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  #91  
Old Sat 18 September 2010, 23:52
ifffff
Just call me: Ivo #38 & #130
 
Parnu
Estonia
Sounds weird, but looks like i got bad set of bits. Yesterday arrived second shipment and i cutted with one bit 6 sheets of alu. That is 12 hours cutting.
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  #92  
Old Tue 05 October 2010, 15:22
ifffff
Just call me: Ivo #38 & #130
 
Parnu
Estonia
And final truth of cutting alu 5754 sheets is totally different as discussed before... I moved from 4mm bits to 5mm bits because they are stronger and dont broke so easy and give better results.

Final cutting data:
5mm one flute endmill (20 degrees spiral angle)
Spindle 20000 rpm
Ramping plunge (10 deg ramp angle 10mm ramp lenght) feedrate 1500mm/min
Cutting feedrate 2000mm/min

I was cutting 4mm sheets and cutting depht inside contures 2mm per pass and outside contures 1,33 mm per pass. Outside i was cutting less with one pass because sheets arent always ideally straight and if cutter takes more than 2mm it goes to resonance and it may broke.

Some pictures too:
Attached Images
File Type: jpg Foto0232.jpg (32.0 KB, 1342 views)
File Type: jpg Foto0233.jpg (35.9 KB, 1341 views)
File Type: jpg Foto0234.jpg (37.9 KB, 1343 views)
File Type: jpg Foto0235.jpg (36.8 KB, 1343 views)
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  #93  
Old Tue 05 October 2010, 18:06
smreish
Just call me: Sean - #5, 28, 58 and others
 
Orlando, Florida
United States of America
Expertly done.
Looks like racing car seat backs.....nice!
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  #94  
Old Tue 05 October 2010, 20:54
Regnar
Just call me: Russell #69
 
Mobile, Alabama
United States of America
Nicely done. How many bits did you end up going through. Are they going to be bent. The reason I ask is the grain direction looks different across the different pieces.
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  #95  
Old Wed 06 October 2010, 01:45
ifffff
Just call me: Ivo #38 & #130
 
Parnu
Estonia
They arent rally car seat backs. they are ATV skid plates. I make cutting job and then they gonna be bent and welded.
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  #96  
Old Thu 25 August 2011, 14:34
ifffff
Just call me: Ivo #38 & #130
 
Parnu
Estonia
Some pictures of one job. Wind turbine blades, 2,8 meters long. Workpiece was 120*400*3000 mm. Cutting time for one blade about 16 hours.
Pictures:
Attached Images
File Type: jpg Foto0764.jpg (66.3 KB, 1102 views)
File Type: jpg Foto0765.jpg (58.3 KB, 1097 views)
File Type: jpg Foto0766.jpg (59.5 KB, 1104 views)
File Type: jpg Foto0768.jpg (64.8 KB, 1102 views)
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  #97  
Old Thu 25 August 2011, 17:59
smreish
Just call me: Sean - #5, 28, 58 and others
 
Orlando, Florida
United States of America
exceptional use of the MM. Bravo.
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  #98  
Old Thu 25 August 2011, 20:12
MetalHead
Just call me: Mike
 
Columbiana AL
United States of America
Sweet !!! Have I mentioned how awesome MechMates and their owners are ?? !!! I am loving all these great projects I am seeing everyone working on.
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  #99  
Old Fri 26 August 2011, 04:09
smreish
Just call me: Sean - #5, 28, 58 and others
 
Orlando, Florida
United States of America
???
Is that blade made from a single block of lumber or is it laminated.
You can't find lumber that is that nice for a good price here in the states.
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  #100  
Old Fri 26 August 2011, 06:43
ifffff
Just call me: Ivo #38 & #130
 
Parnu
Estonia
Its laminated spruce. Price here is about 100€ per piece. Many are already asked for sharing blade file. I post it here. Profile is NACA 4419
Attached Files
File Type: rar turbineblade.rar (62.8 KB, 158 views)

Last edited by ifffff; Fri 26 August 2011 at 06:47..
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  #101  
Old Fri 26 August 2011, 08:02
hennie
Just call me: Hennie #23
 
Roodepoort JHB
South Africa
Those blades look like they can be quite heavy?
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  #102  
Old Sat 27 August 2011, 15:20
ifffff
Just call me: Ivo #38 & #130
 
Parnu
Estonia
No they arent so heavy. One blade weight is about 15-20 kg.
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  #103  
Old Tue 23 August 2016, 09:22
ifffff
Just call me: Ivo #38 & #130
 
Parnu
Estonia
Havent posted here for long time. I decided to build second mechmate. This time all steel tubes. Work area same as first one 3400x2100
For now steel is here.
1471936795086.jpg
2016-08-23 16.42.56.jpg
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  #104  
Old Fri 26 August 2016, 02:35
lonestaral
Just call me: Al #114
 
Isarn
Thailand
Send a message via Skype™ to lonestaral
Good luck with the second build Ivo.

Do you have that turbine blade in STL format.
I tried some online conversions but I keep getting a empty file message.
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  #105  
Old Fri 26 August 2016, 06:26
ifffff
Just call me: Ivo #38 & #130
 
Parnu
Estonia
I have .igs file. Stl seems to be already deleted. If that format is ok give me your e-mail address.
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  #106  
Old Fri 26 August 2016, 06:53
lonestaral
Just call me: Al #114
 
Isarn
Thailand
Send a message via Skype™ to lonestaral
I downloaded the .igs file from your earlier post.
That is the one I tried to convert to .stl online.
Thank you for your reply.
Have a good weekend.

