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[SPONSORED] ----- WING X99 ----- A CNC-milled Scratch Build! (Completed!)

post #1 of 387
Thread Starter 
Project
Wing X99





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

To Overclock.net!
I have been a member here a long time. But I never really posted anything yet. I have mostly been lurking around, checking build logs, drooling over some very nice systems and learned a lot over the years, I finally registered a few years back but never posted anything. I was planing to do my last scratch build "Model 01" here as well. But me being a very broke student at the time I could not at that moment pay the fee required to post a sponsored build. Everything that was not going to rent and food at that time was going into the build. It's time to give something back to the overclock forum and start to contribute with some content! I hope I am welcome here on OCN! I cant wait to hear your suggestions and feedback on this project! smile.gif






Be sure to comment!
I very much appreciate comments/criticism on the project as long as it is constructive! And if you have any suggestions or 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.
post #2 of 387
Thread Starter 
Reserved! smile.gif
post #3 of 387
Thread Starter 
Update 01 | Design and Renders X99

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!



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.





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!
post #4 of 387
Subbed. I remember your previous build. Can't wait to see how this one turns out.
post #5 of 387
Thread Starter 
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... 

If you are interested in some CNC building check the spoiler tag! Over 2 years of my time went down into this thing! (designed and built by me)
Warning: Spoiler! (Click to show)
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 smile.gif


Initial design/model rendered smile.gif


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


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


Motor mounting point


Faced distances for the aluminium table


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


Milling the sides




Milling slots for linear guides on the X-axis


Linear guides mounted.




X-axis servo motor seat




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.


Faceing the Z-axis plates




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


Testing the servos and controller system. Testing everything in Mach3


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






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




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




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.


Made a desk for the computer


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


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.


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


Everything back together after paint, new cables etc!


Making a slot for cooling fluid to escape


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...


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.


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




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


All clean smile.gif


Very much pleased with the quality of the cut


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.


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


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


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


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.


All done... Thank god...


Cleaned the table and was very pleased with the results!




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.




Spoil board all cut out! I Countersunk 12 M6 MF6S so I can face of about 6mm from the 10mm board before hitting the M6 screws. This should last me a very long time.


Really liking the finish after the cutter. I should have adjusted the feedrate of the chamfer cut a bit.


Time to get the spoil board of and face the table.

7hT6pOF.gif
Faceing the orignal table on the router to get the surface flat. This takes out height differences on the aluminium sheet and build errors.


Faceing the 20mm Alu board. About 1200mm/min and 0.5mm ap (depth of cut)


All done! Although a bit dirty from the cutting fluid.


Cleaned with some alcohol!


All done! I also got some weird artifacts from the phone camera (the teal stuff)


Found out it was about 0.1mm per meter. This need to be fixed. This was at 0 deg


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.


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.


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






All set, waiting for a fresh 12mm end mill and then we are go!

post #6 of 387
subbed should be interesting
post #7 of 387
Subbed as hell. Been waiting for this since 01 drool.gif
post #8 of 387
Those are insane specs, definitely subbing to this. exhappysmiley.png
post #9 of 387
Thread Starter 
Thanks for the subs and the interest shown! Still expecting some delays with the aluminium sheets. Getting them on Friday most likely. 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!

Anyway. Here are some more progress on the CNC! redface.gif


Images under the spoiler tab!


Warning: Spoiler! (Click to show)
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 smile.gif

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 smile.gif

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.

NaMYIVV.jpg
Edited by Brodholm - 9/14/16 at 2:46pm
post #10 of 387
You good Sir are out of control!! thumb.gifthumb.gif
    
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CPUMotherboardGraphicsRAM
Intel Core-I5 7600K ASUS ROG Maximus VIII Formula ASUS GTX 1080 Strix OC Corsair Dominator Platinum DDR4 16GB 3000Mhz C15 
Hard DriveHard DriveHard DriveCooling
Samsung 850 Evo SSD 250GB (OS) WD Cavier Black 1TB (Data) WD Velociraptor 150GB (Flight Sim) EK-Supremacy EVO CPU Water Block - Nickel 
CoolingOSMonitorKeyboard
EK-FC1080 GTX Strix - Nickel Windows 10 64-Bit LG 34UM68-P 34" 21:9 UltraWide Full HD IPS LED WASD Custom Mechanical w/ Cherry MX Blues 
PowerCaseMouseMouse Pad
CoolerMaster V1200 Platinum Thermaltake View 27 Logitech G602 Logitech G440 
AudioOtherOtherOther
Bose Companion 3 Series II Saitek Pro Flight Yoke / Throttle Quadrant  Saitek Pro Flight Rudder Pedals Saitek X52 Flight System 
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Overclock.net › Forums › Case Mods & Cases › Sponsored Builds & Case Mods › [SPONSORED] ----- WING X99 ----- A CNC-milled Scratch Build! (Completed!)