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• EU Vevor machine skates: https://s.vevor.com/bfQY16
• US Vevor machine skates: https://s.vevor.com/bfQY2w
• Aliexpress Vevor Skates: https://a.aliexpress.com/_DdXgAlF

Summary

In a remarkable display of determination and ingenuity, the journey of moving a 3.5 ton CNC Mill, the Mycenter Zero by Kitamura, into a personal workshop is shared. The adventure began on New Year’s Eve, a time when assistance was scarce, leaving the task entirely up to the narrator.

Employing VEVOR machine skates alongside a Pallet Jack that I already owned, an attempt was made to maneuver the massive machine into place. Despite the initial optimism, the task proved to be far more challenging than anticipated.

The narrative takes a brief detour to 1992, highlighting the revolutionary introduction of the Mycenter Zero. This wasn’t just any CNC machining center; it was a leap in precision manufacturing, boasting features like a 12k rpm high-speed spindle and compact, robust construction, which enabled the production of complex parts with exceptional precision. Its introduction marked a pivotal moment, setting new standards in the industry and influencing modern machining practices with its ethos of precision, reliability, and innovation.

Returning to the modern-day workshop, the struggle with the machine continues.

Despite several attempts, adjustments, and the use of additional tools, the process was arduous. However, with persistence and a bit of brute force, the machine was finally settled into its new home.

Although the VEVOR machine skates offered some assistance, especially in the final stages, the narrator acknowledges the challenge of such a task when undertaken solo but recommends these tools as a valuable supplement to equipment like a Pallet Jack.

In the end, the mission was a testament to the solo effort and the spirit of innovation that continues to thrive in the world of machining.

The successful relocation of the Mycenter Zero into the workshop, done entirely single-handedly, was not just a personal victory but a nod to the enduring legacy of precision and ingenuity that the machine itself represents.

If you’re one of my YouTube followers, you’ve likely caught wind of my recent acquisition – a used Kitamura Mycenter Zero CNC machine, for $3000.

In this YouTube short, I show the delivery of my CNC machine and a walkaround of this 1992 marvel, running on the reliable Fanuc 0M-C CNC controller. However, there’s a catch with these vintage controllers – they lack the solid-state memory we take for granted today. When the backup battery runs dry, you risk losing all your parameters, rendering your CNC inoperable!

To safeguard against such a predicament, a common practice is to back up the parameters. I wasted no time crafting a custom DB26 to DB9 DNC cable for my Fanuc 0M and efficiently read out the parameters over DNC.

I quickly made a custom DB26 -> DB9 DNC cable for my fanuc 0m and read out the parameters over DNC.

I followed a useful video tutorial to guide me through the parameter backup process, ensuring that even if the worst happens, I can quickly recover my Kitamura Mycenter Zero’s vital settings.

For your convenience, here are the backup files containing the parameters:

I hope this information proves valuable for anyone facing a similar challenge with their Kitamura Mycenter Zero CNC. Don’t let lost parameters stall your projects – stay prepared!

USA Discount codes:

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General Discount codes:

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Poland Discount codes:

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Hope it helps you out =)

Terms and conditions apply. Seize the opportunity and save big during AliExpress Singles Day!

My build has finally begun and in this post I will take you on the building journey. Make sure you have read part 1 here , part 2 here , part 3 here

Lifting it up in the shed

It’s been some time since my last update. The machine is complete, but it’s worth noting that I had to construct a shed specifically to accommodate it; the machine proved too large for the existing brick structure.

I bought a garage “engine block” crane to lift the approximately 350kg structure in the shed. You really notice that using the right tools in a situation likes this makes huge amount of difference.

Replication method at work

After moving and leveling the machine I had to make the surface of the aluminium extrusion flat in order to mount the rails to it.

It is a bit of a messy situation but hey! it works.

After making the surface flat I cut out the slot with a hot-knife in order to mount my rails to it.

Adjusting the gantry level

I used the metal epoxy “gap filling” method to level the gantry vs the Y1 and Y2 gantry rails:

I used Mirror glaze wax release on the gantry to make sure it just fills the gap and does not stick to the gantry extrusion itself. Not this works REALLY well!

