Epoxy concrete machine

design
This is the beginning of a journey, a journey without a known end. Not knowing
the exact destination makes the trip exciting. We are seeking an ideal that in
reality can never be reached. If we persevere we will however come close.
Persistence is omnipotent. This document is written to those that like to travel
unknown paths. If you have never undertaken such a trip I encourage you to do
so, your spirit will be uplifted.
john1147@bigpond.net.au
Updated regularly
Published 29 April 2011
This edition 30 April 2011
copyright John C McNamara
The information contained herein is free to individuals
Commercial use is restricted.

Objectives

Design a machine that can be created in a small workshop

A working machine tool using cold casting methods in place of cast iron and heavy steel plate
weldments

The accuracy of work produced to be equivalent to commercially produced production grade

machines.

The finished machine able to be taken apart for ease of access and transport. Access to basement
workshops for example.

Individual part weights are to be within the capacity of a so called Engine crane Available quite
cheaply around the world. A 2 ton version is best.
Check the weight it can handle at maximum reach and height. (To enable the columns to be
assembled on the base) When assembled the machine will be in access of 2 tons.

A google search will find one

http://www.google.com.au/#hl=en&source=hp&biw=&bih=&q=Engine+crane&aq=f&aqi=g10&aql=&
oq=&fp=1

Overview

cast polymer machine members are already being used by the high end machine manufacturers
Hardinge for instance. At the cutting edge end of machining technology with sub micron tolerances
and using diamond tooling, polymer concrete and solid granite has taken over traditional methods.

Polymer concrete has significantly better damping characteristics than cast iron, it absorbs
vibration extremely well. Able to be cast very accurately, with a well prepared mould to high
accuracy often requiring little or no machining after.
You can also cast in place metal inserts and bearings or even a complete sub assembly as
needed.
There is very little shrinkage solvents are not added to the Epoxy, quite different and not to be
confused with polyester resins used in fiberglass moulding. They which have much higher
shrinkage due to evaporating solvents.

The ingredients are simple:

1. Graded aggregates the largest being a quarter of the minimum thickness of the part being cast,
Then successively smaller particles, the objective being the smallest number of voids. The
aggregate mix must be dry and clean.
2. Epoxy preferably slow setting (within a day or so depending on the ambient temperature)
By weight approximately 8 15 % with most around 11%

A search of the web will reveal some really interesting information.

The mould can be simple box formwork or an elaborate prepared pattern mould. In designing the
mould consider which surfaces need the highest accuracy. These areas should be precision made
remembering that the accuracy you build in to that surface will be replicated in the finished work.

Requirements
This is not a project for beginners, it is assumed the
builder will have an extensive knowledge of
metalworking, and have access to or knowledge of
electric control systems.
A metal lathe, milling machine, Engine crane,
measuring equipment, and hand tools will be required.
A Granite or steel surface table minimum size 1000mm
630mm wide
is required to generate flat surfaces.
Woodworking tools to make formwork

Vertical milling machine brief

specification

Working area:
To be able to machine within 500mm Width 500mm length to a height of 500mm (assuming a tool holder and tool
length from the end face of the spindle of 160mm.

The work area may be scaled down, reducing the size, weight and cost.

A spindle that accepts Industry standard BT40 tapered shank tool holders

Accuracy within the range of .001 inches (Minimum) .0005 inches (Acceptable) and .0002 inches (Ideal and
quite difficult)

Spindle:
power a Minimum of 2HP 1.5 KW Controlled by a variable frequency servo drive. 50 to 4000RPM
Able to be positioned and homed
Ideally direct drive. Not achievable with a low power system due to torque fall off; Change pulleys and belt may be
required)
Automatic tool clamping and changing.

Axis drives X,Y and Z:

Optionally step motors or servo controlled DC or AC Motors

An optional powered rotary table. Providing a fourth axis

Control system to be PC based software/hardware for example:

MACH3 http://www.machsupport.com/
EMC2 http://www.linuxcnc.org/

Design Plan

The steps below will be repeated many times.

Each change will have repercussions that will flow through the entire design, often taking you
right back to the start. This is an iterative process each loop taking you a little closer to your
perceived goal.
Develop a 3 dimensional drawing of the machine using computer aided design or paper.
Analyse each component individually and optomise for ease of construction.
Are the tools machines and other resources available to produce the components?
Can the part be redesigned for available resources?
Will the machine be efficient and easy to use?
Is the machine correctly guarded is it safe?
Analyse the assembled machine design concept as a whole,
If possible computer Finite analysis of the structure, that measures stress and deflection will
provide a fairly accurate estimate of the accuracy achievable by the completed machine.
Otherwise use beam analysis for the major components, consider every joint as a source of error.
Remember errors are additive your design will be only as good as the sum of the errors, and that
is only if they are in the same plane. If they are not the total error will be a lot worse.
What are the cutting forces involved, will the load on the tool, that is transferred back to the frame
of the machine deflect it?
There are tools available on the net for free or very low cost. http://www.mitcalc.com/ is a good
example.
An excellent source of machine design concepts is. Principles of Rapid Machine Design by
Eberhard Bamberg
http://www.mech.utah.edu/~bamberg/research/PrinciplesOfRapidMachineDesign/Principles%
20of%20Rapid%20Machine%20Design.pdf

