this is not a hydraulic press this is a mechanical press you know what prices do
they are perfect machines for crash something and almost all of them hydraulic powered but
i thought why not make a mechanical press with the 3d printed gears the main idea is
to move the preset up and down as in hydraulic presses and to get this we need to convert the
circular motion from the electric motor into linear so which mechanism can i use
as you know there are many mechanisms for this for example i can use a rack and pin mechanism
both screw mechanism or something else i'll use the right campaign mechanism in this version but
the second version probably it would be a ball screw mechanism generally it looks easy to make
but i think the tricky part in here is that the press must be strong and solid like a rock
otherwise the press doesn't make sense so maybe the gears could play but on the other hand i want
to see that this video is sponsored by pcb way more about them later the working principle is
very simple there will be two dc mothers one on the right and one on the left first i'll increase
the torque with the gearbox then i'll transfer this high torque to the rack with opinion gears
in this way i'll get a really strong linear force from the circular motion of the motor
and with that i'll be able to move the press head up and down strongly so how will i start
normally the press capacity is determined first and then the model is selected but since i'll use
these since m5 dc motors anyway because these are easy to find and also torques are good
this time i'll go from the dc motors to the press capacity now i have to make the press chassis and
i start with the base i use these 20x20 extrusions to build the whole chassis because it's easy to
assemble and you know it wouldn't be good to weld an at home so frame is ready by the way all the
plastic parts are 3d printed pla i am putting the pieces together and these will be the front
and back sides then i am adding a few extrusions in between and the whole chassis is almost ready
the next step is the gearbox the output shaft is an 8x8 square steel bar and i route them
patiently because i'm gonna place them to the bearing but first let's put the gears on
by the way the reason i chose the square shaft is as you can see it's very easy to connect the
gears no need to cut in or something like that i fixed the output shaft with eight millimeter
ball bearing and i also use metric three bolts and 3d printed t-nuts to fix them to the chassis
after tightening all the bolts the output stage of the gearbox is ready same for the other side
now i have to go to other stages gears but before that i assemble the base and the body
i don't use bearings in these shots so i'll just put the gears on a fixed shot because
as you can see the friction is too low and spins freely i just apply some grease
i chose herringbone gears because any acm movement can cause problems and the total
gear ratio of the gearbox is 48 meaning the output shaft speed decreases 48 times compared to input
shaft and it rotates at about 60 rpm in return the torque also get increases for daily times
and becomes 9.6 newton's meter i will transfer this torque to the rack with two opinion gears
so the torque at the shaft divided by two and each pinion gear transfers 4.8 newton's meter
this torque on the pinion gears create a force of about 500 200 newtons in the pitch circle
and transfer this force to the rack this force is the tangential force of the pinion gear
and the final step is to transfer this force from the rack to the press head and i'll do it
like this way i attach the rack to the extrusions thanks to the profile shell and fix it with bolts
then when the pinion gears push the rack down the extrusions push the press surface
here the pinion gear transfers the tangential force to the rack and the rack also transfers this
force to extrusions with metric three bolts but also the weakest point of this gearbox is final
stage because the maximum torque occurs at this stage and this high torque could break the gears
but actually that's not a problem because the larger gear modules and gear width are chosen
with increasing torque and the gears won't break against the high torques here i chose 1.5 mm
gear module in all gears against this high torque and with this module the tangential force of the
pinion gear is here and the total press capacity is also here actually in this case i should have
chosen larger modules in the final stage like 2 or 2.5 mm but if i choose 2mm module the total
press capacity drops from 230 kilogram to 1600 kilogram and if i choose 2.5 mm it drops to 128
kilogram tour that's a high loss and these values are just theoretical and they don't include even
the friction losses i mean i already expect about 30 percent loss from the frictions and if i also
increase the module the total press capacity drops too much so i chose 1.5 mm and i hope this module
will be strong enough otherwise we will see a lot of broken teeth another thing could be a problem
is the bold holes because the high stress occurs in these areas and can cause different damages