After making sure it is level, I let it cure.

in a Dan Gilbart video I recently learned to make figure 8 motions when doing this. I tried it out and noticed it worked well. I did not actually check it on the surface plate but you notice that the surface is quite flat. Within >=0.0x mm I would estimate. Good enough for this part.

Mirror Glaze

Mirror Glaze Wax release; 16$

Aliexpress.com

Fixing the electronics

I decided to rewire the electronics from scratch. It worked out quite well I must say!

After I wired most of it on the desk I hung it on the wall and started connecting it to the CNC.

Finishing the mechanics

I kinda dropped and messed up the C5 1605 nuts I had on my spindles. As they were already too short anyway I decided to pick up some new ones from Aliexpress:

I was seriously impressed with how riged the DFU version of the ballscrew feels. There is no play at all. I later on measured it on the CNC itself with load and you dont see it budge at all. I can really recommend these C5 1605 DFU screws from Yixindianqi Store on Aliexpress.

So after completing most of the electronics, I went off to mount the spindle and servo motors. Initially, I had put the MAKITA RT0700 router on there; but that died very quickly after a little accident when I crashed it into the toolsetter.

Because the design of my frame is more of an afterthought … I had to add some way to mount the fixture table/wasteboard on the CNC. While it is not ideal to weld on a relatively precise machine frame, it was still the easiest method to do it.

After completing this stage I mounted 36mm of MDF plate to it and went on to the next step

Many small steps in between

So as it goes in a project. you lose focus on documenting a bit and do all kind of small steps. During this time I got probe basic working well on the CNC, tuned the servos and did some final adjustments on the mechanics.

Tramming and aliging the axis

So as in any precision machine build where your mechanics are to perfect, you are going to have to adjust the tram and yaw of the spindle.

I started first with fixing the “nod” of the spindle by putting in a 10mm endmill upside down and using an indicator to make sure the measured distance stayed the same while moving the Z-axis up and down. This was relatively quick to be fixed.

For the trimming (rotation of Z spindle ) I did the following:

So I 3d printed a spacer so I could mount my indicator on the spindle. Turned it round to make sure the distance of the indicated stayed the same. As my z-axis is quite heavy, I found the use of a strap quite useful to slowly get it in the right spot.

Making chips!

After spending some more time with the machine I made another short video where I did some more drilling and milling

Can it mill hardened steel?

So a question that comes up quite a lot is if the Lusintun BT30 ATC spindle can mill steel? The answer is yes, the spindle itself is not the limit. The stiffness of the machine is.

I did some testing on some hardened steel to make sure it could handle normal steel with ease.

Conclusion – Mightymill build Part #4

Since part #3 quite a lot has happened. The machine is together, is working and performing pretty well. As this is the first full CNC build that I have done there are plenty of areas that need improvement. One of the main things is to make the Z-Axis stiffer and make a better connection from the gantry to the ballscrew.

Other than that I’m happy with how it performs!

Make sure to subscribe to the newsletter to make sure you don’t miss any updates.

Feel free to reach out to me on discord

Introduction

In the realm of precision engineering, top-notch precision ground and lapped granite measuring parallels are essential for accurate and stable measuring and inspection processes. However, the cost of premium parallels can be prohibitive, ranging from $500 to $3,000, making it challenging for hobbyists and small-scale machinists.

Venturing into the world of affordable alternatives, I discovered Chinese granite parallels and decided to share my experience with these budget-friendly tools that exceeded my expectations.

Discovering and Ordering Chinese Granite Parallels

Navigating the complexities of ordering from a Chinese supplier that only communicates in Chinese and requires payment through a Chinese bank account [Insert my lovely wife here], I took a leap of faith and ordered a set of granite measuring parallels.

To save on shipping costs, I opted for the economical One Belt One Road rail transport initiative, which delivered the package to my doorstep within a month.