CAD format

The Model is being developed in AutoCAD

If you do not have AutoCAD a free viewer is available:

It allows you to take measurements and also if you have a different version of
AutoCAD convert the drawings to your version. It is available here:
http://usa.autodesk.com/adsk/servlet/pc/index?id=6703438&siteID=123112

If you use a different CAD program that cannot open the DWG format. DXF
versions of the design files are available please email and I will try to assist.

A main drawing linked to supporting drawings for each component has been
created.
Major components are each in a separate file. This makes editing individual
components a lot easier.

They are all packed in a zip file that you will find in the same directory where you
found this Power Point presentation, just unzip and place all the files in a folder and
open the main file

Casting and formwork

The surface finish and dimensional accuracy of the finished result will reflect almost
exactly the quality of the formwork.
Sand cast iron requires wide tolerances to allow for shrinkage of around 1% also
moulding errors
Epoxy concrete has minimal shrinkage.
To generate true planes against which the linear rails will be mounted a surface plate
will be used. This is the reason the base is to be cast upside down.
Surface plates are available in cast iron and granite. It does not matter which is used.
They are available in many sizes and grades. Standard grade is fine.
At no time must the epoxy concrete mix be placed directly on the surface plate. Even
with mould release the risk of sticking; particularly over a large area, is too high.
Applying mould release directly to the surface plate is recommended as an additional
precaution.
A layer of Polythene or other plastic should be carefully stretched over the entire
surface and taped taught around the sides. Care must be taken that this seal is not
broken.
After the plate has been protected the formwork is placed on top and located. It must
be clamped all round this needs to be done from the sides of the plate.
Epoxy can leak through the tiniest holes A bead of silicone or other sealer must be
placed in every corner and joint. If this bead is carefully prepared It will leave a neat
rounded edge in the casting.
Any nail holes mist be filled.
The top surface of the mould will only have a trowel finish This can be cleaned up later
prior to painting There will also be some blemishes in the finished cast to be repaired.

Epoxy Gel Coat

It is planned to apply a gel cote first to mould And after waiting until
this has gelled that is become firm but not set, the aggregate mix will
be added.

The gel coat will comprise epoxy and a filler the formula is not
finalised however the epoxy bearing material I developed already
would. Shows this will not be difficult Possibly with the removal of
the anti friction components which are not needed.

Using a gel coat will reduce the likelihood of the aggregate

damaging the mould release when filling the mould

It will also provide a superior finish.

Epoxy Concrete Formula

Yet to be decided

Assembled
Design
(Concept stage)

Sub Base (Concept)

may be made of epoxy concrete (hollow)

Or tubular frame covered with sheet metal
The coolant tank will be housed within the base
The Sub base will be supported at three points two at the back one at the front

Base

Reinforced epoxy concrete (Steel detailed in

a later slide)

The base will be cast upside down.

The top surface will be cast against a

granite surface plate. The base is bigger
than the available surface plate (1000 X
630) it will be extended by formwork.

(The channels each side and the hollow in

the middle will be formed by strips placed on
the surface of the table prior to casting)
Formwork will form the sides.

The diamond pattern to be formed by

polystyrene shapes previously attached to
light wire reinforcing mesh prior to casting.

The blocks will need to be clamped down to

avoid floating.

Base and columns steel reinforcement

M 12 threaded rod is used to reinforce the columns and the short

dowels below. The other bars are 16mm and 12mm deformed
steel concrete reinforcing bar.

The connection between the column and the base is via a

coupling comprising two 25mm steel plates and 8 M20 high tensile
bolts (One plate is tapped the other has through holes. Three bolts
each end and two in the centre.

There is also provision for 4 jack screws between the M20 nuts at
each end of the plates. These will allow adjusting the columns
square to the table. The gap if formed to be filled with Epoxy
Bearing Material. Once that is set the M20 nuts can be finally
tightened down.

The plates are also drilled and tapped for M12 threaded rods that
are coated with epoxy then screwed into the back of the plate and
securely locked in place by a nut. This is essential to pre tension
the connection prior to casting. Alternatively they could be welded.
(End welding 12mm rod without weakening it is not easy)

Columns and gantry brace

The z axis guide rails and ball screws are

mounted on the face of the columns

Plain face Steel inserts for bolting the rails

and bearing blocks will be positioned prior to
casting. To be drilled and tapped later after
marking out

The columns will be cast face down on the

surface plate. The steel foot will overhang
the edge of the surface plate. forming that
edge of the formwork

hollowed out section at the base is to allow

access to the centre mounting bolt

The gantry brace (Concept only) will also be

bolted to the columns yet to be designed.