for example the rags could broken from the ball section and split in two or the bolt threads could
crush the holes and the other possible damage is the balls may break or crash but there's a
simple way to figure out the all these problems and that is to increase the number of the balls
there will be about 500 200 newtons on the red and if i use one ball then just a single bolt
would try to carry all the force but since i used 4 volts the force on the bolts decreased
so all the problems have solved but still to reduce the crashing
i prepared these formal meter copper tubes that i could put the bolts and place them to drag
if we consider all these problems i think the most possible damage is the gear modules may break
but also maybe the chassis could damaged you'll see that at the end of the video
i also prepared rags as i mentioned now i need a plate to cover this press surface i think pla
wouldn't be enough solid for these forces so i better use the steel sheets here but i don't
have a cnc or steel the best solution in here is pcbway i use pcbway cnc machining services and
for that first i go pcbway.com then i just upload the models i choose stainless steel 304 material
with 1.5 mm thick for both the parts arrived in a short time and as you can see it's really clean
and definitely just the way i want so i have to say clearly their service is really great and also
pc may have many services besides cnc machining they have sheet metal fabrication 3d printing even
injection molding and of course pcb production and by the way they also give a free five dollar
coupon on your first order so i have added a link to description and i'm sure you'll find
something you needed many thanks to pcbway for supporting this project and sending these parts
i'll use this still sheet as a base a theoretical maximum force of 2 kilo newtons will be applied
to this surface and i fix it in the same way with metric three bolts and 3d printed t-nuts
looks nice now i've quickly done a couple things this is the press surface that i mentioned so much
theoretically a maximum force of 2 kilonewtons will applied also on this top surface as at
the bottom surface so it must be solid as you can see i placed the rags like this way thanks
to these slots in the extrusions the distance between rock and pinion can be adjusted easily
i also put a slide at the back so the press head moves a bit better as you can see it sliced freely
but because of this light the press surface didn't fit its place that's why i cut this part off
next i mounted the second piece which is also 1.5 mm thick stainless steel that pc race hand
and this steel sheet covers the top press surface
thanks again to pcb way finally i placed the top surface of the press head it salted all together
thus the press is almost done let's take a closer look
as you can see the gears work smoothly so
it can go down by the gravity now these are the 775 dc motors that i mentioned
at the beginning and they will give the movement then i place them to support
just electric works remain i connect the motors in series because the motors must rotate in the
opposite direction to each other and by the way the press head needs a limit switch when going up
but there is no need to stop when going down so i had just one limit switch for the top side
okay i think it's looking cool but let's see how its performance and start with this little knot
and yes all the gears and slides are looked with grease
just some more nuts
okay it's kind of an early break and it's looking easy to crush these little nuts but
just the physics did its job the required force to break increase it too much with
increased knots and that gear has just 20 percent infield so i think this is normal
now i need to print that gear with more info
okay it works still with us let's see
whoa
again
cool
look at this
come on oh wait
oh no that's not good so i need to print this gear also flink
hmm
it's more fun than i expected
i think that's enough because first the left side gears broke and then i printed them almost fully
in fill and the problem has solved but if i continue probably the right side will break
so let's stop here for now by the way there is no problem with the rack campaign
the gear modules also held up quite well so we didn't see any broken teeth like this and
the chassis is also still solid no problem with that too they're completely fine but i didn't
get the power that i wanted because most of the gears were printed at 20 percent infield except
the ruacampion and first pinion gears i actually thought the 21st infield is high enough but they
were totally terrible the layer edition couldn't take it against the high force so they just broke
and i definitely should have thought about it at the beginning of the video i said so maybe but
but now i want to see the mother stuff before the gears break so i'll just change the gears
with full ones and i hope this time i can crush something harder and besides i'll
test the maximum capacity but i'll leave them for the next video so see you next time bye