Posted by David Colwill on 02/05/2014 08:25:43:
Murray,
When I did my bridgeport clone I used 25mm ballscrews (the leadscrews were 32mm) and the ballnuts fitted straight in, I just had to tap a few holes. I drove the X and Y axis with 12nm steppers with mains steppermotor drivers from zapp automation (usual disclaimer). They drive the ballscrews 1:1 by toothed belt. I also did the Z axis by fitting a pulley directly onto the knee lift, in place of the existing handle but used a 2:1 reduction. The weight of the table eliminates any backlash. The machine has a DRO fitted and when you compare Mach 3 to the DRO there is very little error. I have limited the speed of the steppers to 3m / min on X and Y and 1m / min on Z. Going faster frightens me
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I didn't spend much time doing the conversion so it's a bit of a bodge but it has done some good work since and I'm glad I did it.
Good luck.
David
That's interesting David. Thanks for posting your experience. There seem to be any number of ways to do this but many of the stepper-based conversions seem to be massively overspecified, almost certainly due to lack of clarity about the loads and speeds required. When you look at the torque-speed and power-speed curves for steppers, the ratio has very little effect on the thrust you can get when the motor is flat out. The higher the pulley reduction, the greater the torque is geared up but almost equally the achievable torque is less due to the higher motor speed. It almost boils down to what rapids you want.
Very few of these systems have PSUs above 300W or so, which rather gives you a clue about the thrust x speed (= power) you can achieve. And given the finite spindle power that you have to begin with, there is a limit to what you can actually make use of in terms of X and Y feed.
I removed my 32mm Y-axis nut and it's 39.6mm OD which is particularly annoying, as the (25mm) metric ballscrew nuts are 40mm. Which leaves me with a problem – do I try to machine either the double ball nut or the yoke. Or do I make a new yoke up? I will probably machine the nut down. Mine's a Taiwanese BP clone with a mixture of metric and imperial dimensions which may explain the odd size.
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I'm looking at using these closed loop stepper motor/drive combos **LINK** driving the X axis directly and the Y axis through a toothed belt so I can retain a handwheel. I know the purist CNCers will say you don't need manual operation but I'm sitting on the fence on that one.
Murray