Bridge beam

Concept plan only design not finalised

The beam caries the horisontal linear guide rails supporting

the carriage

The face will be cast against the surface plate.

The bowed back may be too difficult to cast as the beam is

cast face down, a rectangular form may be a better resolution

The two holes at the end are for the z axis ball screws and
nuts.

A steel sleeve will be cast in exact position, parallel to the face

and at 90 degrees to the long axis of the beam

Alternatively the sleeve could be inserted later in a clearance

hole left in the main beam casting. Accurately positioned and
set in Epoxy Bearing Material.

Steel reinforcement will be needed not yet designed

Bridge beam carriage

Concept only

The carriage houses the spindle the X axis ball

screw and nuts and the linear guide way ball
blocks..

The ball screw nuts will be fitted in a steel sleeve

that can be grouted in with epoxy bearing material
later.

The spindle housing could also be grouted in later.

The linear guide way blocks Must be set in a true

plane. Due to the interruption of the spindle housing
it will not be possible to cast that surface directly on
the surface plate. Parallel blocks will be needed.
They can be placed on the surface plate.

A different mix of Epoxy concrete may be needed

due to the fine detail. The addition of fiberglass
whiskers and a fine aggregate mix may be a
solution

Table

Concept Stage

While expensive Cast Iron is the ideal

material

Epoxy concrete could be used However

clamping via T slots may be difficult is epoxy
strong and wear resistant enough? A sample
of T slots will have to be made and tested.

A third possibility a cast in a steel plate for

the top surface and t slots.

Possibly a table with a grid of threaded

inserts? And no T slots

Note pockets in the base for bearing blocks

and the ball screw nut.

Drainage is not yet planned. There will need

to be another channel in the base and holes
in this table for draining coolant.

Automatic tool changer

Concept stage

Safety is a serious issue here the moving members can cause serious injury. Guarding will have to be designed.

Capacity for the concept design is 8 BT40 tool holders.

That can be increased by increasing the diameter of the tool magazine

Not yet designed is the control system using a step motor for magazine indexing and pneumatic cylinders for the
gripper motions and locking.

A small PLC may expedite this functionality.

The control system will have to be compatible with the CNC software chosen.

The magazine is bulky, the design question is where to put it? the closer to the spindle the quicker it will be and the
easier to construct.

At the side of the column is the easiest to implement but it gets in the way of the operator

Through the column under the bridge beam, with the magazine on the back of the gantry brace would be compact.
There may be some interference if a long tool was used with a work piece at maximum height (500 mm)

Alternatively on top of the bridge right out of the way. Possibly the best option although the tool has to travel the furthest
distance from the spindle tool changes would take longer

Tool Magazine

Advanced concept stage

8 stations

To fit BT40 tool holders

Spring loaded clamps with ball

bearing pawl hold the tools in place
against the three locating plates

a hardened steel locating lug at the

back of each station positively
orients the tool to a known index
point. (Needed for possible live
tooling, or turning with a single tipped
tool and a rotary table axis)

Step motor drive system not yet

designed.

Tool Gripper

Advanced concept

Note conic pointed locating pin when

engaged it positively locks the tool
holder in the clamp.

a hardened steel locating lug at the

back of each station positively orients
the tool to a known index point.
(Needed for possible live tooling, or
turning with a single tipped tool and a
rotary table axis)

This gripper has the Clamp located

axially at the end.

It is possible that it will require

redesign if the gripper has to be
located at an angle (Pointing to the
side)

Tool Changer interference checks

Advanced concept
stage.
Clearances check OK

Spindle

Concept

Ideally a commercially made spindle

cartridge is to be used

BT40 taper max 4000 RPM

The initial design allows a spindle

diameter of 110mm as found on many
vertical mills. Possibly a second hand
one in good condition can be found

Research is required to locate a quality

spindle at reasonable cost.

The bridge beam carriage will need to

be adapted to the chosen spindle.

Linear guides and Ball screws

Concept stage yet to be fully investigated.

The concept plans are based on Star (Bosch Rexroth) Linear ball rails and blocks.
Rail section type 25
Runner blocks can be ordered with varying degrees of preload, from free running to high.

There are a large variety available from high priced ultra precision types to modestly priced Asian imports.

Some builders will already them on stock

It will be false economy to use worn or not within

the specification components.

Re standards
http://www.google.com.au/#hl=en&biw=967&bih=615&q=linear+guide+systems+standards+type+25&aq=f&aqi=&a
ql=&oq=&fp=9766b36986326989

Rails and runner blocks cannot always be exchanged between manufacturers.

The mounting points and height for a rail and runner assembly may match between some manufacturers

Choosing industry standard sizes should be a design objective

To increase stiffness runner blocks can be used in pairs.

Where too now?

?

Thank you
I will be pleased to here from you.
John 1147@bigpond.net.au