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Brodholm

WING X99 | A CNC-milled Scratch Build! (Benchmarks, temps and wallpapers posted!)

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Posted · Original PosterOP

cCMFjdS.png


Welcome!
Hello! It is time for a new project that I have been planning over a year now! I also have to give huge thanks to ASUS ROG, INTEL, CORSAIR and EKWB for making this project possible!

To the LTT forum and community!
First of I want to thank you all for the much appreciated feedback and suggestions on my last build Model 01! But you men and women, guys and gals, are amazing! On that build I did not start on this forum until midway through the project. I am not making that mistake again, this time I will start here from the beginning! Comments with suggestions/appreciation or support is what drives me to make bigger and better projects and to put more and more time into making these logs! Be sure to comment! I really value you opinions, again Thanks!

New to the build log?
Don't want to go through all the forum posts? You can easialy check out all the photos posted so far in this Gallery but remember to comment here on what you think after you are done!
 

yEfD4aW.png
5m1MzIH.png
 

Be sure to comment!
I very much appreciate comments/criticism on the project as long as it is constructive! And if you have suggestions on improvements be sure to post them! And if you have ANY questions, feel free to post a comment or PM me here or on social media.



 

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6950X?

1080 SLI?

2x 750 series SSDs?

Custom loop?

Custom case?

 

1032.gif


Project White Lightning (My ITX Gaming PC): Core i5-4690K | CRYORIG H5 Ultimate | ASUS Maximus VII Impact | HyperX Savage 2x8GB DDR3 | Samsung 850 EVO 250GB | WD Black 1TB | Sapphire RX 480 8GB NITRO+ OC | Phanteks Enthoo EVOLV ITX | Corsair AX760 | LG 29UM67 | CM Storm Quickfire Ultimate | Logitech G502 Proteus Spectrum | HyperX Cloud II | Logitech Z333

Benchmark Results: 3DMark Firestrike: 10,528 | SteamVR VR Ready (avg. quality 7.1) | VRMark 7,004 (VR Ready)

 

Other systems I've built:

Core i3-6100 | CM Hyper 212 EVO | MSI H110M ECO | Corsair Vengeance LPX 1x8GB DDR4  | ADATA SP550 120GB | Seagate 500GB | EVGA ACX 2.0 GTX 1050 Ti | Fractal Design Core 1500 | Corsair CX450M

Core i5-4590 | Intel Stock Cooler | Gigabyte GA-H97N-WIFI | HyperX Savage 2x4GB DDR3 | Seagate 500GB | Intel Integrated HD Graphics | Fractal Design Arc Mini R2 | be quiet! Pure Power L8 350W

 

I am not a professional. I am not an expert. I am just a smartass. Don't try and blame me if you break something when acting upon my advice.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

...why are you still reading this?

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Posted · Original PosterOP

Update 01 | Design and Renders
Fist update of the project, the renders. A lot of work has come before this. Approximately 500 hours of planing, designing and drawing. A few things have changed. Due to the nature of renders (time consuming!) I have not updated them for a few minor fixes and design tweaks!

Do you want to browse pictures in fullscreen? Here is a link for you!. Then use (View album in fullscreen). BUT! Remember to comment here when you are done!

3yEBFsb.png
UTg4SU5.png
The AF logo before WING X99 have been removed and replaced with the WING logo as seen below on the accent line on top of the chassis.
eLrD5pT.png
H2bemyS.png
UgbcCIA.png
hBZ47bb.png
AdOdaSp.png
I'm going to leave it with these render and not show everything right now. Every render takes 1-8 hours to do. And I also want to have some surprises left for you to uncover along the way!

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On 8/19/2016 at 0:32 PM, Brodholm said:

Update 01 | Design and Renders
Fist update of the project, the renders. A lot of work has come before this. Approximately 500 hours of planing, designing and drawing. A few things have changed. Due to the nature of renders (time consuming!) I have not updated them for a few minor fixes and design tweaks!

Do you want to browse pictures in fullscreen? Here is a link for you!. Then use (View album in fullscreen). BUT! Remember to comment here when you are done!

Spoiler

3yEBFsb.png
UTg4SU5.png
The AF logo before WING X99 have been removed and replaced with the WING logo as seen below on the accent line on top of the chassis.
eLrD5pT.png
H2bemyS.png
UgbcCIA.png
hBZ47bb.png
AdOdaSp.png

I'm going to leave it with these render and not show everything right now. Every render takes 1-8 hours to do. And I also want to have some surprises left for you to uncover along the way!