Upon unboxing the well-packaged granite parallels, I was impressed by their visual finish and clean, chamfered edges. Each parallel and granite square came with a factory measurement certificate, verifying their 000 grade (Chinese national standard) quality.

The granite parallels held up well within the tolerances specified by the manufacturer (at least how well you can measure using primitive tools). They were flat and parallel, indicating a high degree of precision.

Sharing My Findings with Friends

After validating the quality and performance of these affordable granite parallels, I shared my findings with friends in the machining community. Their interest led me to order more sets, which I distributed among them, receiving positive feedback on the value for money these Chinese granite parallels offered.

I ordered a few more sets and distributed them among my friends, who were equally impressed by the value for money these Chinese granite parallels offered. They have since become a popular choice among our community, especially for those seeking cost-effective options without compromising on quality.

One of my friends out of the machining community who got two parallels even made a video showing its performance:

[Note turn sound off!!]

Conclusion

My experience purchasing and testing Chinese granite measuring parallels has been enlightening, proving that budget-friendly alternatives can provide satisfactory results for hobbyists and small-scale machinists. While caution is necessary when purchasing from overseas suppliers, I believe it’s worth exploring affordable options like these Chinese granite parallels, as they can save you a significant amount of money without sacrificing quality.

In addition to my own positive experience, my friends in the machining community have also found these affordable granite parallels to be a game-changer in their work. These tools have enabled them to achieve high levels of accuracy and precision in their projects without breaking the bank.

Ultimately, the key takeaway is to keep an open mind when searching for affordable tools and equipment, as it’s possible to find hidden gems that offer excellent value for money. Chinese granite parallels are just one example of such a discovery that can benefit precision engineering enthusiasts on a budget.

Interested in Getting a Set?

Occasionally, I go through the trouble to import a batch of these parallels from China. If you’re interested, feel free to contact me through this page or on Discord. I will also be sending a set to a nationally recognized metrology lab to verify the factory’s measurement certificate.

Have you tried any budget-friendly tools that have exceeded your expectations? Share your experiences in the comments below!

Introduction

When my laptop met its untimely demise, I was on the hunt for a new computer to run LinuxCNC for my CNC projects. In this post, I’ll discuss my experience with the Dell Optiplex 7050 Mini, featuring an Intel Core i5-6500 processor, and determine whether it’s the right choice for LinuxCNC enthusiasts like myself.

Dell Optiplex 7050 Mini – Key Specs

The Dell Optiplex 7050 Mini is a compact, yet powerful computer that comes with the following specs:

• Intel Core i5-6500 Processor (6M Cache, up to 3.60 GHz)
  
• Up to 64GB DDR4 RAM – Mine is fitted with 8GB
  
• Integrated Intel HD Graphics 530

• Penty of USB ports , and a 256GB SSD fitted

• Plenty of these units are available used through third parties. I bought mine for 150$

These specs seemed promising for running LinuxCNC, but the true test would come in the form of latency testing and real-world performance.

Installing Debian 12 + LinuxCNC + Probe basic in 2023

I had previously made a post about installing LinuxCNC 2.8.4 with Probe Basic, but unfortunately, there are several broken repositories in the probe basic installation script… so I was forced to install LinuxCNC 2.9 on Debian 12 using the instructions posted on the developer’s website and that worked … mostly. So I devoted a new post relating to how I installed it and the small challenges I faced.

Read more about it here: [placeholder]

Latency Testing for Dell Optiplex 7050 Mini LinuxCNC

Latency is a critical factor for LinuxCNC, as it determines the system’s ability to respond to changes in the CNC machine’s position. Lower latency results in smoother and more accurate operation. To evaluate the Dell Optiplex 7050 Mini, I used the LinuxCNC ‘latency-test’ utility to measure the maximum base thread and servo thread latencies.

As I’m using a Mesa 7i96S the base thread is not actually not applicable but I still had it running in my tests.

