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Old 07-25-2011, 08:12 PM   #1
skray775
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Default Custom Aluminum Frame

So I always wanted a CNC machine and a few months ago I converted an old Mill/Drill over. Here is the
build thread if you are into such things.

http://www.cnczone.com/forums/bencht...selection.html

I have been playing with a couple of projects to help me learn the CAM software. This Heli frame is one of them.

The idea was to design and build upper and lower frame half's with the lower frame being sacrificed in a crash most of the time, I hope! :-) Since I Fly 12s A123 packs another advantage for me would be a wider lower half for batteries to slide into.

This is a direct servo to swash conversion. The upper frame is .1 oz heavier then a Rotoworks frame half. Once you factor in the other weight savings from hardware it should be close to even in the weight department. Again flying 12s A123 packs I am not all worked up about weight.

I just though I would share my project with all of you.
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Old 07-25-2011, 08:17 PM   #2
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Wow! that's pretty neat looking. Not too shabby
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Old 07-25-2011, 08:27 PM   #3
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Awesome! Now, make some more and sell those puppies!
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Old 07-25-2011, 08:36 PM   #4
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i see you strayed away from the frameplates, i like this
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Old 07-26-2011, 06:06 PM   #5
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Thanks Guys,

It takes about 45 minutes to cut but I picked up some 3 flute end mills and might be able to speed it up a bit.
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Old 07-26-2011, 06:09 PM   #6
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Next trick is to learn how to anodize them in custom colors!
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Old 07-26-2011, 08:08 PM   #7
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What heli is that? Align?

What CAD/CAM software do you use?

Looks pretty slick man. I'd be proud.
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Old 07-26-2011, 08:13 PM   #8
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that is awesome! great work.

However, I would be concerned about crashing and bending the frames compared to CF plates.
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Old 07-26-2011, 11:38 PM   #9
skray775
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That is a Trex 600e.
I draw with Autocad since I am used to it from work and purchased a very inexpensive Cam software called CamBam. Pretty nice for the price. I run Mach3 on the mill.

I cranked up the feeds a little when I cut this part for the mill yesterday. If I can up the RPM on the mill past 2580 I can go even faster. [ame]http://www.youtube.com/watch?v=6l06xSD6yp4[/ame]

I am hoping the lower G10 fiberglass frames break before the aluminum bends... Will see when I crash it!

I don't/can't do wild 3d (unless i'm crashing) so I mainly do loops, rolls, FFF, just fly around.

I only have the natural color G10 right now but I plan on purchasing the black for the final build.


Quote:
Originally Posted by kauaicuda View Post
What heli is that? Align?

What CAD/CAM software do you use?

Looks pretty slick man. I'd be proud.
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Old 07-27-2011, 12:23 AM   #10
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Man, that's just awesome, go ahead and let that creativity flow .


Regards,

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Old 07-27-2011, 12:40 AM   #11
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I think the g10 is stronger than the aluminum. But you are doing good making those, even If im right you could also machine g10 frames. Looking it over, you need to fill in the gaps with bracing, theres not enough structural integrity to it.
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Old 07-27-2011, 08:13 AM   #12
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Very nice! .. I like the video .. using the machine to manufacture new parts for it's self

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Old 07-27-2011, 08:19 AM   #13
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I sit in an office and push paper around all day, so seeing someone actually make something is refreshing!
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Old 07-27-2011, 08:37 AM   #14
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Excellent job, I am jealous - I still have to turn the handles on my Bridgeport.
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Old 07-27-2011, 09:26 AM   #15
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Thats awesome man. I went through your build thread on the other site and its pretty impressive. What did it cost to turn your mill over?
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Old 07-27-2011, 09:45 AM   #16
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This video made me reflect on the bad choices I made in my life. Well not all bad but this is something I would have loved to do so much. Your mill works great and being a DIY CNC convert is very impressive. You seem really good at what you do and I applaud your skills and determination
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Old 07-27-2011, 11:19 AM   #17
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Awesome!
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Old 07-27-2011, 11:33 AM   #18
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Looking good!! I've been CNCing for years in RC. Bought my TAIG for doin car parts. But then the Chinese got into it and can't compete. When I get it back up and running in my shop, I will do some Heli parts too. cnczone.com a great site as well
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Old 07-27-2011, 11:36 AM   #19
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Very Nice set up... good job.. like to see the finished bird
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Old 07-27-2011, 12:53 PM   #20
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Nice...need some for nitro.

Aliuminum is a great choice, if the proper aluminum is chosen, I like 7075 t6. Some of the other alloys are just too soft.

the great thing is that when you do crash, you just hammer the bends out and get back to flying...no need for a new frame in many cases. In a bad crash you may tear the alloy but that is easily fixed too.
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