Tempered glass?

Edited by alpenwasser
pic spoiler

Main Gaming Rig:

Spoiler

Core i7-4770, Cryorig M9i Cooler, ASUS B85M GAMER, 8GB HyperX Fury Red 2x4GB 1866MHz, KFA2 GTX 970 Infin8 Black Edition "4GB", 1TB Seagate SSHD, 256GB Crucial m4 SSD, 60GB Corsair SSD for Kerbal and game servers, Thermaltake Core V21 Case, EVGA SuperNOVA 650W G2.

Secondary PC:

Spoiler

i5-2500k OCed, Raijintek Themis, Intel Z77GA-70K, 8GB HyperX Genesis in grey, GTX 750 Ti, Gamemax Falcon case.

 

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21 minutes ago, Brodholm said:

I'm going to leave it with these render and not show everything right now. Every render takes 1-8 hours to do. And I also want to have some surprises left for you to uncover along the way!

1-8 hours renders... You're doing something wrong with render settings as by the looks of it, the scene should render in max 10 minutes even at 3840x2160. What are you using for render?


EVGA SR-2 / 2x Intel Xeon X5675 4.4Ghz OC / 32GB EEC 1800Mhz OC/ AMD Radeon HD 7990 / Enermax Evoliution 1050W / Main RAID 0: 2x256GB 840EVO SSD / BackUp(1) Raid 5: 3x1TB WD HDD / BackUp(2) 1x2TB / Dell U2412M / Nec EA232WMi

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1 hour ago, multifrag said:

1-8 hours renders... You're doing something wrong with render settings as by the looks of it, the scene should render in max 10 minutes even at 3840x2160. What are you using for render?

If he is doing proper ray tracing in CAD the renders should take about that long, especially when you have that many components. Subbed BTW. 


Check out my YouTube channel here and don't forget to subscribe :D

Current build: Project Athena

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23 minutes ago, nmil said:

 

1 hour ago, multifrag said:

1-8 hours renders... You're doing something wrong with render settings as by the looks of it, the scene should render in max 10 minutes even at 3840x2160. What are you using for render?

If he is doing proper ray tracing in CAD the renders should take about that long, especially when you have that many components. Subbed BTW. 

 

Haven't used Autocad, but working daily with maya and 3dsmax and hobby time in fussion. 1-8 hours of simple model render would be unacceptable. 7 rays would be enough to go through all the objects and show glass. Putting 999 rays won't change a thing in that sake. Maybe it's Autocad as I'm not familiar, but knowing Autodesk I don't think they would not include it. Just now Autodesk bought Arnold renderer and is including  £1000 renderer for no additional cost.


EVGA SR-2 / 2x Intel Xeon X5675 4.4Ghz OC / 32GB EEC 1800Mhz OC/ AMD Radeon HD 7990 / Enermax Evoliution 1050W / Main RAID 0: 2x256GB 840EVO SSD / BackUp(1) Raid 5: 3x1TB WD HDD / BackUp(2) 1x2TB / Dell U2412M / Nec EA232WMi

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11 hours ago, multifrag said:

Haven't used Autocad, but working daily with maya and 3dsmax and hobby time in fussion. 1-8 hours of simple model render would be unacceptable. 7 rays would be enough to go through all the objects and show glass. Putting 999 rays won't change a thing in that sake. Maybe it's Autocad as I'm not familiar, but knowing Autodesk I don't think they would not include it. Just now Autodesk bought Arnold renderer and is including  £1000 renderer for no additional cost.

I know that when I used Showcase to render this (the model has 200+ components):

config 1 v2.jpg

It took me around 4 hours. I did 10 layers of ray tracing and cranked anti-aliasing to the max. I have a potato PC, but I think it would still take at least 1 hour to do it on a workstation.  


Check out my YouTube channel here and don't forget to subscribe :D

Current build: Project Athena

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Now this I have to see to fruition! Subbed for sure!

 

I really want to see how those nice big bends in the aluminum turn out. Sheet metal braking fascinates me.


I like good humans and good food

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Posted · Original PosterOP
On 2016-08-19 at 0:32 PM, ThinkWithPortals said:

6950X?

1080 SLI?

2x 750 series SSDs?

Custom loop?

Custom case?

Indeedios :D

On 2016-08-19 at 0:41 PM, NinjaJc01 said:

Tempered glass?

