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3D Printed Ball Nut for the Insane

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Joules:
hanermo, thank you, detail like that is very useful.  I literally just sat down and from what I had seen and perceived of ball screw nuts designed this as a starter to increase my understanding and knowledge.  Details like yours and the others help greatly.

hanermo:
Welcome.
I help where I can, when I think It might be helpful.

I also learned from others with more experience.

As my area straddles industrial and commercial stuff, sometimes my posts get mis-interpreted as erroneous, arrogant, or boasting, which is never my intention.
Most customer-related stuff is off-limits, as they donīt want their confidants to spread info.
(I was the commercial mgr for Haas Spain, 2011-2012).

I respect that, leading to, mostly, unfortunately few details.
Some customers have given explicit permission.

The ballscrew model I liked, as one of the challenges I mention in CAD-CAM posts is modelling a ballscrew.
Accurately (less than 1 micron error, so it could be made-from-model).

So it can be made (cannot have abrupt cut-off in groove, for example (or how will it be cut ?).
And my challenges are;
1. make a model
2. how long will it take You ? (estimate before starting). How accurate was Your estimate ?
3. how accurate will it be ? Sure ? Explain sure.
4. how large will the model be ?

I made my model in rhino 3d, in 2014/2015 or so, V5, in about 1 hr, for a 30MB file of accurate solids.
1 hr of research (but I knew a lot about ballscrews).
(Sufficient resolution and scaling for 1 micron modelling accuracy.)
I used an ogive arch, so its theoretically somewhat correct, but I did not look for a "correct" arch.
I suspect it does not really matter.

A 5-axis grinder with plunge grind and shape dressed via diamond  could finish the screw, correctly. Imho.
Grinder or live tool lathe or cnc lathe could rough the screw (hardness and support considerations).

Joules:
That's some going hanermo doing a nut in 1hr to 1 micron.  I don't work to those tolerances as the work I current do is happy at 50 micron, that being half the resolution I print at.  When the detailing is needed I switch to my 5 axis needle files   :lol:

ddmckee54:
It amazes me every time I think about 3D printers.  The 3D print resolutions that you're talking about, from reasonably affordable printers, were the minimum sizes for cutting edge integrated circuit devices when I was in school for my BSEE.

Don

hanermo:
My goal was to make a model that could be used directly in a cnc grinder.

The most accurate grinders I have seen, were at a customer, at 0.7 microns.
Envelope.
5 axis.

They use them to grind solid carbide.
For tuna cans.
Of all things..

They are the punches, ie molds, and run about 400 times/minute.
Single punch = can.

20 l paint cans run at 80/min.

Apparently, they need 1-2 microns accuracy.

Another most unbeliavable anecdote, of their 50 machines, +/-, are made by about 45 different manufacturers.
But really nice guys.

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