Re: [CAD_CAM_EDM_DRO]polymer concrete

Hi bill, well the base of the machine after filling with polycrete weighed
just over 10 tons. it was a welded structure with rounded gussets and
several layers of open bottom drawers so to speak. bottoms smaller than top.
They poured up to the first level, vibrated to remove air, then secured a
polyethelene faced door with a strap clamp, moved the pour up to the top.
each time they got to a door it was closed and sealed the same way. The box
rails without ways on top were supported evenly with gusseted framework.
part of the reason for this fancy design was so the whole head assembly
could rest on the framework untill the pour cured. then the head was lifted,
the box top was scraped and the ways set. head was lowered onto the ways.
Looking and thinking about that design i see no reason why a very light
frame could be made and after pouring setting rails like thompson makes
should be quite easy. I do not know the price of the stuff tho, Less Watts
should tho!?! for small stuff even if the rail was just iron, and ground and
scraped after casting should be super stable...A printing co. i worked for
used to set iron and brass castings at a seasoning yard out in the weather
for about 3 years, sometimes more just because of supply or demand.
I bought a new unseasoned casting and used it for a boat anchor for 4 years,
then they asked if i still had it, needed a casting to build one more
machine. yep its a machine now..even when seasoned, it still can move around
when being machined..if the body of the machine is a cured casting on a
frame it would be hard to move, good stability even if you machined it!!!
cul brian f.
--Original Message -----
From: "William Scalione" <wscalione@...>
To: <CAD_CAM_EDM_DRO@yahoogroups.com>
Sent: Sunday, October 20, 2002 3:50 PM
Subject: Re: [CAD_CAM_EDM_DRO]polymer concrete

>
>
>
> > Hi, well i am no expert but the machine i saw being built they poured

the

> > urethane/concrete like material into the machine once it was at the
> > customers site. Then final scraping and set-up was done. The material

was

> a
> > base of Urethane, stone powder and some type of emulsion binder to keep
> the
> > viscosity even till it was set-up. The small piece i had didnt bounce

when

> > tossed to the floor but more of a flap-n-thud sound. You really couldnt
> > damage it with a screwdriver..go to a place where they use those

materials

> > and ask to see how it is used. Maybe they will tell you who's material
> they
> > use. cul brian f.
> >
>
> Brian,
>
> Was the machine base basicly a hollow form made of steel, or cast iron?
> What I'm trying to figure out is, if it would be possible to build a small
> machine base out of 1/2" thick aluminum or steel plate, bolt it together,
> and then have it machined to be square and true. Once everything is done,
> fill it full of the polymer concrete, and bolt THK style rails to the

frame.

> Seems like if this could be done, we could come up with a design for the
> group and have a bunch of the frame parts made and sold as a kit. Looks

like

> it would make a nice machine, Desktop size, maybe 8 X 12 working envelope.
> It would look like this http://www.incrediblemachine.com/index.html
>
> No idea what it would cost to have something like that done
>
> Bill
>
>
>
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