No, 6mm PMMA (Plexiglass)

On 2016-08-19 at 0:57 PM, multifrag said:

1-8 hours renders... You're doing something wrong with render settings as by the looks of it, the scene should render in max 10 minutes even at 3840x2160. What are you using for render?

Well, was what it took. The renders with almost no glass or reflection ran for about an hour. But for the ones with all the plexiglass I let run over night but they could probably have gone for longer. It's 4 pieces of plexi for the rays to go through, and I ran 12 rays I believe, and even with that it did not go all the way through. I set no max time for the renders, I just let them run and when I deem them good enough I stop.

I am using keyshot. 

On 2016-08-19 at 2:03 PM, tj1795 said:

OH MY SWEET MOTHER OF PEARL THIS LOOKS SO GOOD CAN"T WAIT.

Thanks mate :)

On 2016-08-19 at 2:18 PM, nmil said:

If he is doing proper ray tracing in CAD the renders should take about that long, especially when you have that many components. Subbed BTW. 

If I render in Inventor it takes muuuch longer than keyshot. Did the "Model 01" renders there. And they ran for a very long time. I have not tried Showcase though.

On 2016-08-19 at 2:48 PM, multifrag said:

Haven't used Autocad, but working daily with maya and 3dsmax and hobby time in fussion. 1-8 hours of simple model render would be unacceptable. 7 rays would be enough to go through all the objects and show glass. Putting 999 rays won't change a thing in that sake. Maybe it's Autocad as I'm not familiar, but knowing Autodesk I don't think they would not include it. Just now Autodesk bought Arnold renderer and is including  £1000 renderer for no additional cost.

Idk, I do not have access to maya etc. Simple? Depends on what you compare it to. Well over 300 objects, and screws, fittings etc all that is included in the renders. I may be doing things wrong but I don't think so.

On 2016-08-20 at 3:26 AM, nmil said:

I know that when I used Showcase to render this (the model has 200+ components):

config 1 v2.jpg

It took me around 4 hours. I did 10 layers of ray tracing and cranked anti-aliasing to the max. I have a potato PC, but I think it would still take at least 1 hour to do it on a workstation.  

Proper ray tracing In Inventor parts take super long for me to render. Similar models like that takes about 10 min for me in keyshot with similar results, with there being no transparent objects etc. That was the reason I got keyshot. But hey, I'm not a professional renderer. Probably did something wrong. :D

On 2016-08-20 at 4:45 AM, colinreay said:

Now this I have to see to fruition! Subbed for sure!

 

I really want to see how those nice big bends in the aluminum turn out. Sheet metal braking fascinates me.

Yeah, I am a bit worried about that. But hey, gotta try! :)

On 2016-08-20 at 9:58 AM, Str8f4c3 said:

Omg omg loved your last build and subbed for this one cant waaaaaiiit!!!!

Thanks! So very sooon done with the last fix for the CNC. Started to work but noticed very quick that I had way to few holes in the router table. Had to make some more. I hand tapped about 300 holes of M10 a few days back...

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8 hours ago, Brodholm said:

Idk, I do not have access to maya etc. Simple? Depends on what you compare it to. Well over 300 objects, and screws, fittings etc all that is included in the renders. I may be doing things wrong but I don't think so.

Try maya with arnold renderer. It has true raytracing and is the top dog in the vfx rendering world. I can guarantee that you will render the same image, same quality in under 10 minutes(unless you have a pentium cpu)


EVGA SR-2 / 2x Intel Xeon X5675 4.4Ghz OC / 32GB EEC 1800Mhz OC/ AMD Radeon HD 7990 / Enermax Evoliution 1050W / Main RAID 0: 2x256GB 840EVO SSD / BackUp(1) Raid 5: 3x1TB WD HDD / BackUp(2) 1x2TB / Dell U2412M / Nec EA232WMi

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Posted · Original PosterOP
35 minutes ago, multifrag said:

Try maya with arnold renderer. It has true raytracing and is the top dog in the vfx rendering world. I can guarantee that you will render the same image, same quality in under 10 minutes(unless you have a pentium cpu)

Thanks for the tip! Will check it out!

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Posted · Original PosterOP

Getting new aluminium sheets in a few days. The 10mm and 8mm ones I got deep scratches from bad storage. The sat next to some steel plates and now they have 1mm deep scratches in some places. That is not going to be usable so I had to get new ones. A bit annoyed since they cost a lot. I'm not using all of those plates but I still have to get a whole sheet of each. They cost 10,5 USD/KG in sweden with taxes and weigh 54kg and 42kg. That is 10.5*(54+42)= 1008 USD. Well, nothing to do about it. I might be able to salvage some pieces and grind them down, but that is such a pain and the results are usually a 100%. 


