|Stever]] ([[User talk:Stever|talk]]) 10:55, 27 September 2018 (UTC)
⚫
* The x-axis stepper driver has failed under test, is being investigated to determine if it can be repaired or replaced [[User:Stever|Stever]] ([[User talk:Stever|talk]]) 20:11, 23 September 2018 (UTC)


== Image Gallery ==
== Image Gallery ==
Line 121: Line 141:
File:IMG 20210515 131100.jpg| Engraving a brass Plaque for the [[User:Stever/Projects/rondeldagger|Rondel Dagger]]
File:IMG 20210515 131100.jpg| Engraving a brass Plaque for the [[User:Stever/Projects/rondeldagger|Rondel Dagger]]
File:Fujividlink.png|Making Mount Fuji from Aluminium|link=https://www.youtube.com/watch?v=-0FMsCgrvdA
File:Fujividlink.png|Making Mount Fuji from Aluminium|link=https://www.youtube.com/watch?v=-0FMsCgrvdA
File:CNC-Milled-Resin.jpg|Milling a cast resin block
File:CNC-Milled_Mountains.jpg|Milled mountains from a Terrain Model
</gallery>
</gallery>


Latest revision as of 15:49, 9 November 2023

Boxford 260 VMC CNC Milling Machine

This tool requires induction
Owing to it's dangerous nature, delicate nature, or expense, this tool requires that you be inducted on it's proper handling before use.

Introduction[edit]

The Boxford 260 VMC Milling machine
The working area of the Boxford 260 VMC Milling machine

The Boxford 260 VMC is an educational model CNC mill that is in the process of being upgraded with a modern controller and electronics. The CNC milling machine has a maximum travel of 250mm x 130mm and a vertical travel of 180mm, the spindle is speed controlled from 100-3000rpm. It's suitable for use with Aluminium, Brass, Mild steel (with caution), stainless steel (very, very slowly) and most Plastics. The Boxford mill requires induction before you can use it as it is a complex and challenging to use tool.

The Boxford is kept downstairs on the west wall between the drill press and the linisher. The lab does not keep a regular stock of milling cutters, although you might find some around the place from time to time. If you have a specific job in mind then it's recommended that you bring your own tooling, we do this because a clumsy operator can easily break hundreds of pounds worth of tools in a few minutes and it wouldn't be fair to other members for the lab to have to pay for that. At the moment we're recommending a maximum speed of 800mm/sec for travel moves (although speeds up to 1200mm/min are available) and 300mm/sec for cutting moves, although the exact speed you want to use will depend on many factors (see the induction). The Boxford is protected from damage by Prudence, the safety goat. The Fusion-360 definition file for the boxford is here, and the post-processor is here

A quick reference guide for trained users can be found here.

Steve's done a reference guide for speeds & feeds that have been tested on our machine.

Current status[edit]

Date Status Comment
30th July 2021 Operating Normally Spindle bearings have been replaced, normal operation can resume

Specifications[edit]

Operational Specifications[edit]

Working Area

X 250mm

Y 130mm

Z 180mm

Maximum load on table 25Kg
Spindle Speeds 100-3000rpm (500-2500rpm recommended)
Spindle power Originally 500W, now limited to more like 250W
Maximum travel speed 800mm/min recommended, 1200mm/min allowed
Maximum recommended cutting speed 300mm/min
Maximum tool size 16mm in ER25 collet, a larger carbide insert face mill is available
Maximum recommended drill size 6mm (8mm possible if feed is slow enough, holes over 6mm should be milled where practical)
Cooling system Minimum Quantity Lubrication via oil mister
Electrical requirement 10A 240V single-phase
Air requirements 8CFM @ 5 Bar

Technical and maintenance specifications[edit]

Spindle Bearings 45 x 75 x 16 mm bearings (2 required), Originally 6009-2Z-C3 Deep groove

Replaced with 7009B-P4 Angular contact bearings

Spindle Motor Lenke 180V DC permanent magnet motor
Spindle Driver Parker Controls 508/00/20/00 12A 180V motor driver
Limit Switches SIP10-C2 NPN NO AECO V3 Shielded inductive sensors
Stepper PSU 60V DC 1500W switch mode power supply
Air system PSU RS components 24V 2A DIN rail PSU
Logic PSU RS components 12V 2A DIN rail PSU
Stepper drivers DM860H 7.2A fan-cooled stepper drivers, set for 4.3A continuous, 5.2A peak, no idle current reduction
Stepper Motors NEMA34 8-wire steppers that are about 80mm deep, The X and Y Axis motors are unknown, the Z-axis motor is RS part number 180-5291

Planned Upgrades[edit]

  • Make new front panel - Will require linuxCNC upgrade first
  • Reinstate touch probe
  • Replace controller with MESA 7i76E
  • Install LinuxCNC option
  • New spindle motor and driver - To possibly increase max spindle speed

Known Issues[edit]

  • Door interlock switch disconnected (might not want to reconnect)
  • Head needs tramming

Boxford Caretakers[edit]

Inductions[edit]

The following people offer induction for the Boxford.