LinuxCNC BIOS Modifications for Dell Optiplex 7050 Mini

I did some small modifications in the BIOS setting to hopefully make LinuxCNC run smoother on the Dell Optiplex 7050 Mini. I basically disabled any power-saving features, sleeping states, and any virtualization options. I left the “turbo” feature of the CPU on, as I was unsure if this would benefit or harm the latency results.

Grub Modifications for Dell Optiplex 7050 Mini LinuxCNC

I did some modifications in the Grub including isolating CPU cores for LinuxCNC and reducing sleep modes and states for the Intel i5-6500 CPU on the Dell Optiplex 7050 Mini.

Follow the instructions provided in the original article to perform these modifications.

at the terminal, type:

sudo nano /etc/default/grub

when this opens, add this line (for a 4 core system):
GRUB_CMDLINE_LINUX_DEFAULT="isolcpus=2,3,4 intel_idle.max_cstate=0 processor.max_cstate=0 idle=poll"

You can add this below the other command line parameters in the file. Then hit control-x to save it.

then type:

sudo /sbin/update-grub

then reboot.

Verify that it worked by doing:
sudo dmesg
or
cat /proc/cmdline
which shows the parameters used for the current bootup

You should see your isolcpus command in that list.

This modification was inspired by this PrintNC wiki article.

Note: I have not independently verified if the idle max, state and idle poll settings benefit.

Comparing the Modifications

I read somewhere that there might be a performance benefit by isolating a CPU core pair i.e. 2,3 for a 4 core system instead of separating random cores so I did a quick test:

This test was conducted with 4x glxgears running and YouTube full HD video in the background.

The isolcpus 1,2,3 option resulted in lower latency, hence that is what I kept.

Results of Dell Optiplex 7050 Mini LinuxCNC Latency Test

The Dell Optiplex 7050 Mini performed admirably in the latency tests. The measured latencies were well below the recommended maximums for LinuxCNC, which means that LinuxCNC should be running smoothly on the Dell Optiplex 7050 Mini. However, it’s worth noting that individual results may vary depending on the specific configuration of the computer, as well as the connected CNC hardware. I’m utilizing a Mesa board for the direct control of my servo motors, so the latency requirements are also much less strict.

Conclusion: Dell Optiplex 7050 Mini LinuxCNC – A Solid Choice

Based on my experience and the latency test results, the Dell Optiplex 7050 Mini with the Intel Core i5-6500 processor is a solid choice for running LinuxCNC. Its compact form factor, powerful processor, and compatibility with Linux make it a reliable option for CNC enthusiasts. At ~$120 for a fully tested and working unit with 8GB RAM and a 256GB SSD, the Dell Optiplex 7050 Mini LinuxCNC is also cost-effective.

However, keep in mind that the ideal computer for LinuxCNC depends on your specific needs and budget. It’s essential to evaluate your requirements and research other options before making a final decision. Overall, the Dell Optiplex 7050 Mini LinuxCNC stands out as a cost-effective and capable choice for those looking to run LinuxCNC on a reliable system.

The replication method is a widely used technique in manufacturing and metrology to obtain accurate copies of a surface. The method involves replicating the surface of a reference material onto a workpiece using a medium such as metalized epoxy. This article provides an overview of the replication method, including its advantages, limitations, and applications.

Replication Method:

The replication method involves using a medium such as metalized epoxy to make a copy of the surface of a reference material, such as a granite surface plate to a workpiece. The surface to be replicated is first cleaned and coated with a thin layer of release agent, typically some kind of wax. The release agent is allowed to dry and is buffed to a shiny surface before the epoxy is applied. The epoxy is applied to the setup by pouring or injecting it into the setup and then allowed to cure. Once the epoxy is cured, it is peeled (or hammered) of the reference material, leaving behind an exact replica of the surface.

Advantages of the Replication Method:

One of the main advantages of the replication method is its ability to produce accurate copies of a surface. The method is also relatively easy to perform and requires only basic equipment and materials. Another advantage of the replication method is that it can be used to replicate surfaces of different shapes and sizes, making it suitable for a wide range of applications.