But I got some more work done on the CNC, realizing I needed even more holes to be able to easily clamping pieces down. I have tapped over 600 holes of M10, sigh... 

Anyway, for those interested. Here is the render when it started out (More pictures in the spoiler tag).

 

uuSaAKP.jpg

 

 

Here are pictures from the CNC work log, Over 2 years of my life have gone into this thing :) I realize this is not for everyone so I put it in spoiler tags!

Check the spoiler tag underneath

Spoiler

Some basic info. 3x100W servo motors, 2.2kW Spindle, 18000rpm, 600hz "high torque" model. About 950mm*950mm*200mm of XYZ travel. Designed and built by me :)

uuSaAKP.jpg
Initial design/model rendered :)

koUVaa0.jpg
The router chassis have been milled and faced so the aluminum sheet that lays on it will lay as flat as possible

YqsQ5Oa.jpg
Both sides milled in the same mill without letting the setting gobetween the passes.

4CvLABS.jpg
Motor mounting point

t7rPwBy.jpg
Faced distances for the aluminium table

0lwvbEV.jpg
Holes for the ball screw. We ended up changing this. Going for two ball screws with a drive line between them.

s1KD0dR.jpg
Milling the sides

FfBaUTl.jpg

uzxlRNn.jpg
Milling slots for linear guides on the X-axis

dGCLNiY.jpg
Linear guides mounted.

sHxpplD.jpg

nbVrpGM.jpg
X-axis servo motor seat

JqOAcG3.jpg

ZrGoxhz.jpg
Most of the frame done! We ended up changing the arms for 40mm steel thickness because of issues with vibration. Turns out that was not the issue but the machine did get more sturdy because of it.

MhdF0Se.jpg
Faceing the Z-axis plates

zU2UctE.jpg

oT5YSlP.jpg
Faced and milled Z gantry. These are also grinded in this picture so they are very even in thickness.

q75nHYa.jpg
Testing the servos and controller system. Testing everything in Mach3

4244ink.jpg
Testmounted spindle and servos. An 2.2kW, 18000 rpm 600hz "high torque" spindle.

PXqGpbP.jpg

Cee33zS.jpg

xp2eQZx.jpg
Realized that this was a bit messy so I ended up getting a box.

eOg9yjs.jpg

nIYNUti.jpg
First time together with the protective housings on. You can also see the bigger arms here. 40mm thick steel.

BFGaK9x.jpg

9sh9lrh.jpg
Testing for the first time! Not a very good run. Z-axis lost steps like crazy. After several days I finally found the problem. The VFD was giving noise to the Z-stepper motor. I had to get shielded cables and finally ended up putting the VFD on the X-axis to reduce the amount of meters the cables had to go along each other.

sZ8u0jG.jpg
Made a desk for the computer

S6nk3Bf.jpg
New shielded cables (orange) and some very much needed paint! Time to assemble everything again...

gEdfWqb.jpg
The box I built to house all the different cables. The VFD on the right is not there now (moved to the X-axis). Also fuses and added safety measurements was added.

Zbi2Iuf.jpg
I knew I had to take everything apart so I did not spend that much time fixing this right here.

65nbXmw.jpg
Everything back together after paint, new cables etc!

9WrIujf.jpg
Making a slot for cooling fluid to escape

snD0rGN.jpg
Had to let go of the table and use clamps from underneath the table to hold it down since I did not have the range to do the top slot otherwise...

xCljH7X.jpg
Super pleased at this moment. ap:3mm ae:10 feed:1000mm/m and about 7000 rpm if I remember correctly. Further than this would probably be pushing it.

m7b8F4U.jpg
Really need to design a dust shoe to take some of these chips from the beginning.

QbYw3IX.jpg

JbmeSF9.jpg
Hole for the fluid to escape. Will be making a sieve that fits here.

Vc3q2qx.jpg
All clean :)

t3nbXng.jpg
Very much pleased with the quality of the cut

2LXjSrM.jpg
I was going to start with my projects here. But I realized that I needed to make more holes for clamping and also some kind of sacrificial board in a material that can handle the cutting fluid.

J2vYfAU.jpg
Lots and lots of chips, and they are going everywhere in a 2m radius...

