Carbon Fiber Plates and Aluminum Bearing Blocks

discussion of design changes / improvements / suggestions
Improbable Construct
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Carbon Fiber Plates and Aluminum Bearing Blocks

Post by Improbable Construct » Wed Feb 27, 2013 12:13 am

I went a bit crazy today and made some changes to my Shapeoko.

First I made some Carbon Fiber motor plates.
Carbon Fiber plate.JPG
Carbon Fiber plate.JPG (118.61 KiB) Viewed 4461 times
They are 4mm thick and look awesome.
mounted plate.jpeg
mounted plate.jpeg (117.42 KiB) Viewed 4461 times
I don't have any idea if they are stronger or better but they have to be faster, right?
I mean, look, carbon fiber! They make race cars out of that stuff!]

I added a misumi 40x40 extrusion with hard coated open rail on both sides to replace my double X makerslide.
I am using the open builds steel V-wheels as well.
steel wheels.jpeg
steel wheels.jpeg (111.5 KiB) Viewed 4461 times
I put a dial indicator on my X axis motor plate before and after and there seems to be about .020" less flex in the X axis carriage. I used my calibrated pushing hand to put pressure on the spindle.
Here are a couple of shaky videos of before and after.

Before:

After:
.
Last edited by Improbable Construct on Fri Mar 01, 2013 9:46 pm, edited 1 time in total.
Shapeoko #Classified some of the bolts may be original parts.
Shapeoko 1 # ???? Stainless plates, still in the box.
Shapeoko 2 # 3926 not stock
Shapeoko 3 # 0003
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http://ImprobableConstruct.com
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mjohn
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Re: A bunch of new upgrades.

Post by mjohn » Wed Feb 27, 2013 3:40 am

Fancy, I love it!

Put a Neuspeed sticker on it too, that's guaranteed to raise the RPM's by a thousand or two.
John Milleker Jr. - Historical Process Photographer/Instructor
Baltimore Maryland, USA - http://www.JohnMilleker.com
ShapeOko #1,284 - Upgrades: 2x4Oko (24x48" footprint), Double X rails, Acme-Z, Dual Y, DW660, IC's Dust Shoe w/Dust Collection.

PsyKo
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Re: A bunch of new upgrades.

Post by PsyKo » Wed Feb 27, 2013 7:26 am

Is it also double open rail on the X axis ? 40x40 misumi with OR edge on both side ?
Would you recommand Open Rail instead of Makerslide ?
Shapeoko #736
Kress 800, Z Axis upgrade, dual Y, 600mm X&Y rails, metal spacers and V Wheels, home switches, 4th axis
Goko - Free CNC Control Software - http://www.shapeoko.com/forum/viewtopic ... 380#p44380

Tom Smith
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Location: North Vancouver, British Columbia

Re: A bunch of new upgrades.

Post by Tom Smith » Wed Feb 27, 2013 4:39 pm

Interesting, so do you find the cf compares well to the steel during operation? Do things vibrate more with the lighter weight?

Tom
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deejayspinz
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Location: Burlington Ontario, Canada

Re: A bunch of new upgrades.

Post by deejayspinz » Wed Feb 27, 2013 5:58 pm

Very nice IC... Carbon fibre.... drrrrruuuulllll...

Improbable Construct
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Re: A bunch of new upgrades.

Post by Improbable Construct » Wed Feb 27, 2013 6:30 pm

PsyKo wrote:Is it also double open rail on the X axis ? 40x40 misumi with OR edge on both side ?
Would you recommand Open Rail instead of Makerslide ?
It is double open rail on the X. I ordered 1000mm of 40x40 and 4 1000mm sticks of hard coated OpenRail.
I don't really know how it is going to hold up but the steel wheels work really well.
I went with the OpenRail because it was way cheaper than the local quote I got to have my Makerslide hard coated.
They wanted over $100.00 and two weeks to do it.
The new setup seems to have eliminated a fair amount of the Z-Axis twist on the X-axis.
Tom Smith wrote:Interesting, so do you find the cf compares well to the steel during operation? Do things vibrate more with the lighter weight?
Tom
The new plates are quite a bit lighter than the steel ones. CF=0.8 lbs Steel=2.65 lbs
The weight loss is more or less mitigated by the increase of weight in the 40x40 and open rail. 2x1000 mm of Makerslide=3.12 lbs 40x40 + 4x1000 mm OpenRail=4.8 lbs
So that gives a net increase of .17 lbs.
In theory the CF should dampen the vibration, but I really never had a problem with vibration. (Although I think my DW660 is about to die. It sorta sounds like it is starting to spin a bearing, so it is vibrating a bit more than it should.)
I haven't had a chance to run a job yet but I should be able to comment on the performance in the next day or too.
Shapeoko #Classified some of the bolts may be original parts.
Shapeoko 1 # ???? Stainless plates, still in the box.
Shapeoko 2 # 3926 not stock
Shapeoko 3 # 0003
Store:
http://ImprobableConstruct.com
Twitter:
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Improbable Construct
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Joined: Tue Apr 10, 2012 3:21 am
Location: Fairhope, AL
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Carbon Fiber Plates and Aluminum Bearing Blocks