Limitations of the Replication Method:

While the replication method is generally accurate, it is important to note that it is subject to certain limitations. One limitation is that the replication method can only produce a replica of the surface that is in contact with the reference material. If the reference material has any defects or irregularities, these will be replicated onto the workpiece.

Applications of Replication Method:

The replication method is widely used in metrology to produce accurate copies of surfaces for measurement purposes. It is also used in manufacturing to replicate surfaces for quality control and inspection. Additionally, the replication method can be used in the restoration of damaged surfaces, such as those found on antique furniture or architectural features.

Resources:

Academia:

There is a book from the 80’s or 90’s by a professor of a US university who writes about the surfaces replication method, and how they used it to make a giant 5 axis grinder… I just cant find it at this moment…

Ah, here it is!

Principles of Rapid Machine Design – MIT – Eberhard Bamberg:

https://my.mech.utah.edu/~bamberg/research/PrinciplesOfRapidMachineDesign/Principles%20of%20Rapid%20Machine%20Design.pdf

At-scale use of the replication method for big cnc machines – Rampf group:

https://www.rampf-group.com/en/aktuelles/blog/2021/how-to-2-replicating-mineral-casting-components-with-maximum-accuracy/

Replication techniques and portable machining in machine tool rebuilding – Molglice:

http://www.moglice.com/articles/replication_techniques/wrotethebook.html

PRECISION the easy way, making CNC parts too big for a hobby mill – @floweringelbow:

DIY experiment:

With most DIY builds the most difficult part is creating flat mounting surfaces for your carriages and rails. In my Mightymill build, I have the same challenges.

Creating precision surface copies using metalized epoxy

Total Time: 9 hours

Prepare your workpiece

Make sure it is free of oil, and has a decent amount of surface roughness for the epoxy to adhere to.

Prepare the reference surface

I used Miracle wax no.8 as a release agent. Follow the manufacturer’s instructions (I did 3 coats) with buffing in between. I used a 40$ <2um error small granite surface plate.

Prepare the metalized epoxy

I used West epoxy 105 + 206 hardner, although I’d think 209 might even work better. I did a 50/50 mix of epoxy + iron powder (<63um particle size).

Tape off your part

Note: I used a 3-4mm thick parallel to regulate the thickness of my epoxy layer.

Pour the epoxy

Make sure you remove all air and have proper coverage. This is actually the most difficult part

Let the epoxy cure

I think I let mine set for about 12 hours

Remove from the reference surface and inspect

Any overflowing epoxy you can just hit off with a hammer or grind it away with a die grinder. The initial surface is quite rough due to the remaining release agent on there and any defects of your reference material.

Optimize the surface roughness and flatness

You can use either something like a 123 block + abrasive, a “kitchen” flattening stone, or any other relatively flat material. I used some dishwashing soap + the above-mentioned iron powder to basically do a lapping operation to the surface.

After about 3 – 5 minutes of lapping the surface should be smooth with most of the high sports removed.

Inspect and repeat

There are various ways to inspect surface flatness. I used a Mitutoyo indicator, a 123 block, and a high-precision HGW20CC block as my reference.

The initial flatness before the optimization stage was about 8um over the whole surface. After a cycle of 1-3 times of optimizing and inspection, it is <= 2um. Which equals my reference material. Lapping becomes challenging because the materials just want to stick together. The main issue at this point is that this is extremely difficult to measure.

As you are at or nearing the requirement of lab-based CMMS or optical measurement methods.

You could make this perfectly flat by doing this to 3 surfaces and using the Withworth 3 plate method.

Does it pull a vacuum?

yes: https://youtube.com/shorts/egtODwy4WiE

Estimated Cost: 5 USD

Supply:

• Slow cure no shrink epoxy such as West 105 + 206
• Iron powder <63um particle size
• Tape

Tools:

• 123 block

Materials: Workpiece Reference material Mold release wax

Conclusion:

The replication method is a simple yet effective technique for producing accurate copies of surfaces. While it has certain limitations, it is a valuable tool in metrology, manufacturing, and restoration. It allows a hobbyist or a professional to make micron-to-sub-micron accurate copies of reference surfaces. And thereby able to create flat surfaces for DIY CNC machines or metrology equipment at a relatively low cost and low effort.

