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

[KrMaH]

this is hands down the most amazing computer build I've ever seen, and definitely the the most awesome thing I've ever seen!
dude, this is pure beauty! wish I had the skills to build my own CNC machine ( guess I would've had I taken mechanical instead of structural engineering, but oh well).
Im in awe, Im speechless...
words cant describe it...
watch out so that I dont slip across the border and... uhm... steal your pc... 

[BeardRex]

You have my attention!

[Brodholm]

On 2016-11-12 at 1:28 PM, Hasle said:

Looks very clean! Can't wait to see it all come together, and especially looking forward to when you'll be CNC'ing the acrylic blocks for the water cooling.

Me too! Milling plastics is very satisfying and also a bit frustrating

On 2016-11-12 at 7:46 PM, KrMaH said:

this is hands down the most amazing computer build I've ever seen, and definitely the the most awesome thing I've ever seen!
dude, this is pure beauty! wish I had the skills to build my own CNC machine ( guess I would've had I taken mechanical instead of structural engineering, but oh well).
Im in awe, Im speechless...
words cant describe it...
watch out so that I dont slip across the border and... uhm... steal your pc... 

You can try! Assemble fellow Swedes!  
 

 

On 2016-11-15 at 0:03 AM, BeardRex said:

You have my attention!

[Brodholm]

Toolbendythingupdate!

 

A simple radius bock, simple right? Wrong, this was much more complicated than I would originally have thought. I was first thinking of going with the original V-die and a upper tool to make this. But I soon realized that this would most likely cause marks on the aluminium. So I had to design a special bending machine and then build it. We also don't have a round upper die for a bending machine.

The base of the bender. No cylinder installed here.

Scale for positioning the piece on the correct distance from where the bend starts. Also an "edge" that that is perpendicular to the cylinder to insure that the bend is straight.

Changed my mind last second and decided to screw the bending machine in the CNC-router table instead of using clamps. Also added some neoprene rubber to not leave marks in the very soft  EN1050 (~99% pure) aluminium spill board.

Base stationary cylinder that decides the inner radius. Made this interchangeable so I can make several size bends. Made custom washers for the M16 bolts that holds it secure.

A simple holder that screws down in the tool with a rubber surface to hold the aluminium piece in place while bending.

This is a cylinder with ball bearings that can roll so the thing actually spins instead of slide on the surface of the aluminium. This insures that bending process leaves no marks on the aluminium.

Mounted the leaver and set the correct height and aligned up everything.

Stop screws insures that no sliding occurs when the aluminium tries to push the roll up when you bend it.

Same procedure on the bottom stationary cylinder. Really do not want them to move during the bend. That would ruin the piece and you would have to start again.

Clamp that uses two M10 bolts and some rubber to not damage the pieces.

Here it is from the other angle.

Here you can see the bend when fastened down with the clamp. Put it in the middle and used piece and put that against the guide. The mark on the top side of the radius I made with upper roll when I forced it the wrong way to test how much beating it could take

Quite easy to bend. The front piece will be about 2.5 times wider than this piece so it will require some more force. But It should be okay since this thing is fairly sturdy.

Here you can see the piece bends back after the bend is made. So with this 64mm diameter roll produced a slightly bigger inner radius than 32mm that I want. So I have to take of a millimeter or so to get the desired radius.

Very pleased with the result, no marks from the actual bend. Since this piece have been in the scrap bin it have gotten some bad treatment. Did some light brushing to see if that would be ruined after the bend. But it seems to have managed fairly well. Only needing some slight touch up!

This machine took about a week (>40 hours) to design, produce, test out and work out the kinks. "Just" for some damn round corners! High radius front bends sure is a PITA, but it was well worth it in the end!

[Notional]

On 18/11/2016 at 5:21 PM, Brodholm said:

Me too! Milling plastics is very satisfying and also a bit frustrating

You can try! Assemble fellow Swedes!  
 

 

Pfft silly swedes. You're passives, and the Danes defend your airspace with our jets.

 

Anyways, looks really nice. Can't wait to see the end result.

[Brodholm]

18 hours ago, Notional said:

Pfft silly swedes. You're passives, and the Danes defend your airspace with our jets.

 

Anyways, looks really nice. Can't wait to see the end result.

hahahaa  To anyone not familiar its is sort of a custom here in Scandinavia to trash your neighboring countries. All in god fun of course   

OT: I have been busy with work also! Will post an update in the coming few days. I am cutting the backside of the case.

