Project: OSIDIAS (SFF taken to the extreme)

**avddreamr** · 03-23-2010, 03:32 PM

What's the maximum depth of aluminum that you can cut with that cnc machine?

**craigbru** · 03-23-2010, 04:04 PM

Originally Posted by avddreamr

What's the maximum depth of aluminum that you can cut with that cnc machine?

Technically it could cut a few inches deep. It's just a matter of multiple passes. I wouldn't cut anything thicker than 1 mm or so in a single pass. Your mill bits wouldn't last long, even if the machine could handle it.

**craigbru** · 03-30-2010, 09:14 AM

While I know everyone is anxiously waiting to see the CNC running, I needed to take care of a few small details first. One of those details involved a custom misting solution for cutting aluminum. Why mist? Well, for the work I have to do it can be just as effective as flood, yet it's so much easier. I should say it's easier, only if you can find a workable and convenient way to implement it.

I have been doing some research into CNC misting techniques, and most of the options are geared towards commercial applications, and are quite expensive. I wasn't really willing to spend $300 on something I was convinced I could do myself. Since I'm a modder, it only made sense to mod a homebrew solution. Many hours were spent Googling anything that misted, before I came across the mention of using an airbrush as an option. I tried to find where someone had actually followed through using this method, and came up with nothing. So, I figured I might as well be the first. Even if I'm not, I'm hoping my methods and documentation will make it easier for others to find and implement themselves.

Now, before any fabrication could begin, I needed an airbrush and dedicated on-demand compressor. Amazon came through with this nicely outfitted kit.

Okay, well, now that I've got the airbrush, I need to find a way to get it mounted to the Romaxx machine. Since the mister needs to follow the mill bits as they cut through the material, it was obvious that it needed to be attached to some location near the spindle. It just so happens that there were some unused spindle mounting locations that would be perfect. So, I just needed to come up with a workable bracket of some kind. Not only did the bracket have to hold the airbrush securely, but it couldn't interfere with any machine operation whatsoever. I needed full X, Y, and Z operation with no limits or restrictions. I broke out the cardboard and started experimenting. This got me in the ballpark...

Since I was satisfied I had a workable idea, I committed it to metal...

I love bending things, so the newly cut bracket received some attention.

With the cutting of a few well placed slots, and the help of some rubber o-rings, the brush and it's coolant reservoir were attached to the bracket. I used a simple mounting method for two reasons. Ease of maintenance, the ability to have flexible mount points should some unforeseen interference occur.

So, let's get this bracket mounted! You can see how cleanly it sits in it's location. It's also easily adjustable for height.

There is plenty of room for travel with no interference.

Now finally, here are a few pics of the machine as assembled and ready to run.

All that I've got left to do is make sure I'm set for live streaming, and I'm ready to cut. If I can find a good material hold down solution, I'll give it a go tonight. (Yes, I'll likely be getting the aluminum top w/ mounting holes soon.)

**Xion X2** · 03-30-2010, 09:29 AM

Nice CNC.

What size is the working area?

**craigbru** · 03-30-2010, 09:53 AM

Originally Posted by Xion X2

Nice CNC.

What size is the working area?

Thanks man! The working area is around 14 x 24. It's perfect for me since I focus on SFF.

**Waterlogged** · 03-30-2010, 11:08 AM

Hmm, I have a Smithy 1220XL and the craziest I go is some magnetic coolant nozzles blowing compressed air. Have you given any thought about how you might protect the MDF from repeated soakings?

**craigbru** · 03-30-2010, 11:33 AM

Originally Posted by Waterlogged

Hmm, I have a Smithy 1220XL and the craziest I go is some magnetic coolant nozzles blowing compressed air. Have you given any thought about how you might protect the MDF from repeated soakings?

I'll eventually get an aluminum plate that would take care of the problem completely, but in the interim, I'll be using another piece of sacrificial MDF on top of the current bed. I also should mention that I'll be using denatured alcohol as the coolant. I've got a few machinist friends who swear by it, and use it in their own small CNC setups. Now, of course this means I'll need proper ventilation (to avoid getting high or blowing my ass up), but it's quick evaporation means minimal mess. If it will work, I'll also try isopropyl alcohol too. It would be much less of an irritant.