But before we dive into the specific coatings, it’s important to understand what an endmill coating is and why it’s important. An endmill coating is a thin layer applied to the surface of an endmill, a type of cutting tool used in milling operations, to improve its performance and extend its lifespan. There are various types of coatings available, each designed to address specific issues and improve the tool’s performance in specific materials.

The choice of endmill coating is crucial because it can significantly impact the efficiency and accuracy of the milling process. A good coating can reduce tool wear, improve cutting speeds, and increase tool life, leading to cost savings and increased productivity. On the other hand, a poor coating choice can result in tool failure, poor surface finish, and increased cycle times.

When milling aluminum, it is essential to choose a coating that has excellent non-stick properties and prevents chip welding. This is because aluminum has a high affinity for sticking to cutting tools and is prone to chip welding, which can lead to tool failure and poor surface finish. A non-stick coating helps to reduce the risk of tool failure and improve the overall performance of the milling process.

What is an Endmill Coating and Why is it Important?

An endmill coating is a thin layer applied to the surface of an endmill, a type of cutting tool used in milling operations, to improve its performance and extend its lifespan. There are various types of coatings available, each designed to address specific issues and improve the tool’s performance in specific materials.

When milling aluminum, it is essential to choose a coating that has excellent non-stick properties and prevents chip welding. This is because aluminum has a high affinity for sticking to cutting tools and is prone to chip welding, which can lead to tool failure and poor surface finish. A non-stick coating helps to reduce the risk of tool failure and improve the overall performance of the milling process.

Best Endmill Coatings for Milling Aluminum

There are several endmill coatings available on the market, each with its unique properties and benefits. Some of the best coatings for milling aluminum are: Platit Naco-Blue, PCD (Polycrystalline Diamond), and Diamond-Like Carbon (DLC).

#1 PCD (Polycrystalline Diamond) Coating

PCD (Polycrystalline Diamond) is a superhard coating that is made up of diamond particles that are sintered together using a high-pressure, high-temperature process. It has a coefficient of friction of 0.1-0.3u and is known for its excellent wear resistance and ability to prevent chip welding, making it an ideal choice for milling aluminum. PCD coatings offer excellent lubricity and can withstand high cutting speeds, making them suitable for high-speed milling operations. They also offer excellent tool life and reduced tool wear, making them a cost-effective choice for milling aluminum.

One of the main advantages of PCD coatings is their excellent wear resistance, which allows them to maintain their performance for longer periods of time compared to other coatings. This can lead to increased productivity and cost savings by reducing the need for frequent tool changes. PCD coatings also offer excellent surface finish and can be used on a variety of materials, including aluminum, steel, and titanium. However, one of the main disadvantages of PCD coatings is their high cost, which can make them less cost-effective for some applications. They also require careful handling and storage to prevent damage and maintain their performance.

#2 Diamond-Like Carbon (DLC) Coating

Diamond-Like Carbon (DLC) is a hard, wear-resistant coating that is known for its excellent non-stick properties and low coefficient of friction of 0.1-0.2.

It is applied using a PVD process and is made up of a thin layer of amorphous carbon that contains small amounts of hydrogen and other elements. DLC coatings offer excellent wear resistance and can withstand high cutting speeds, making them suitable for high-speed milling operations. They also offer excellent tool life and reduced tool wear, making them a cost-effective choice for milling aluminum.

One of the main advantages of DLC coatings is their excellent non-stick properties, which helps to prevent chip welding and improve the surface finish of the milled parts. They also offer excellent lubricity and can be used on a variety of materials, including aluminum, steel, and titanium. However, one of the main disadvantages of DLC coatings is their sensitivity to temperature and humidity, which can affect their performance. They also require careful handling and storage to prevent damage and maintain their performance.