O5hjyF6.jpg
Chamfers for tapping. Will be faceing this whole surface 0.5mm so don't mind that the chamfer tool was too small :)

BeJEfGe.jpg
Run out of battery for the second time here. Doing all these M10 by "hand" was quite taxing, both for me and the power drill! A much needed break

TGSZaah.jpg
I don't have to do all the holes but almost all of them. 18*18 rows of holes (324 holes!!!). But some was done earlier.

ZzrQ6yi.jpg
All done... Thank god...

9fXxNZP.jpg
Cleaned the table and was very pleased with the results!

qg2glFu.jpg

2CfgCgs.jpg
Clamping down the sacrificial board. A 10mm sheet of aluminium that will be faced and 12mm holes will be drilled over all the M10 holes. The plan is to be able to fit 12mm solid shafts to use as guides and also as holes for M10 screws for clamping.

vXa5joV.jpg
Even worse here, over 0.2mm (this error for over a 250mm diameter). This was at 180 deg. I adjusted the 90 and 270 deg position with a angle and moved it quite a bit and that got very close after just doing that. But it was bad before that.

blOGdhQ.jpg
Time to put some shims in. Very, very sensitive. Had to try a lot of different sizes. 2x0.08mm shims turned out to give very nice results. I am now keeping the error within 0.01mm over a circle of 250mm in diameter. Very happy with this. Took about 2 hours to fix in total. But I hope it pays of in the long run.

iAYoGRL.jpg
All four positions below 0, 90, 180 and 270 degrees.

3I2oXaD.jpg
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rGEsVdV.jpg
fVPwjwZ.jpg
Very pleased with the result. I also decided on doing another 300+ M10 holes. They are all done, I need to post some images of this also. And I will also face the entire surface again doing a very shallow cut with the spindle calibrated.



 

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12 hours ago, Brodholm said:

snip

Jealousy levels over 9000!!!

I only have an X-Carve.


Check out my YouTube channel here and don't forget to subscribe :D

Current build: Project Athena

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Posted · Original PosterOP

While wating for the new aluminium pieces I got some more work done on the router. These improvements should make the chassis much easier to make. I also leaned a whole lot on these parts I made. And made a few mistakes that I learned a lot from. Mistakes I will not make again (I hope)

Anyway, here are the progress so far. Friday should be the day I get the new alu, and I hope to be done with the fixes on the CNC by Thursday/Friday. So it should line up perfectly! Cutting the sheets of alu and making the very first cuts on the project should start next week!. Really excited to really get to use the machine for some fun!


NaMYIVV.jpg

Check the spoiler tag underneath

Spoiler

 

FyNh7KB.jpg
Decided that I needed more holes. So I made another 300+ M10 tapped holes

jNug8jv.jpg
I also did another faceing pass over the board with the newly calibrated spindle. The result was much better than earlier. Now you can basically not even feel the edges between the cuts.

DH8YYpo.jpg
Time to re-attach the spill board to the table.

AZnkPWX.jpg
Screwed down the spill board.

WgN4qse.jpg
12mm holes made above all the M10 and screw-down points. Boremilled 11.8mm holes and plunged with a fresh 12mm Endmill so that the holes are exactly 12mm

pPAYvCv.jpg
M10 holes in the table, and 12mm blind holes in the soft 1050.

rFnXmuX.jpg
Diamater 12mm and length 20mm

C596fe5.jpg
Fits perfectly. And ensures that all the work pieces are parallel to the machine.

Cyj41Tv.jpg
Needed to make some custom clamps since I have non. This temporary clamping of the piece have do do for now...

tgGGwoC.jpg
This is the reason I had to get new sheets of alu for the project. New sheets will arrive by mid september. I am trying to get as much work as possible done before they arrive to make the CNC more efficient for that project!

ksVCQ0o.jpg
Getting the clamps done!

BG0S1dI.jpg
As seen on the image above. It makes a HUGE mess with the coolant and chips all over the place. This is why I have designed a dust shoe to pick some (hopefully most) of the mess.

p1Ujsm5.jpg
Klf4TKO.jpg
Main "holder piece" done!

FTu24LC.jpg
I designed and milled this LED-ring for this holder.

tlUnK6T.jpg
Fits perfectly :)

5CH8tmy.jpg
3 SMD leds in series with a resistor. Milled with a 0.5mm END MILL. Those are SCARY small. Thought it would break but it held up!

3Q8Txuy.jpg
Time to get my soldering station fired up!