[Brodholm]

Next update! I am a bit behind on editing, but I am working to get them out. Due to the nature of the CNC the process it is pretty much the same all the time. So I will not describe the process each time for each part. I catched myself writing the same things over and over

If you have any questions feel free to ask

This update I am making the back frame of the case!

[Brodholm]

Top frame that will hold the plexi glass and a cover fastened with magnets.

[nofxz]

Nice bender

[Brodholm]

21 hours ago, nofxz said:

Nice bender

Not much, It's just a "fender bender" huehuehueheu

Okay, I am sorry, that was very bad, even with my very low standards...

[Brodholm]

Left inner frame of the case. Each part is so much work. Slowly but surely I am getting there. Had a bit of a mishap with this though, but redoing it will be easier.

Last thing that happened is that it started to chatter. Did not design this very good. It is very difficult to clamp this down. Will have to redo this part... This mistake costs about 4-5h of work wasted. Not very fun nor motivating but I do not have much of a choice.

[nofxz]

Try doing multi steps down arround the outside profile. It looks like you were trying to take it in one with your web thickness vs height. I would say atleast 4 steps if not 6.

[Brodholm]

7 hours ago, nofxz said:

Try doing multi steps down arround the outside profile. It looks like you were trying to take it in one with your web thickness vs height. I would say atleast 4 steps if not 6.

Yep, I am doing multiple depths. I am taking about 2mm each time. The issue was on the final pass (10mm ap, 0.2mm ae) it started to chatter. I just need to clamp that part down or just add another ridge that I can clamp down. Or just don't do the finishing pass. I do not seem to get "waterlines" either way so doing the finishing pass is a bit of unnecessary. It does clean up the finish a bit, but sometimes things like this happens... 

[nofxz]

width of that rib is like 5mm, so your like double in the ap. you can do multi step down finish passes. 

[Brodholm]

Same as before, but this time its the right side

[KrMaH]

Why is there so many cool things that comes from Sweden?...

[Str8f4c3]

I've said this like a million times, but I LOVE watching this come together!

[Brodholm]

On 2016-12-18 at 2:00 AM, KrMaH said:

Why is there so many cool things that comes from Sweden?...

Its so cold here so people get bored  

On 2016-12-18 at 3:21 AM, Str8f4c3 said:

I've said this like a million times, but I LOVE watching this come together!

[Guest]

amazing! 

[Brodholm]

The time has come to do probably the part I was most worried about, the front of the case.

Test piece

Clamped down

Same width as the real piece. Needed a large amount of force on this. Had to get help, I was to light weight so I lifted myself...

Really pleased with the results on the test piece.

Making the actual sized part

Made two while I was at it.

Same length piece bended to insure that the length between the bends was correct. It was of about 0.3mm or 0.012 inches for you metric fellas! Very pleased with the results and I will not be able to get it much better than that

Final piece bent and done! Did not take any photos during this since we had to be two people checking and bending at the same time. Did not want to ruin the piece just to get some pictures. Same procedure as before, just with the correct sized piece.

Really good bends, very close to 90 deg if not perfect.

Ended up about 0.2mm of the real measurement. So I am very happy with that. I decided before that 0.5mm would be good, around 1mm would be okay and 1.5mm and I would redo it. This measurement does not matter that much since the plexiglass sides could be made slightly of angle and you never notice a 1mm change in height over half a meter.

The front now needs to be machined to fit. First up is some covers though!

[Str8f4c3]

Awww ChooChoo Hype Train!!!!

[paddy-stone]

21 hours ago, Brodholm said:

The front now needs to be machined to fit. First up is some covers though!

Well, all I can say is very well done again, and it's nice to see such a thing take shape. Very excited to see the final results, and TBH it's great just seeing the updates and how work is progressing even

 

[Brodholm]

Thanks, cant wait either! More progress pictures!


Making these covers to hide screws and unwanted things. They will fit stay put with magnets if everything works out.

Here you can see the spring when milling down to 3mm from 8mm. Should really get some 3mm sheets. Had to bend it for a good 20 mins to get it straight.

A very snug fit. Really pleased!

Milling the top cover here.

Same procedure as always, rinse and repeat!

Done! The "final picture" of the top was very out of focus. Turned out great and fits nicely over the top part. Also had to do some manual forming of this since it also had some springback from inner tension in the material (I am guessing that's it)
 

[RGProductions]

On 8/31/2016 at 1:17 AM, nmil said:

I only have an X-Carve.

Jealousy levels over 9000!!!

I only have a hand saw and a dremel!

[KrMaH]

On 12/19/2016 at 2:14 PM, Brodholm said:

Its so cold here so people get bored  

It's pretty cold here in Norway as well... and all we ever do is burn churches and complain about oil...