Platit DLC Coating Information Pamphlet

#3 Naco-Blue Coating (Platit nACo)

Platit Naco-Blue is a high-performance endmill coating that is known for its excellent non-stick properties and ability to prevent chip welding. It has a low coefficient of friction of 0.4u and is applied using a physical vapor deposition (PVD) process. It is made up of a thin layer of titanium nitride (TiN) with a thin layer of aluminum oxide AlTi(Si) on top. The TiN layer provides high hardness and wear resistance, while the AlTi(Si)N layer offers excellent lubricity and prevents chip welding.

One of the main advantages of Platit Naco-Blue coatings is their ability to reduce tool wear and improve cutting speeds, leading to increased productivity and cost savings. They also offer excellent surface finish and can be used on a variety of materials, including aluminum, steel, and titanium. However, one of the main disadvantages of Platit Naco-Blue coatings is that they can be brittle and prone to chipping if subjected to high impact forces. This can be mitigated by using a thicker coating or by applying a secondary coating for added toughness.

Platit nACo Coating Information Pamphlet

My personal experience and recommendations

In my experience, PCD (polycrystalline diamond) coating is excellent for creating mirror-like finishes on aluminum. However, the high cost of this coating means that I personally use APKT1135 R0.4 PCD inserts in combination with a BAP300R tool holder, only for the finish pass to maximize its lifespan.

For roughing, both DLC (diamond-like carbon) and Nano blue coatings work well. Personally, I prefer DLC coating as it still provides a good finish and is more affordable than PCD. It has better non-stick (chipweld) properties than Nono-blue coating.

I had good results with the 1 flute and 3 flute Dreanique DLC 5$ endmill from Aliexpress.

Nano blue coating is a good choice for a multi-material endmill that can handle aluminum and steel. This versatility makes it a useful general-purpose endmill coating.

Conclusion

In conclusion, choosing the right endmill coating is essential for efficient and accurate milling of aluminum. PCD, DLC and Platit Naco-Blue, coatings are some of the best options available, each offering unique properties and benefits for milling aluminum.

It is important to consider the specific needs of your application and choose a coating that offers the best balance of performance and cost-effectiveness. By choosing the right endmill coating, you can improve the efficiency and accuracy of your milling process, leading to increased productivity and cost savings.

However, there is no one-size-fits-all solution when it comes to endmill coatings. Different coatings are better suited for different materials and applications, and it is important to carefully consider the specific requirements of your operation before making a decision.

We would love to hear from you in the comments below about your experiences with endmill coatings for milling aluminum. What coatings have you used, and what were the results? What factors did you consider when choosing a coating? Share your thoughts and experiences with us and let’s continue the discussion!

Total Time: 1 hour

Download the required software tools

Download LinuxCNC 2.8.4 Debian 10 Buster PREEMPT-RT ISO
Download Rufus 3.2.0 https://rufus.ie/en/

Format USB stick and make bootable USB

WARNING: Your USB stick will be formatted, you will lose any info that is on there.

Insert USB stick, open RUFUS , select correct USB drive/partition,select linuxcnc ISO and press start.

If you get the POPUP “ISOHybrid image detected -> Select Write in ISO image mode

If you get the popup “Download required” accept yes to get the required files

Boot from USB stick

Insert the USB stick in the device you want to install linuxcnc to. Turn on the device and select USB stick to boot from.
(google if you do not know how; this is universal knowledge)

Install Debian

Start installer and follow installation instructions. In case of troubles there are plenty of videos online regarding how to fix issues.

I found this video quite useful.

Install probe basic

Follow the instruction listed on kcjengr.github.io from step #1

[This is a summary for source look at kcjengr link above]

1- Update the operating system
After installation, copy the following in the main terminal one line at a time and hit enter, select Y for yes if asked at any point during installation:

sudo apt update
sudo apt upgrade

2- Start Linuxcnc first time
Now linuxcnc needs to be started for the first time for it to create its directory folders. This can be done by the drop down menu and selecting CNC and then LinuxCNC. After the program has started, you can shut it down and continue below.