Name/Contact Notes

Workshops[edit]

The following workshops are available which use the boxford CNC milling machine

Maintainers[edit]

Name/Contact Notes

Recent Changes[edit]

  • Fit spindle current gauge and readjust the spindle controller for better response and stability Stever (talk) 17:55, 26 January 2022 (UTC)
  • Tighten play on spindle bearings slightly. Seems to be settling down and wearing in OK, Easy-change chuck still performing poorly Stever (talk) 22:28, 20 September 2021 (BST)
  • Increase rapid G0 speed limit to 1200mm/sec on X and Y, increase travel limit on Y to 130mm Stever (talk) 18:08, 12 September 2021 (BST)
  • Added Script to allow Rapid G0, even on Fusion360 Personal accounts. For more ask Steve. Ruperte (talk) 17:34, 12 September 2021 (BST)
  • Fit non-return valve on MQL system, priming should no longer be needed and valve should not be adjusted Stever (talk) 17:04, 11 September 2021 (BST)
  • Readjust Y and Z axis gibs for best balance between backlash and slop, screws on order to adjust X-axis Stever (talk) 22:48, 6 September 2021 (BST)
  • Replace spindle bearings, re-manufacture pre-load shim and retaining washer, set up and run in, replace spindle cooling fan. Stever (talk) 10:35, 30 July 2021 (BST)
  • Clean and lubricate spindle, bearings continue to give concern. Clean and relube the EZ change chuck, replace damaged release pin Stever (talk) 16:50, 12 July 2021 (BST)
  • Implement proper spindle shut-down on E-stop, increase maximum allowed travel speeds to 1000mm/min Stever (talk) 15:48, 5 July 2021 (BST)
  • 2A slow-blow fuses do not work in the controller circuit, decision made to rate the circuit at 4A regular speed fuses Stever (talk) 08:15, 22 May 2021 (BST)
  • Phase-2 rewire finished Stever (talk) 18:13, 5 May 2021 (BST)
  • Replace fusing system with better breaking capacity fuses Stever (talk) 16:04, 30 April 2021 (BST)
  • Final fit of limit switches, connect stepper enable lines to +12V, add proper EMI suppression on air solenoids Stever (talk) 18:43, 29 April 2021 (BST)
  • Replace failed spindle motor controller Stever (talk) 22:52, 21 April 2021 (BST)
  • Install limit switches and configure Stever (talk) 21:41, 19 April 2021 (BST)
  • Replace Z-axis stepper motor, reinstate mist cooler and covers Stever (talk) 22:06, 7 April 2021 (BST)
  • Replace PSU with 60V 1500W unit, re-install enclosure lights, tidy wiring considerably, re-install protection fuses, connect spindle driver to E-stop system Stever (talk) 18:03, 25 March 2021 (UTC)
  • Readjust gibs that had loosened Stever (talk) 18:00, 19 March 2021 (UTC)
  • Fitted new drivers, wiring is a mess that needs redoing. Stever (talk) 22:01, 27 February 2021 (UTC)
  • Adjust gibs on all axis, neaten up wiring and improve star-grounding, re-connect spindle cooling fan. Stever (talk) 22:30, 21 February 2021 (UTC)

Image Gallery[edit]

  • Machining a cast gear to final size

    Machining a cast gear to final size

  • Setting up to cut and drill a stainless steel sword pommel

    Setting up to cut and drill a stainless steel sword pommel

  • Machining cold-rolled 304 Stainless Steel

    Machining cold-rolled 304 Stainless Steel

  • Finished stainless steel pommel plate

    Finished stainless steel pommel plate

  • Decking off some aluminium to make an insert for the Bandsaw

    Decking off some aluminium to make an insert for the Bandsaw

  • Bandsaw table insert being cut out of the stock

    Bandsaw table insert being cut out of the stock

  • Engraving a brass Plaque for the Rondel Dagger

    Engraving a brass Plaque for the Rondel Dagger

  • Making Mount Fuji from Aluminium

    Making Mount Fuji from Aluminium

  • Milling a cast resin block

    Milling a cast resin block

  • Milled mountains from a Terrain Model

    Milled mountains from a Terrain Model

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