**Xion X2** · 03-30-2010, 08:42 PM

Originally Posted by craigbru

Thanks man! The working area is around 14 x 24. It's perfect for me since I focus on SFF.

That's not a bad size at all.

Great job on the homebrew mist. I missed that when I had replied before. Looks great!

< wants a CNC...

**callen_1** · 03-30-2010, 10:17 PM

I love how you made the mister bracket. How the hell do you make such tight, clean bends?? I don't think it can be done with a regular bending brake, so is it just scored and bent by hand? Sorry, i don't mean to pry

, i'd just really, really like to know

.

I also can't wait to see what you can do with this thing. I was looking at milling machines but this project may be a turning point

.

**masska** · 03-30-2010, 11:28 PM

looking great craigbru

If you don't mind, where are you based?

**phinix_mike** · 03-30-2010, 11:52 PM

..hmm... now I wish I was your neighbour

Sweet little machine you have there Craig. Oh man, I can see what you going to do with this now! Imagine... endless ideas for SFF projects...

**Waterlogged** · 03-31-2010, 01:54 AM

Originally Posted by craigbru

I'll eventually get an aluminum plate that would take care of the problem completely, but in the interim, I'll be using another piece of sacrificial MDF on top of the current bed. I also should mention that I'll be using denatured alcohol as the coolant. I've got a few machinist friends who swear by it, and use it in their own small CNC setups. Now, of course this means I'll need proper ventilation (to avoid getting high or blowing my ass up), but it's quick evaporation means minimal mess. If it will work, I'll also try isopropyl alcohol too. It would be much less of an irritant.

Sounds like a plan, though. . .I've never heard of using denatured alcohol as a coolant before. In most cases, coolant is primarily used for washing chips out of the cutting area, will be interesting to see if/how well it works.

**craigbru** · 03-31-2010, 05:54 AM

Originally Posted by Xion X2

That's not a bad size at all.

Great job on the homebrew mist. I missed that when I had replied before. Looks great!

< wants a CNC...

Oh man, I'd love to see what you could do with CNC. Now that would be epic.

Originally Posted by callen_1

I love how you made the mister bracket. How the hell do you make such tight, clean bends?? I don't think it can be done with a regular bending brake, so is it just scored and bent by hand? Sorry, i don't mean to pry

, i'd just really, really like to know

.

I also can't wait to see what you can do with this thing. I was looking at milling machines but this project may be a turning point

.

I seem to make quite a few bends like this in most of my projects. Planning ahead is critical... I clamp the piece to be bent between a 2ft framing square and another piece of thick aluminum flat bar. It works really well as you can see. I may have a picture of me doing it in one of my Rogue worklog pics.

If you can find any reason to justify one of these machines, then do it!

Originally Posted by masska

looking great craigbru

If you don't mind, where are you based?

Thanks man! I'm in northeast Nebraska.

Originally Posted by phinix_mike

..hmm... now I wish I was your neighbour

Sweet little machine you have there Craig. Oh man, I can see what you going to do with this now! Imagine... endless ideas for SFF projects...

Thanks Mike! You may be the one other person that truly loves SFF like I do.

One of the greatest reasons to have one of these machines is the time it will save me. I'm certainly not afraid to get my hands dirty, but I seem to have so many projects I want to take on. This should get me through them a little more quickly, and allow for the excellent quality I really strive for.

Originally Posted by Waterlogged

Sounds like a plan, though. . .I've never heard of using denatured alcohol as a coolant before. In most cases, coolant is primarily used for washing chips out of the cutting area, will be interesting to see if/how well it works.

Yeah, it should work well. Kerosene is also a really good option for aluminum, but I won't be using that in the shop. At least not as long as I have the machine in the basement of my home.

I was testing the mister last night, and it is functionally perfect. Since the compressor is on demand, turning it on or off stops the mist in about a second. The Romaxx machine has an extra relay controlled outlet on the machine, so I can start and stop the mister in Mach3 while cutting.

There is also one other benefit to the airbrush. There is enough air coming out of the airbrush (whether actually misting or not), that it should keep the end mill free of shavings and debris.

