Pushing DIY CNC to the LIMITS Milling an Aluminum Star

[@CATANOVA]

I went beyond the limits and watched it at 2X speed. It was more cool 👍

[@PiefacePete46]

That was unexpected!... thanks for your honesty. 😊 Looking forward to more. (I mean more videos about your mill, not more crashes!) Liked & Subscribed.

[@ttgtomr]

That's a pretty aggressive cut for one of those 24k spindles. Nicely done. You'd do well to get some coolant. Chip evacuation is pretty important

[@manuelortis3747]

Un ottimo lavoro!!! 👍

[@jonjon3829]

build log/pictures?

[@marson_cnc]

SOON.

[@iamthebiker]

Also interested in more info on the machine. Thank you

[@Doug10106]

Where did you buy the DLC coated chip breaking mill?

[@marson_cnc]

it.aliexpress.com/item/1005004639835481.html

[@littleshopofrandom685]

@@marson_cnc Do you find the DLC coating to be functional, or just pretty colours? (as in, do you see a difference between them and uncoated? Did the coating rub off?). I bought what seem to be the same ones from a different seller, have not tried them yet, but I am told sometimes "rainbow DLC" is fake on these and no different than uncoated.

[@Windows350]

@@littleshopofrandom685i tried a finishing endmill (without chip breakers) with dlc because i wanted to mill dry and the tool could handle way more sfm before clogging in aluminium

[@amrsvn-uf2jk]

How much NM(newton force) / Kw of a spindle power as minimum required for steel milling process ? please accurate as possible

[@marson_cnc]

You can download the Sandvik calculator app and discover It by yourself. With small diameter mill (4 mm and less) forces involved are very low even with steel.

[@amrsvn-uf2jk]

@@marson_cnc Im super thankful to You for Your most perfect answer as the most helpful I got.

[@GelX]

Really nice milling 👍

[@SquidHunting]

How much did this machine end up costing to make?

[@marson_cnc]

About 5k euro.

[@brettturnage533]

Put me to shame with the speed of that second procedure. I’ve got to go play with my speeds and feeds.

[@mynamisis]

What is that face mill?

[@marson_cnc]

m.it.aliexpress.com/item/4000343935726.html?gatewayAdapt=Pc2Msite

[@priestgaming3335]

Is there any vacancy in this company ❤

[@testboga5991]

The CAM on this part was mediocre. Too much variable chipload, way too slow.

[@marson8870]

Lets see your diy machine do better...

[@johnharding9936]

Nice job, I'm doing similar. Your surface speed on Op1 is a bit too high though, around 603, you should be between 250 and 450 really for roughing aluminium with this style of cutter. From my calculations your op is drawing around 0.91kW. Seems to work pretty well but the spindle is bogging down a bit, the max torque of your spindle is probably lower down in the speed range so I would try figure out where it is and to optimise for that. Try increasing the chipload to something like 0.08mm/tooth and reducing the Vc (surface speed) you should be able to achieve very similar MRR whilst moving the spindle speed down to say, 18000rpm, where it has likely a lot more torque (I calculate 83cm3 MRR with these changes so you don't loose out, really. Where exactly your spindle has its greatest torque is not clear without the spec sheet but it is almost certainly not at full speed) Manufacturer should have a chart. A 6mm cutter with similar settings, and 0.07mm/tooth, should get you to around 63cm3/min with 0.72kW @20krpm. YG1 roughers are similar closer to 0.17mm/tooth but you'd need a bit more horsepower for that. A 6mm YG1 does 117cm3/min but needs 1.34kW. So an example would be (Vc 464, Fz 0.08mm/tooth, RPM 18500, Feed 4440, DOC 10, WOC 1.8 (23%) - MRR 80 to 83cm3/min (ish) - Power 0.91kW

[@johnharding9936]

incidentally, for similar YG1 tools, you would normally go 1.5* diameter for the DOC and 50% Diameter radial WOC. I haven't calculated around that in your case with regards Horse Power and MRR but worth mentioning since they are quite similar tools in terms of geometry (I also use DLC tools like this too, they are good but every machine is different).