FKoalfu.jpg
First SMD resistor mounted!

6JJYuzR.jpg
First "section" done and tested! Now I just need to solder a few more...

5PEvk0s.jpg
All done!

mzqUVQk.jpg
Tested with the diode tester on my fluke. You can see the diodes light up slightly and all seem to work!

SMgIYfl.jpg
Very bright! Really pleased with the results. With 12V put on they produce a really bright white light.

DsMZhxE.jpg
Looking really good if I dare say so myself!

ex4HBzW.jpg

NjoDJTX.jpg
Milled a protective acrylic sheet from a 10mm piece that screws down in the 4 mounting holes. Also 2 o-rings keeps the LED-s safe from water and dust.

BEDteQ2.jpg
Did some light flame polishing on the acrylic I cut with coolant. The result was that the surface went from almost clear to less clear. Still a very good result. I have purchased a cold air gun to keep the plastic cool and remove the need for coolant that produces the slightly foggy surface. Also flame polishing 2mm thick acrylic caused it to get very soft and it got a bit skewed so I had to fix that by heating and bending some more to get it straight. Still a very good result.

SxVcOhE.jpg
Cable comes out in the back.

NcNacct.jpg
Light tested and mounted! Success! I hope that the heat will go out in the aluminium seat it is in and not overheat. We will have to see what happens. It should be fine... I hope :)

BPuvn7D.jpg
Making the top side for the dust shoe

gm6ftux.jpg
IgF9bb7.jpg

olevULk.jpg
Top completed

p7ekuxC.jpg
A very nice result. This is Polycarbonate that is VERY durable and almost "unbreakable". About 10x more durable than acrylic (PMMA)

NaMYIVV.jpg
Same procedure as above with the bottom piece. The small pockets you see here are made to fit 8x5mm N45 neodymium magnets.

qV33erX.jpg
A very nice surface finish.

khA3fLR.jpg
Did not have the correct screws that I needed so I sanded down some M6 insex screws to fit my needs. I also drilled some holes and sanded down the diameter of the 100mm hose connector and made clearance slots for the magnets.

oavrEo8.jpg
Mounted on the top piece of the shoe.

RE0FG5f.jpg
Top and bottom pieces all done! Magnets glued in place and the brush secured with some silicone.

wBrAnxE.jpg

z0miP8A.jpg
nLYnixW.jpg
Made the clamp with some of the scratched aluminium. Drilled and tapped two M5 holes

4diXAZK.jpg
uGOdVuZ.jpg
All ready to clamp the axles!
QlKtY88.jpg
Holes for the "snap-fasteners" to secure the shoe in place when doing a tool change.

7FnNvdQ.jpg
Two teflon bushings pushed in place to ensure low friction.

zJW6rOE.jpg
Sanded down the cylinders to the correct diameter.

ZnPtGns.jpg
All fitted! All that's needed now is to attach the hose and connect the wires.

 

 

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I can't believe what's happening before my eyes!  I'm very subbed sir, very subbed :x


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Man's Machine- i7-7700k@5.0GHz / Asus M8H / GTX 1080Ti / 4x4gb Gskill 3000 CL15  / Custom loop / 240gb Intel SSD / 3tb HDD / Corsair RM1000x / Dell S2716DG

The Lady's Rig- G3258@4.4GHz(1.39v) on Hyper 212 / Gigabyte GA-B85M / gtx750 / 8gb PNY xlr8 / 500gb seagate HDD / CS 450M / Asus PB277Q

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Sublime (already) :Q_
Subbed ofc :)


MAIN Core V21 | i7 5820K @ 4.2 1.21v | Corsair H100i + NF-F12 | Asrock X99M Killer | Crucial Sport 4x4GB 2400 CAS16 @ 2666 CAS15 | 290X DCUII OC @ 1115/1450 1.3v | Samsung 850 EVO 500GB + 830 128GB + WD Blue 1TB | Corsair AX650

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Posted · Original PosterOP

Second update of the main work-log will be coming tomorrow or Monday. It's me cutting the raw materials for the case. I am also doing CAM programming right now for the first case parts themselves. Should make those cuts Monday or Tuesday if everything goes as planned. So very soon the first parts of the case should be done. 

Right now, Ill give you some more CNC-stuff for those interested

 

Kei8Uq1.jpg


Check the spoiler tag underneath

Spoiler

vbfNkjA.jpg
This is what I am going to make my Z-axis tool setters from.

dkfn12H.jpg
Started with making a 5mm hole through the whole part and a partially drilled 15mm hole. Then I cut it of.

