My machine improvements

All info relating to the Denford Starmill CNC milling machines

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LucDav
Posts: 25
Joined: Wed 27 Sep , 2017 20:46 pm

My machine improvements

Post by LucDav » Thu 30 Mar , 2023 22:24 pm

I have just done a bit more improvement to my starmill and thought it may be useful to others.

The starmill is stated to have 170x100mm table travel. I had to replace my stepper motor on the x and lost 5mm. Since then I have machined down the end bearing block down by 10mm to get to 175 once the block no longer interfered with the case I made a new plate to hold the y home switch. That gained me 10mm on the y travel. I have also made a lever action TTS tool changer system which is working well.

I have upgraded the electronics cabinet and am running modern stepper drivers through UCCNC. I also sealed the cabinet and added a small flood coolant system to the machine which has really made machining easier.

In the next few weeks I intend to swap out the Y axis motor as it is showing signs of struggling and adding gas springs to the head to allow for faster z movement.

Finally I have purchased a replacement spindle motor good for 9000 rpm and will swap out the spindle bearings at the same time.

Finally I built a heavy box section fram for the machine to sit on to increase the vibration damping of the machine I have some places I intend to fill with epoxy granite and also fill the 80mm box section with concrete.

Each one of these mods has made the machine far more capable machine piggy backing off denford excellent build quality has been a pleasure. Recently acquired triac is the next project. :D

Martin
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Re: My machine improvements

Post by Martin » Fri 31 Mar , 2023 10:18 am

It`s good to hear the machine is still going strong.

Any chance of a couple of pictures if you have time?

LucDav
Posts: 25
Joined: Wed 27 Sep , 2017 20:46 pm

Re: My machine improvements

Post by LucDav » Sun 02 Apr , 2023 10:07 am

I'll get a few on here this week. It's in bits again as I'm changing the spindle motor and y stepper.

dpslwk
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Joined: Sat 25 Jan , 2020 19:00 pm
Hardware/Software: Novaturn
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Fusion 360

Re: My machine improvements

Post by dpslwk » Wed 21 Jun , 2023 3:00 am

I'd be interested to see pic and drawing for the TTS conversion

Thanks Matt

Magicniner
Posts: 1
Joined: Wed 28 Jun , 2023 14:40 pm
Hardware/Software: Starmill / Mach3

Re: My machine improvements

Post by Magicniner » Sat 01 Jul , 2023 11:30 am

LucDav wrote:
Thu 30 Mar , 2023 22:24 pm

Finally I have purchased a replacement spindle motor good for 9000 rpm and will swap out the spindle bearings at the same time.
I have just acquired a Star Mill and plan an upgrade, it would be useful to know what motor you are using for the upgrade,
TIA,
Nick

LucDav
Posts: 25
Joined: Wed 27 Sep , 2017 20:46 pm

Re: My machine improvements

Post by LucDav » Tue 04 Jul , 2023 22:04 pm

Magicniner wrote:
Sat 01 Jul , 2023 11:30 am
LucDav wrote:
Thu 30 Mar , 2023 22:24 pm

Finally I have purchased a replacement spindle motor good for 9000 rpm and will swap out the spindle bearings at the same time.
I have just acquired a Star Mill and plan an upgrade, it would be useful to know what motor you are using for the upgrade,
TIA,
Nick

Ni Nick,

I found a small SEM 0.5 kW dc motor. I also had to upgrade the drive to suit. I'm having to over volt it to achieve higher speeds. I found that above 6k rpm the spindle balance isnt good enough. I have been running at 5k without issues. I have found another couple of options. You can get 18000 rpm spindle motors that run 800w and 100vdc. Putting that on with a reduction of 3 or 3.5 would work. And finally I'm considering a brushless motor in future. You can get a motor and driver off aliexpress for around £100 which takes 240v ac and does 5 or 6k rpm. I'll try and finally get some pictures and details up in the next few days.

LucDav
Posts: 25
Joined: Wed 27 Sep , 2017 20:46 pm

Re: My machine improvements

Post by LucDav » Wed 12 Jul , 2023 20:15 pm

dpslwk wrote:
Wed 21 Jun , 2023 3:00 am
I'd be interested to see pic and drawing for the TTS conversion

Thanks Matt
I don't have any drawings but I'll upload a few pictures shortly. It's basically a frame with a lever and a few belville washers. Because the machines so low powered I have got away with less spring pressure than they would normally have for tts. Also allows me to put direct pressure on the bearings though I admit it isn't the ideal. I will be upgrading it to be pneumatic or hydraulic in the near future.

LucDav
Posts: 25
Joined: Wed 27 Sep , 2017 20:46 pm

Re: My machine improvements

Post by LucDav » Wed 12 Jul , 2023 22:53 pm

Here's the mill finally.
A lot of the upgrades not visible.

Running UCCNC with a touch screen interface.

5500rpm dc spindle 0.55kW with index sensor added and a sprint 800 drive.

x and y steppers replaced with 400 step per rev units. X stepper has a coolant sheild (that's what killed the last one. A lot of material removed from x bearing block to extend the travel, y limit moved to extend travel by about 15mm. Gives me a total movement of 175-110. Currently running 24v.

Flood coolant system added (a lot of sealing was necessary. Including the epoxy granite ramps and extentions to the front to make the tray deeper. Flood coolant tank is in process

Led strips added to see what's going on.

TTS lever system added and works well, with side tool rack.

Base frame is 80mm x 3mm box section with the machine bolted down.

Z axis gas spring assist 5kg each.

Mods remaining:
Fill machine base with epoxy granite.
Fill frame legs with concrete and add retractable castors with anti vibration feet
Replacement control cab running 48v and a second input output board.
Probe input
Spindle encoder
Possibly convert to bt30 to match triac
Air blast
Windscreen wiper?
Riser block
Upgrade drawbar to pneumatic/hydraulic
Possible toolchange carousel.
Stepper encoders
Replace Z stepper
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