**zads** · 04-01-2010, 12:23 AM

I wouldn't think an airbrush has enough flow to keep the bit cool,
but I guess as long as you keep your cutting speed slow and your material thin, maybe??
I know there are dedicated misting nozzles out there but not sure if its good for a bit that small.
Let us know how it goes.

**craigbru** · 04-01-2010, 06:16 AM

It shouldn't need as much flow as much as it needs lubrication and chip removal. Romaxx themselves suggest just a little machining oil brushed on the aluminum before cutting. This is definitely a step above that. However, the real results will only come from testing. The flow on the brush is adjustable, and I'll have to find the right ratio.

**sniperbob** · 04-01-2010, 09:59 AM

will you have the CNC table in some sort of basin/catchpan? It'd be cool to figure out some sort of a recirculation/filtration setup for the Coolant. Or maybe it's just the watercooling junky in me lol

**zads** · 04-01-2010, 12:44 PM

Originally Posted by sniperbob

will you have the CNC table in some sort of basin/catchpan? It'd be cool to figure out some sort of a recirculation/filtration setup for the Coolant. Or maybe it's just the watercooling junky in me lol

That's the "flood" type cooling setup, which I'm more accustomed to on larger CNCs.
I've also seen misting type bit cooling, but those were in fully enclosed CNC machines, and the whole inside basically gets foggy in there.. not sure how it works in an open environment?

**craigbru** · 04-01-2010, 07:44 PM

Originally Posted by sniperbob

will you have the CNC table in some sort of basin/catchpan? It'd be cool to figure out some sort of a recirculation/filtration setup for the Coolant. Or maybe it's just the watercooling junky in me lol

Originally Posted by zads

That's the "flood" type cooling setup, which I'm more accustomed to on larger CNCs.
I've also seen misting type bit cooling, but those were in fully enclosed CNC machines, and the whole inside basically gets foggy in there.. not sure how it works in an open environment?

As zads mentioned, this is a mist as opposed to a flood setup. No recirculation needed. If I can get the proper ration of fluid, there should be minimal mess, and minimal fog. It really won't take much to keep the aluminum lubed for cutting.

I did a live streaming test tonight on a dry run. I was having mic issues that have since been fixed. I was also experimenting with a dual webcam setup just to test it's feasibility. I'm not sure what I'll do with a second cam, but as you see, it's certainly possible to use one.

http://www.livestream.com/losiastech...2-6283ae9d8f69

(If you happen to get an irritating overlay on the bottom of the video, just pause and start again, and it should go away.)

**phinix_mike** · 04-01-2010, 11:24 PM

I just watched your dry run video... cool stuff Craig, I love this machine! It is so great to have sth like that, you can make so many new mods, like you said, saving all the time making those mods by yourself.
Its one of those machines that can make a grown man so happy!

)

**craigbru** · 04-02-2010, 06:16 AM

Thanks Mike! I think I love setting it up and getting it ready as much as I'll love using it.

**callen_1** · 04-02-2010, 06:38 AM

I watched 1 of your vids showing the planing and the sketch up you did. God i'd love to be able to do that!!!! Very awesome indeed

**shazza** · 04-02-2010, 06:49 AM

Agree - overwhelming stuff. Love watching where you're going with this.

**craigbru** · 04-02-2010, 07:19 AM

Originally Posted by callen_1

I watched 1 of your vids showing the planing and the sketch up you did. God i'd love to be able to do that!!!! Very awesome indeed

Thanks! I plan on making more videos as work progresses. It's really a great way to cover everything that can't be explained well with pictures alone.

Originally Posted by shazza

Agree - overwhelming stuff. Love watching where you're going with this.

Thanks shazza! Most people at this point are a little beyond anxious in wanting me to start. All I can say is... soon!

**The Shooter** · 04-04-2010, 01:12 PM

Originally Posted by craigbru

Thanks! I plan on making more videos as work progresses. It's really a great way to cover everything that can't be explained well with pictures alone.

Thanks shazza! Most people at this point are a little beyond anxious in wanting me to start. All I can say is... soon!

Great to hear that you will be making videos love the thread and im exciting of the progres you make.