OSGfwLU.jpg
22mm drill

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First drilled with the 22mm then I used the insert to get the correct diameter of 23mm and a flat hole

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Pushing in a 20mm ID teflon brushing

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All nice and flat. Measured 20.08mm ID.

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Making the tool itslef. Got it down to about 20.15mm. That leaves me with some room to carefully grind it down to the correct diameter

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Grinded down to about 20.7mm and did a small cut that a stop screw will run along.

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Time to cut of the axis to the correct length and flip it around.

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Faced of and a 3mm chamfer.

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Work in the lathe done, now its time to get to polishing and a few holes.

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Made a small hole for a M4 stop screw.

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The stop screw keeps the top of the tool from coming of.

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All the parts for the Zero tool. Tool body, Tool top, spring, sensor (inside) and a stop screw

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Need this to be very flat.

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Much better. Did not bother with the small scratches on the bottom surface, its flat, and that is what matters.

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Quite deep scratches here. About 0.05-0.10mm deep. This is a pain...

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After A LOT of slow paced wet sanding I got it down to this finish. Went from 120 grit to 240, 400, 800 and finished with 1200. This took probably an hour to get. I was very careful to sand it down flat and on a flat surface granite sheet (that weighs sooo effin much!!!). I had to do this procedure twice since i needed 2 tools. One as Z-axis zero and one as a fixed reference.

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Light mounted and connected! Its very bright and the phone turned down the aperture way down. So its much brighter than it appears. You can check the surrounding area and this is in the middle of the day with all the other lights on. Very pleased with the amount of light coming from this thing.

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Fixed the aperture so you can grasp the difference

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The reference tool shown here.

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Comparison with no light on (notice the background and how bright that is)

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And with the light on. As you can see the camera adjusted the aperture down to not over expose the shot. But compare the background to the previous picture and you can see the difference. It's not overly bright but still very bright.

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Made a tool holder for the auto zero tool. Fits nicely and keeps it secure.

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Yes, I need to clean the machine, and yes the switches have no labels! All in due time! :)

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Getting the tooling from a big box of mixed tools is a pita and I spend at least a few minutes checking the lables and fiddling around trying to find the tool I need. So some holders for the mills was really needed. Started with some leftover planks and cut them in to 105mm long pieces.

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Milling wood is a bit different, and without the dust shoe not yet connected with the new hose it makes a mess.

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Another one for clamps and tooling. Notice the thin layer of dust that is EVERYWHERE!!! Need to cut that pipe ASAP.

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All done!

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Much better! Everything organized and easy to find and put back.

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The "complete set" of tooling. Starting from the left, the green wood mills, soft metal/plastic mills, screws, and parallel plugs, and finally all the ER25 collets (These are the ones you put your end mills in for those not familiar).

 

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Posted · Original PosterOP

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Yes getting the ore from the ground might be considering from the ground up, but close enough :)

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10mm casted (GS) PMMA/Acrylic plexiglass or whatever you want to call it!

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Very big sheets, to big in fact. Next time I will be going for the much more convinent sizes of 1x2 meters. These are 2x3 meters...

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Absolutely huge!

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Time to cut these down!

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As always, safety! Really important to protect your eyes. It is very easy to get dust/particles that is a pain in the ass to remove and worst case you get some framgent that can make you blind. ALWAYS use glasses when cutting material!

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Lines and a aluminum guide plane! Can't go wrong then with that amount of safety. Really don't want to scrap these. They cost quite a bit...

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Gap saw i believe its called in English.

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The saw fits in the straight strip of extruded aluminium. And then follows that exact path for a very straight cut.

 

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Went really smooth and the cuts was very nice!

 

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Lots and lots of these chips that become electrically charged when you cut. And they want to stick to everything!!!

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10mm and 6mm sheets are all cut. Left half of each 2x3 meter sheets uncut. This will be more than enough for a while.

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Time to get down to the harder stuff. Aluminium, got this special blade that is supposed to be designed for this purpose.

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10mm aluminium EN1050A H111. I ended up not using these since they got heavy scratches after bad storage next to steel sheets!!! I was not happy about this but there was nothing to do other than getting new ones. This time I went for EN5754 H111, which is much harder and better for machining.

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They are very nice and clean (But as I said, these got deep scratches in them now, rendering them useless for decorative work).

