3/8th in. Aluminum DWP611 Mounts

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TonyB
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3/8th in. Aluminum DWP611 Mounts

Post by TonyB » Mon May 12, 2014 5:55 pm

I designed some DWP611 Mounts to be cut out of 3/8 6061 Aluminum. I bought a sheet of 1 ft. x 1 ft. x 3/8 in. from a random vendor[sp]on eBay[sp]for rougly $32 to my door.[br>It took about two hours to cut one mount. I used a 1/8th carbide endmill that I bought from[sp]drillman on eBay. My specs were, target depth: 4mm, step down: 0.2mm, feed rate: 240mm/min, plunge rate: 20 mm/min.[br>(Because I'm using Mach3; I choose a conservative[sp]feed/plunge rate, since Mach3 has functionality to increase and decrease these rates while the job is running.)

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MegaSquirted 62mm 7m @ 20psi on 91 octane
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Woodworker
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Re: 3/8th in. Aluminum DWP611 Mounts

Post by Woodworker » Mon May 12, 2014 11:05 pm

What was it designed in an would you consider posting? I'm attempting to keep my options open for a spindle and if I have brackets, then I can test before I lock myself in.

Thanks
BRuce - SO2 #4798 - IC's Z axis upgrade, customized Z rail and Z motor mount, spindle Dewalt 611

Simon P
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Location: Wiltshire, UK

Re: 3/8th in. Aluminum DWP611 Mounts

Post by Simon P » Tue May 13, 2014 8:49 am

Having just been down the same road, albeit in HDPE, I have to say I like how you've incorporated a locating lug in the mount using the milled groove on the router body. Also impressed that you are tackling aluminium - what spindle did you use to cut it?
Shapeoko 2 #3697 - Dewalt D26200 Spindle, Precisebits Collets, 250mm Z-Axis Makerslide

Schruminator
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Re: 3/8th in. Aluminum DWP611 Mounts

Post by Schruminator » Tue May 13, 2014 1:03 pm

Those are some good looking mounts-- nice!
1.8m x 1.0m SO2 #3638 / Vectric Aspire / ACME Z-axis / View my photography at http://www.mschrum.com

TonyB
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Location: Norwalk, Ia

Re: 3/8th in. Aluminum DWP611 Mounts

Post by TonyB » Tue May 13, 2014 2:19 pm

Woodworker wrote:What was it designed in an would you consider posting?
I drew it in Inkscape. I can post the file; does anyone know how to upload SVG's?

(as a side note: I'm thinking of grinding off the two inner tabs, on the top bracket. That would allow the top bracket to be mounted higher, giving more Z axis depth.)
Simon P wrote:Having just been down the same road, albeit in HDPE
I'm curious to know whether doing aluminum was really worth my time?

I know HDPE is going to be softer, but would it be soft enough to create backlash? The two reasons I went with aluminum where: 1. Rigidity, 2. It looks good (It matches my Z axis plate and my bearing blocks, since I cut my own for these).
Simon P wrote:I have to say I like how you've incorporated a locating lug in the mount using the milled groove on the router body.
Thanks, though I got the idea from someone else... lol

This was version 2 of my design. After seeing this:
http://www.shapeoko.com/projects/project.php?id=64
I decided to change my original design (which was two pieces).
Simon P wrote:Also impressed that you are tackling aluminium
Milling aluminum was my original requirement to building a Shapeoko. I planned (and really haven't yet) to build stuff for my car project. I did build a few things for my motorcycle, however.

The biggest complaint I have about aluminum, is mill time. One bracket took 2 hours to mill! I took a day of vacation from work and cutting two brackets consumed about 8 a.m. to 3 p.m. Hopefully I can refine the process and work on other things while it's milling.
Simon P wrote:what spindle did you use to cut it?
A DW660.
Schruminator wrote:Those are some good looking mounts-- nice!
Thanks!
MegaSquirted 62mm 7m @ 20psi on 91 octane
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WillAdams
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Re: 3/8th in. Aluminum DWP611 Mounts

Post by WillAdams » Tue May 13, 2014 2:38 pm

TonyB wrote: I drew it in Inkscape. I can post the file; does anyone know how to upload SVG's?
rename the file to <filename>-svg.txt and then upload it.
Shapeoko 3XL #0006 w/Makita RT0701 Router w/0.125″ and ¼″ Elaire precision collets
Nomad 883 Pro #596 (bamboo)

TonyB
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Re: 3/8th in. Aluminum DWP611 Mounts

Post by TonyB » Tue May 13, 2014 4:16 pm

WillAdams wrote:
TonyB wrote: I drew it in Inkscape. I can post the file; does anyone know how to upload SVG's?
rename the file to <filename>-svg.txt and then upload it.
Thanks!
MegaSquirted 62mm 7m @ 20psi on 91 octane
410whp/411ftlbs

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scott216
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Re: 3/8th in. Aluminum DWP611 Mounts

Post by scott216 » Wed May 14, 2014 4:53 pm

TonyB wrote: I drew it in Inkscape. I can post the file; does anyone know how to upload SVG's?
You could upload to Thingiverse. It's the perfect spot for something like this. And it makes it easier for people to find.
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Other Toolchain: Fusion 360 > Chilipeppr or GRBL Panel
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scott216
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Location: New Jersey

Re: 3/8th in. Aluminum DWP611 Mounts

Post by scott216 » Wed May 14, 2014 4:56 pm

TonyB wrote: Milling aluminum was my original requirement to building a Shapeoko. I planned (and really haven't yet) to build stuff for my car project. I did build a few things for my motorcycle, however.

The biggest complaint I have about aluminum, is mill time. One bracket took 2 hours to mill!
I haven't done any aluminum yet but I want to try some soon. What settings did you use to mill these brackets?
Shapeoko 2 with DW660
grbl v0.9g
PCB Toolchain: Cadsoft Eagle > pcb-gcode > Chilipeppr or GRBL Panel
Other Toolchain: Fusion 360 > Chilipeppr or GRBL Panel
My Build Log
Location: New Jersey

Simon P
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Joined: Wed Mar 12, 2014 9:17 pm
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Re: 3/8th in. Aluminum DWP611 Mounts

Post by Simon P » Wed May 14, 2014 5:50 pm

Hi Tony,

I have no means of quantifying the flex in the Z axis yet and obviously I have only ever had my Dewalt 611 in HDPE mounts. From visual and haptic observation it feels as stiff as the dremel ever did in it's aluminium 'universal' mounts. I have observed that I get a lot more flex by torquing the whole carriage around the X-axis makerslide than I do from the HDPE mounts - any contribution to flex at the router bit from them is negligible. I'm keeping my eyes open for a decent test indicator which I can use to take some comparative measurements and hopefully hone in on where improvements can be made. I think it is actually the V-wheel assemblies that are the weakest link in terms of backlash at the bit now and improving on them would be quite a lot of rework. I could be wrong, but that's what it seems like.

Simon
Shapeoko 2 #3697 - Dewalt D26200 Spindle, Precisebits Collets, 250mm Z-Axis Makerslide

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