Post by Improbable Construct » Fri Mar 01, 2013 9:32 pm

So I decided to put my new carbon fiber motor plates to the test.
First I milled a new standard carrier plate out of carbon fiber.
I don't know if it is a gain in stiffness but is was most certainly not a loss. :)
And besides its freaking carbon fiber!
Anyway that all went well, so I decided to try and mill some 10mm 6160 aluminum plate.
I made a NEMA 23 bearing block / motor mount for my Z-axis.
I ran it at:
400 mm/min feed
20000 RPM
1/8" four flute solid carbide endmill.
Spiral plunge
I also added lots of tap magic cutting oil throughout the milling.

The Bearing would not go into the hole on the first try.
I used the settings for plastic and obviously the aluminum would not flex to allow the bearing to seat.
So I had to run the end mill around again taking off .05 mm.
It worked perfectly and the bearing slides right in with just a bit of effort.
I modified the bottom block to remove unnecessary holes and rounded off the end.

Pictures:
aluminum bearing blocks.jpeg
aluminum bearing blocks.jpeg (118.24 KiB) Viewed 4249 times
Here are the finished blocks. I also flipped the bottom block and cut counter sinks for the screw heads.
Aluminum and carbon fiber.jpeg
Aluminum and carbon fiber.jpeg (128.18 KiB) Viewed 4249 times
Here are the finished X and Z axis with the carbon fiber motor plate and standard carrier plate.
The aluminum bearing blocks can also be seen.
Last edited by Improbable Construct on Mon Mar 18, 2013 8:03 pm, edited 1 time in total.
Shapeoko #Classified some of the bolts may be original parts.
Shapeoko 1 # ???? Stainless plates, still in the box.
Shapeoko 2 # 3926 not stock
Shapeoko 3 # 0003
Store:
http://ImprobableConstruct.com
Twitter:
https://twitter.com/ImprblConstruct

cvoinescu
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Re: Carbon Fiber Plates and Aluminum Bearing Blocks

Post by cvoinescu » Fri Mar 01, 2013 10:42 pm

I am literally drooling here (but it could be that I was thinking of pear tart just before I read your post).
Proud owner of ShapeOko #709, eShapeOko #0, and of store.amberspyglass.co.uk

Tom Smith
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Joined: Mon Apr 09, 2012 9:55 pm
Location: North Vancouver, British Columbia

Re: Carbon Fiber Plates and Aluminum Bearing Blocks

Post by Tom Smith » Fri Mar 01, 2013 10:59 pm

Yeah, that looks nice and all, but it really needs some pinstripes...
.
.
.
j/k, that looks awesome, and very inspiring!

Tom
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ShapeOko1 191

PsyKo
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Joined: Thu Aug 30, 2012 8:42 pm
Location: France

Re: Carbon Fiber Plates and Aluminum Bearing Blocks

Post by PsyKo » Fri Mar 01, 2013 11:37 pm

Improbable Construct wrote: I made a NEMA 23 bearing block / motor mount for my Z-axis.
I ran it at:
400 mm/min feed
20000 RPM
1/8" four flute solid carbide endmill.
Spiral plunge
I also added lots of tap magic cutting oil throughout the milling.
.
Any information about the pass depth ??
I'm about to mill some aluminium tomorrow :)
Last edited by PsyKo on Sat Mar 02, 2013 8:42 am, edited 1 time in total.
Shapeoko #736
Kress 800, Z Axis upgrade, dual Y, 600mm X&Y rails, metal spacers and V Wheels, home switches, 4th axis
Goko - Free CNC Control Software - http://www.shapeoko.com/forum/viewtopic ... 380#p44380

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