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A bit nervous here. It's a 10 mm thick sheet of aluminium that is being cut with a tool designed mainly for woodworking and carpenters.

 

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To my surprise it cut it like butter. Very impressed with the blade and the quality of the tool

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These are the new EN5754 sheets, very disappointed with the delivery. They came wet and have probably been stored like that for a while. The got this oxidation that needs to be removed with either sanding or polishing. Not what you want from a new sheet that you paid good money for.

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It is not deep or something that can't be fixed. Its just a hassle, not like those 1-0,5mm deep scratches I got in the other plates (although that was not the suppliers fault but the workers at the workshop I am at)

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This also... This is like an IKEA sticker nightmare. There was this thin sheet of paper between the sheets that is now one with the aluminium. Will probably have to use some alcohole or something to get this of. Sooooo much unnecessary work for me...

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Believe me I will be making a call to our supplier to see what they have to say about this. They usually deliver everything in tip top shape with excellent quality.

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Ohh well, I will get started with these plates anyway and if I can get new ones I will switch to those sheets as I progress.

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Anyway, now everything is cut and ready to go on the CNC router. All sorted in different slots for different materials!

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Next update will be some cutting action and finally production of the case can begin. Took a lot of steps to get here but I am ready to begin now. And all these delays with the material have enabled me to get all the components that is going into the chassis so I can really check that everything will fit nicely. And I have also improved the CNC a lot. And that should really speed up the milling process of the case. So all in all, they delays have not been all bad. These updates are sometimes lagging behind a few days due to the nature of editing both video and photos as of now. This should speed up when I get better routines as the updates progresses!
 

But my question to you is how you want these updates if you could chose. Will be a lot of milling and programming in CAM and also design setup etc. Would you like the whole process with video of me editing code, setting up sheets, doing preparations, video of the actual cutting (cut down into manageable segments etc). Myself I think that gifs for example is a very good substitute for video when there is only short segments that I need to visualize. What is your opinion? Let me know, I would really like to have everyone's thoughts on this :)

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Holy Crap! :o This is an absolutely glorious start! Definitely following this log!

 

I like the idea of pics and gifs with descriptions underneath (But that's cause my PC can actually handle loading it all :P even if my internet strains)


Use this guide to fix text problems in your postGo here and here for all your power supply needs

 

New Build Currently Under Construction! See here!!!! -----> 

 

Spoiler

Deathwatch:[CPU I7 4790K @ 4.5GHz][RAM TEAM VULCAN 16 GB 1600][MB ASRock Z97 Anniversary][GPU XFX Radeon RX 480 8GB][STORAGE 250GB SAMSUNG EVO SSD Samsung 2TB HDD 2TB WD External Drive][COOLER Cooler Master Hyper 212 Evo][PSU Cooler Master 650M][Case Thermaltake Core V31]

Spoiler

Cupid:[CPU Core 2 Duo E8600 3.33GHz][RAM 3 GB DDR2][750GB Samsung 2.5" HDD/HDD Seagate 80GB SATA/Samsung 80GB IDE/WD 325GB IDE][MB Acer M1641][CASE Antec][[PSU Altec 425 Watt][GPU Radeon HD 4890 1GB][TP-Link 54MBps Wireless Card]

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Carlile: [CPU 2x Pentium 3 1.4GHz][MB ASUS TR-DLS][RAM 2x 512MB DDR ECC Registered][GPU Nvidia TNT2 Pro][PSU Enermax][HDD 1 IDE 160GB, 4 SCSI 70GB][RAID CARD Dell Perc 3]

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Zeonnight [CPU AMD Athlon x2 4400][GPU Sapphire Radeon 4650 1GB][RAM 2GB DDR2]

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Server [CPU 2x Xeon L5630][PSU Dell Poweredge 850w][HDD 1 SATA 160GB, 3 SAS 146GB][RAID CARD Dell Perc 6i]

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Kero [CPU Pentium 1 133Mhz] [GPU Cirrus Logic LCD 1MB Graphics Controller] [Ram 48MB ][HDD 1.4GB Hitachi IDE]

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Mining Rig: [CPU Athlon 64 X2 4400+][GPUS 9 RX 560s, 2 RX 570][HDD 160GB something][RAM 8GBs DDR3][PSUs 1 Thermaltake 700w, 2 Delta 900w 120v Server modded]

RAINBOWS!!!

 

 QUOTE ME SO I CAN SEE YOUR REPLYS!!!!

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