[@Lucas_sGarage]

Where did you buy the surfacing tool ?

[@marson_cnc]

Aliexpress

[@dolfstromer3498]

Much more rpm, optimal 15-16 thousands

[@marson_cnc]

Impossible with this type of spindle. I tried and It clogged.

[@BuildItAnyway]

Try dlc and ethanol mist

[@marson_cnc]

​@@BuildItAnyway in this video i used DLC coating mills and ethanol with MQL.

[@BuildItAnyway]

@@marson_cnc what kind of alu are you using? With those two items sticking alu shoukd be very rare. Perhaps check rounout and or vibration of the spindle. Bot of these cause uneven cuts -> heat -> alu sticking

[@marson8870]

@@BuildItAnyway sorry, by clogging I meant that the spindle gets stuck. No problems with material sticking.

[@julianweiser9985]

Nice work! I think you switched Ae and Ap, is that correct?

[@marson_cnc]

Yes.

[@mrjackdavies95]

Do you have a link to the 20mm face mill? Thanks!

[@marson_cnc]

m.it.aliexpress.com/item/4000343935726.html?gatewayAdapt=Pc2Msite

[@ArtutMarkov]

Эх... Коварную сталь бы показали как обрабатывает или нержавейку какую.

[@marson_cnc]

A me non interessa lavorare l'acciaio, quindi mi basta che lavori bene metalli morbidi.

[@Flipla_Scrip]

What spindle did you go with?

[@marson_cnc]

Chinese ATC ISO20

[@paulywilson445]

What cnc machine are you using?

[@marson_cnc]

I made it from scratch. Link for the 3d model in description.

[@geekoid183]

What a nice mill ! For the next time, just know that you confused ae and ap 😉

[@marson_cnc]

I reversed the values ​​in the roughing operation. Thanks for the tip.

[@geekoid183]

Also, thanks for providing the 3d model of your CNC ! I have a few questions 😅 What was the design process, sizing of components, simulation etc ? What would you do differently apart from the servo if you were to design and build another one ?

[@Nunak91]

Roughing should be described as ae 2 mm and ap 10 mm or am I mistaken? How much ae you took on side finishing? 0,3 mm?

[@marson_cnc]

Yes, ap 10 ae 2. Mistake was mine. Final side pass of 0.1 mm.

[@Nunak91]

@@marson_cnc I always thought 0,1 mm is too thin (chattering, rubbing) but here it looks great. Gotta try thinner finishing.

[@Windows350]

@@Nunak91really depends. in soft aluminium alloys you can leave a little bit more, but in steel 0.1 is enough mostly

[@titaninventor]

excellent. Colleague👍

[@istvan.palotai]

sooo much Vc..... but why? :d

[@marson_cnc]

I don't know. Existence Is a mistery.

[@carbonarne675]

Really good cam work!

[@testboga5991]

I'm not so sure. This could have been faster with better constant chipload.

[@shiznak8098]

Great work :) Did you try the same roughing operation with the finishing tool. Is there more load on the spindle or less?

[@marson_cnc]

I didn't try but the load should be more with a standard mill.

[@shiznak8098]

@@marson_cnc Thank you, i googled and seems to be around 25% more load. Maybe you can increase feed on chamfering, i normaly do 0.07mm/tooth. With your rpm and two flute its something around 3300mm/min. Have a great day :)

[@rueuflecomte2539]

учиться и учиться тебе ещё

[@marson_cnc]

Mi piace il cazzo

[@alessio55555]

wow, have you done some video on the steel?

[@marson_cnc]

No, milling steel Is not on my plans.

[@alessio55555]

@@marson_cnc but do you think machine is able to do it?

[@marson8870]

@@alessio55555sure, but 24k rpm spindle is not good for steel, unless you use very small mills, 4 mm and below.

[@mizarstifmeister7298]

Where did you get that spindle? also the run time is impresive, mine would have taken something like 3 hours to do that lol

[@marson_cnc]

From AliExpress. 1.8 kW ATC. It Is the weakness of this machine, the structure can handle way more Power but i don't Need that.