Last edited by lonestaral; Fri 26 August 2016 at 06:54.. Reason: Weekend wish
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  #107  
Old Sat 27 August 2016, 00:06
ifffff
Just call me: Ivo #38 & #130
 
Parnu
Estonia
Here is stl file. tiivik.rar
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  #108  
Old Sat 27 August 2016, 03:01
lonestaral
Just call me: Al #114
 
Isarn
Thailand
Send a message via Skype™ to lonestaral
Smile

Thank you very much.
It worked.
I will build one to scale some day
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  #109  
Old Thu 08 September 2016, 02:14
ifffff
Just call me: Ivo #38 & #130
 
Parnu
Estonia
Its taking shape. Has someone good idea how should i turn this beast on feet? If i gonna weld base table all togehter i weights about 900kg.
Some pictures too:
2016-09-06 13.17.27.jpg
2016-09-06 19.08.52.jpg
2016-09-08 10.44.35.jpg
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  #110  
Old Thu 08 September 2016, 20:27
Borko
Just call me: Techstarve
 
Veles
Macedonia
Good luck with second build Ivo.
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  #111  
Old Fri 09 September 2016, 08:26
ifffff
Just call me: Ivo #38 & #130
 
Parnu
Estonia
Its now on feet, with help of telescopic loader. For cross bearers i added one rectangular tube to support center. With 115kg load ( i standed on it) bends cross bearer 0,08mm. On my first mechmate i havent measured bending, but it is visible if i stand on table.
2016-09-09 16.27.19.jpg
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  #112  
Old Fri 09 September 2016, 12:21
Fox
Just call me: Fox
 
Amsterdam
Netherlands
Nice and beefy ;-) good to see some activity here.
Why did you make your triangulation short as in with straight pieces in between ? You loose a little of the effect yoir are after that way.
Also since you are all welded, other way round would mean even more stiff tabletop.
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  #113  
Old Fri 09 September 2016, 23:19
ifffff
Just call me: Ivo #38 & #130
 
Parnu
Estonia
Making triangulation is limited by bandsaw sawing edge. But i think its strong enough like this. Diagonals and lower cross braces are made from 80*60*4 rectangular tube, cross bearers 120*60*5 tube. By adding 5x more steel i think table is almost unbendable, but this is already story of third build.
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  #114  
Old Sat 10 September 2016, 01:54
ifffff
Just call me: Ivo #38 & #130
 
Parnu
Estonia
More about rigidity. Main beams are 200*100*8 tube, end plates not welded yet. I fixed indicator on cross bearer and its needle to upper edge on main beam. Flex with twisting it with hands are 0,02mm. #38 main beams are made from 200*75 C channels and i can twist them about 1,5mm!!!!!!
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  #115  
Old Fri 16 September 2016, 05:49
ifffff
Just call me: Ivo #38 & #130
 
Parnu
Estonia
To achieve better accuracy i gonna use hiwin HGR20 linear guideways. To get linear slides better fixed and keep them on their place i made from 12*80 steel bar linear slide bases. Of course i milled them out with mechmate.
Milling with endmill tip is good endmill killer.
2016-09-14 13.16.52.jpg
For saving bits as cutting 2,5*20 stripe on steel bar i drilled some holes.
2016-09-16 13.58.47.jpg
Steel bars were quite warped too, so lets cut them straight.
2016-09-15 14.36.58.jpg
2016-09-14 16.59.43.jpg

Milling steel bar

On video i am cutting steel bar straight with endmill side. Spindle 10000rpm, feedrate 480mm/min, stepover 0,6mm. Endmill is TaeguTec TSE 2060M UF10
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  #116  
Old Mon 19 September 2016, 01:19
Fox
Just call me: Fox
 
Amsterdam
Netherlands
That's cool ! Interested to see the linears, I have same laying around, but never mounted them yet still using MM v rails.

Last edited by Fox; Mon 19 September 2016 at 01:21..
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  #117  
Old Mon 19 September 2016, 23:47
ifffff
Just call me: Ivo #38 & #130
 
Parnu
Estonia
To make main beams straight i am levelling them with epoxy.

Dams made from melamine board and coated with mold release wax are in place:
2016-09-19 18.10.19.jpg
To seal it correctly i poured first on corners one layer fast curing epoxy:
2016-09-19 18.10.31.jpg
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  #118  
Old Wed 21 September 2016, 03:46
ifffff
Just call me: Ivo #38 & #130
 
Parnu
Estonia
Meanwhile when epoxy is curing i have lots of holes to thread. For rails about 230 pieces.
2016-09-21 11.45.09.jpg
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  #119  
Old Wed 21 September 2016, 23:29
ifffff
Just call me: Ivo #38 & #130
 
Parnu
Estonia
Laying epoxy went out good. Nice and flat surface.
2016-09-22 08.23.00.jpg
2016-09-22 08.23.11.jpg
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  #120  
Old Mon 07 August 2017, 03:47
ifffff
Just call me: Ivo #38 & #130
 
Parnu
Estonia
Here are some updates about buildlog over looong time.
Linear rail straightness is checked with steel wire. Hanging weight on one side is about 35kg
2017-07-14 17.39.32.jpg
2017-07-14 17.39.49.jpg
2017-07-14 18.06.32.jpg
Linear rail block mounts milled
2017-07-31 11.24.44.jpg
To make it more stiffer as original Mechmate, gantry tubes are 120*60*5
2017-07-31 11.39.38.jpg
2017-07-31 17.49.09.jpg
2017-07-31 17.49.19.jpg
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