Max spindle weight on Lead 1515

Im asking the same question

 

You get zero benefit from a 2.2kW. Larger tools are pointless if you can't use them, plus it gets much more expensive as you go up in size.
Even a 1.5kW can't be used to it's to potential. Not even close.

Anything with an ER11 is perfect for the V-wheel setup. A smaller build can kind of make use of ER16, for the sake of having options, but even an ER11 can offer more than the machine can push.

 

With my machine, with added bits and lots of modifications, I run a 2.2kw water cooled spindle with no problem. I have driven up to a 1/2” endmill and regularly use a 3/8” end mill for profile cuts on aluminum with no problem. I just did some new end plates for my machine, 1” thick, with a 28mm hole through the plate for a bearing to be mounted. Using a 3/8” end mill and had no problems at all.

A larger spindle, if done right, can be done, but the plastic v-wheels might be a major limiting factor. A 1.5kw spindle would probably be overkill unless you stiffen up the rest of the machine.

Biggest difference I notice between the standard spindle, a dewalt or the like, vs a 1.5/2.2kw spindle is the noise level. The true spindles are much quieter. and if your working is a smaller area, maybe the noise level will help justify the spindle. (Not taking into account the power difference. Which if the machine can’t handle the added forces a larger spindle can create doesn’t matter.)

but. This is just my thoughts. And my observations.

 

I have a 1.5KW spindle. After using it for a while I realized, just like you stated, that I don't use it to it's full potential and probably will never use. I saw on AliExpress that they now have 500W DC spindles that would have been a much better match to my use of the machine.
Mind you, that DC spindle is not much cheaper than the 1.5KW spindle, maybe $50.

 

Spindles can be whisper quiet. I have both a 500w and a Makita. They are quiet till you start cutting. Reason I would want a bigger spindle is the horsepower at lower RPM. 500w spindle at 10000rpm compared to a 2.2kw spindle at 10000rpm. I am thinking big difference. Reason why I throw 10000rpm out there is anything higher on my smaller machine like I have it falls apart.

 

Now there is a huge difference between a DC spindle and an AC spindle.

DC:

• requires more maintenance as it relies on brushes to transfer current to the armature. The armature (coils) spin with the shaft.
• due to firing only once (two 'pulses' at the same time), there is an in-between phase of no torque
• usually runs on lower voltage. Voltage is very important to a motor. It can be viewed as a 'torque' number when all else is equal (except Kv - rpm/volt). A router is probably the only 'high voltage' DC spindle you will deal with.
• I'm not sure about the bearing configuration in the actual DC spindle, but routers often use bronze bushings.

AC/Brushless

• The armature remains fixed to the housing, while the magnets spin. There are parts in contact with each other. This means that an AC motor will last as long as it's bearings will.
• there are three 'pulses' (phases) which mean that at some point, there is always a full load of current being applied to rotate the magnets. This results in at least 30% more torque (can be much higher).
• shares the same desire for voltage as any other motor. AC spindles are designed to work with ~115V/~230V AC supplies. Unless your are converting a remote control motor, you will not be using anything lower than 48V.
• A decent AC spindle has angular contact bearings.

I have a 2.2kW 24k on my custom build (KRE Mill). It has an ER20 collet, but I've only gone up to 3/8" tooling so far as I cut aluminum. Larger tooling is also really flipping expensive! I learned to appreciate the 1/8" and 1/4" stuff I was using before. I love to run it at 12k-15k rpm. I only drop to 10K with the 3/8" end mills. Torque starts to drop off quickly under 8k. You compensate speed/rpm with feed rate, which is where the entire system comes into play.

Jumping for a 1.5kW to a 2.2kW is a surprisingly huge leap in almost every way. It's much larger and heavier. As for the machine falling apart, that's another issue entirely. Force is still force. If it falls apart at 10k with a 500W DC spindle, it's going to fall apart when you try homing with a 2.2kW.

 

"As for the machine falling apart, that's another issue entirely"

As for this quote my friend you are totally right! For the 3 of us that built this machine Me, Myself and I. I should ask for a refund!

Well just to clarify the parts the are failing are the MGN12 blocks I'm using. I notice about 2 or 3 aluminum parts ago when you push it to fast and hard those little bearings fall out, one bearing every 4 parts I was not too concerned but I am seeing a bit more of them every part I cut. So bigger machine I am building. And you have very good points on weight of a spindle and Aluminum machine holding it.

 

were did you find ER11 with 8mm collet? can only find up to 7mm

 

The spindle I've talked about is called a DC spindle but it's a brushless spindle. See here.

 

Interesting it comes with ER16 version. I have been curious about these. One of the brushless spindles description on Ebay states it can rotate CW/CCW direction. Is there any reason to be able to mill in both directions?

 

I don't have a machine yet. I have nothing to go by to calculate the deflection. I would think someone would know if the lead 1515 machine can handle a 1.5 kw spindle. I have to make a decision on which machine. For me, heat will be a problem and even noise since I would be placing it upstairs, with no heat or Ac..Someone said adding the high Z mod would help

 

I switched my Lead 1515 to a 1.5kw air cooled spindle and very happy with it. I converted to High Z prior to adding the 1.5kw spindle as I found the standard height very limiting for some of the stuff I do. I very happy with the spindle so far; more torque and much quieter than the DeWalt.

Added a 1.5kw spindle with VFD

 

I'm curious why folks aren't making more use of the AMB/Kress spindles. I have the 1400 digital control one.. 1.4 kw, it weighs less than most of the VFD based spindles, and you don't need the added hardware.

 

Price?

 

For 1000 Watt, ER16 collet, speed set manually or by 0-10 volt signal, 355 euros from sorotec.

Mafell FM1000 PV-ER 16

Alex.

 

Products - Spindle Select Guide - Midwest Circuit Technology
I bought mine a while back, I think I paid around $600 from MCT. Prices seem to have gone up though..

 

Exactly. My post was not meant as a question for the price but an answer to your post of why not more people are buying these spindles. I bought my 1.5KV spindle on AliExpress US$250 shipped. That's over 120 Euros more.

 

Wasn't my post - just trying to be helpful.
Alex.

 

I'm the one who brought up these particular spindles. The thread is about weight, which is why I brought it up. They are significantly lighter, and while I can't speculate on the quality of the spindle you got, the AMB/Kress quality is high, with almost zero runout on the spindle and it's aircooled and quiet, and well balanced. It is also smaller and lighter overall compared to many of the spindles, which I think is a plus for the light weight frames on these machines. Another plus, is how it is mounted, the mounting collar is right at the spindle end, not the middle, which gives me a little more z axis working area.

But it does cost more. There are some interesting accessories though, including a $600 ATC attachment... but that probably won't work without the high z mod.

 

Where did you purchase that kind of spindle?