3- Install Probe Basic requirements
On a terminal emulator run:

sudo apt install python-pyqt5 python-pyqt5.qtquick python-dbus.mainloop.pyqt5 python-pyqt5.qtopengl python-pyqt5.qsci python-pyqt5.qtmultimedia qml-module-qtquick-controls gstreamer1.0-plugins-bad libqt5multimedia5-plugins pyqt5-dev-tools python-dev python-wheel python-setuptools python-pip git python-pyqtgraph python-pyqt5.qtwebkit

4- Download ProbeBasicInstaller
Link on the github page is broken. Luckily I still had an old copy.
You can download it here: ProbeBasic-Installer-py2+3.g231c7ff.run

Click the link below to download the ProbeBasicInstaller file. Once downloaded, find in its destination folder and right click and select properties. Select the Permissions Tab in the window that appears and check the box for “Allow this file to run as a program”, see images below for reference. now double click the installer icon to begin the installation. Follow the installer instructions to install Probe Basic. Select all of the available items during initial installation. after installation probe basic should show up in the linuxcnc launch screen and you can select to create a desktop icon for it by selecting the check box to do so at the bottom of the page.

Congratulations! You now should be able to launch Probe basic!

Tools:

• Rufus 3.20 Portable
• Linuxcnc 2.8.4 buster ISO

Materials: USB stick 8 or 16GB

My build has finally begun and in this post I will take you on the building journey. Make sure you have read part 1 here and part 2 here .

Assembling the machine frame

It took a while, but finally I was able to move the machine frame in my recently cleaned shed and get it assembled. For me, the concrete filled machine frame was one of the most time consuming aspects of this build.

The leg assembly was the most difficult to move. While I had put GD-60S wheels under it, it is till a top heavy assembly which weighs 120kg. With a bit of sweat and hurt, I was able to position it and get the assembly going.

I was able to assemble it without too much hassle. To get it all square I had to use the Farmer’s jack to pull the legs inward as there was a slight misalignment. After that it is square (diagonal measurement) within 1-2 mm over a span of 1.6 meters. Which is fine for this application.

It all seems to fit pretty well. Time to go on to the next step.

Lets “rise” up!

It was time to make the riser plates. I used my old and not so trusted HBM BF25 manual mill for this. It actually had lots of troubles during this process. Wobbliness … (DC) motor brushed dying, and other fun electronics issues… But i got it going again and was able to finish the job.

As you can see in the image, the side finish of my milling does not look very good. As I mentioned before my HBM bf25 is quite wobbly and not in a good state. There is still quite some play in the column and in the gibs even after tuning.

As the side surface is not a critical one for my application it is not too bad.

in a Dan Gilbart video I recently learned to make figure 8 motions when doing this. I tried it out and noticed it worked well. I did not actually check it on the surface plate but you notice that the surface is quite flat. Within >=0.0x mm I would estimate. Good enough for this part.

Whetstone set

This set of whetstones was affordable at 25$ and I was able to get it locally quickly.

Aliexpress.com

It all fit well without too many issues. With such precision applications be sure to torque bolts and screws correctly. It is essential that you do in precision applications to ensure equal load and proper contact between surfaces.

After this I also ran the whetstones over it quickly to remove all the burrs.

In addition to this I had to buy the following items:

I used some 3mm thick ground steel parallels for equal spacing vs the alu block.

I used this method to ensure that the side of the extrusions meet the adapter plate perfectly at the same reference plane.

Finally! it is starting to look like a CNC!

Conclusion – Mightymill build Part #3

Moving and re-assembling the machine frame was one of my biggest hurdles. But once I got going it went relatively smooth. The Farmer Jack’s helped a lot with this.

I ordered some new goodies such as Delta ASDA-M controller, 400W ECMA 20b optical encoder ac servo motors. A 1 meter 000 grade granite parallel (all surfaces) and some nice steel AC servo motor mounts. It is now all on the train from China. Hoping for it to arrive at the beginning of December.

The next step will be making the adapters for the ball screws and motors, mounting the extrusions to the table and making the z-axis adapter so it can all be mounted together.

Stay Tuned!

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