Tools/boxford: Difference between revisions
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=== Known Issues === |
=== Known Issues === |
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* Door interlock switch disconnected (might not want to reconnect) |
* Door interlock switch disconnected (might not want to reconnect) |
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* Spindle resumes automatically when E-stop is released, proper re-start procedure can deal with this safely but it still shouldn't happen |
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* Spindle bearings need replacement, killed by too much exposure to sawdust |
* Spindle bearings need replacement, killed by too much exposure to sawdust |
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* Head needs tramming |
* Head needs tramming |
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Revision as of 17:20, 9 July 2021
Boxford 260 VMC CNC Milling Machine
 |
| 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
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 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 1000mm/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.
Current status
| Date | Status | Comment |
|---|---|---|
| 5th May 2021 | Operating normally | Rewiring Stage-2 complete |
Specifications
| Working Area |
X 250mm Y 120mm Z 180mm |
| Maximum load on table | 25Kg |
| Spindle Speeds | 100-3000rpm (500-3000rpm recommended) |
| Spindle power | Probably around 250W |
| Maximum travel speed | 800mm/min recommended, 1000mm/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 (8mmm possible if feed is slow enough, holes over 6mm should be milled where practical) |
| 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 |
| Air requirements | 8CFM @ 5 Bar |
Machine Details
- Controller: Custom built smoothieboard made by Richard-I connected to a micro-PC
- 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
- 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
- Make new front panel - Will require linuxCNC upgrade first
- Reinstate touch probe
- Replace controller with MESA 7i76E
- Install LinuxCNC option
- Rebuild spindle - Bearings need replacement to reduce noise and heating
- New spindle motor and driver - To possibly increase max spindle speed
Known Issues
- Door interlock switch disconnected (might not want to reconnect)
- Spindle bearings need replacement, killed by too much exposure to sawdust
- Head needs tramming
Boxford Caretakers
Inductions
The following people offer induction for the Boxford.
| Name/Contact | Notes |
|---|---|
| Steve-R |
Workshops
The following workshops are available which use the boxford CNC milling machine
Maintainers
| Name/Contact | Notes |
|---|---|
| Steve-R |
Recent Changes
- 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)
- Phase-1 rewire completed, boxford returned to service. 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. Stever (talk) 02:58, 19 August 2019 (UTC)
- The stepper driver has been repaired, boxford is functional again. 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 Stever (talk) 20:11, 23 September 2018 (UTC)
Image Gallery
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Machining a cast gear to final size
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Setting up to cut and drill a stainless steel sword pommel
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Machining cold-rolled 304 Stainless Steel
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Finished stainless steel pommel plate
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Decking off some aluminium to make an insert for the Bandsaw
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Bandsaw table insert being cut out of the stock
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Engraving a brass Plaque for the Rondel Dagger
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Making Mount Fuji from Aluminium
