Hello everyone, I'm just getting started with researching what would be the best way to go about my next project. I'm looking to build a 5-axis CNC mill to work with foam stock. The ultimate goal is to fabricate aircraft structural components to assemble into a remote control aircraft. I currently have a 3D printer and was impressed with the 5-axis head that Reiner Schmidt developed. I was thinking of printing the components to assemble the head in order to use on my CNC mill. Home Made 5-Axis CNC Head Is A Project To Watch The world of CNC mills is rather daunting, so I am hoping to be pointed in the right direction towards some plans, as well as some material suggestions, as I imagine building for foam milling wouldn't require the same type of materials as for aluminum milling. I would like to have a workspace of 0.75m x 1.50m x 0.50m. As for accuracy, I think +/- 1mm would be more than acceptable. Budget, I really have no idea what would be realistic for a mill of this size/capability. All of the research I have done seeking 5-axis CNC mill plans has turned up dry. From what I've read however, a 3-axis mill could be turned into a 5-axis with some work. Am I looking for a good 3-axis CNC foam mill that I can modify to accommodate my 0.50m Z-axis dimension and mount the 5-axis head on it? Any help would be much appreciated! Thank you!
for most shapes you do not need 5 axis as 3 axis can cut it using a ball end mill. I suggest getting a Workbee or Sphinx kit and using it for a month or two before trying to 5 axis. My belt drive OX clone cuts foam airplane parts just fine (-:
Hi David So a 3-axis with a ball end would be sufficient to mill out and surface the top half of a wing or fuselage? The design of aircraft I have in mind would have an air intake embedded into the fuselage much like the Boeing MQ-25 Stingray. Would a feature such as this require 4 or 5 axis? Also, the two models that you have recommended, could these be easily modified for 5-axis?
Yes I believe so. It all depends how you split the fuselage in the CAM software. you can do halves, top half/bottom half that are joined later. (or even left/right halves) you can do quarters so each quarter 'skin' lies flat for milling and then gets attached to a subframe at the correct angle. both machines I referenced can be easily modified to 4 axis though maybe the Sphinx is easier because of the way the router mounts (if the router is to be the 4th axis). (but you would need a different controller for 4 or 5 axis, the GRBL based controllers like the BlackBox cannot do it). for both it is quite easy to mount them on a custom table so that the fuselage can be mounted between centers (the A axis) instead of the flat cutting board. kinda like the Legacy machines which have a space frame to accomodate the A axis. Have you searched these forums for existing 4th and 5th axis posts? It has probably been done (-:
Here a half fuselage mould is being cut, but the idea is exactly the same as cutting a foam fuselage half.
If it were me, I would be tempted to go with the Lead High Z model and then put a removable rotary axis underneath. In fact, that is exactly what I plan to do with mine when I get around to installing my linear rails. I just need to sketch it up first then order the parts. So basically, my current modified Ox design will become a modified 4 axis LEAD high Z design...maybe.
