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polaraligned - 10/15/2017 2:41:08 PM

+x

 

David Morland - 10/15/2017 11:24:10 AM

Hi,

I'm looking at using some self leveling epoxy resin to apply approx 2mm layer on top of a 10mm steel plate steel 1000x500mm once the resin has cured I am going to then drill and tap the steel and place hiwin linear rails on top. I'm hoping for 0.05mm or as close as I can get flatness. 

Do you think this would be possible? Also will the epoxy have any significant shrinkage? What sort of forces will it crack at? As the linear rails will be bearing considerable force maybe static load of 4000N and with dynamic loads up to maybe 6000N.

If so what kind of epoxy resin would be suggested to be suitable?

Thanks in advance for your help.

Dave.

What is the purpose of the epoxy?  To make the plate flat?  If so, I would just have the plate machined flat.  I doubt any epoxy will self level to the flatness you are looking for. 

+x

 

Lars Steffenrem - 11/1/2017 11:27:19 AM

The strengthened epoxy will not flow like you want it to. 
10 mm steel is not that rigid either, so it will conform somewhat to what you bolt it to, or lay it on. I would get hold of a 1m straightedge and just shim the first (master) rail straight. 
Then you use one of the carts, with a dial gauge mounted on it, to align the second rail. Hiwin type rails should ideally have machined edge of 2-3mm height, to be mounted against, but you can always check sideways alignment with the gauge against the straightedge. When things are all set , level and straight, you can pour epoxy around the rails, and they will stay in the right place.

Lars

+x

 

David Morland - 11/1/2017 12:03:12 PM

+x

 

Lars Steffenrem - 11/1/2017 11:27:19 AM

The strengthened epoxy will not flow like you want it to. 
10 mm steel is not that rigid either, so it will conform somewhat to what you bolt it to, or lay it on. I would get hold of a 1m straightedge and just shim the first (master) rail straight. 
Then you use one of the carts, with a dial gauge mounted on it, to align the second rail. Hiwin type rails should ideally have machined edge of 2-3mm height, to be mounted against, but you can always check sideways alignment with the gauge against the straightedge. When things are all set , level and straight, you can pour epoxy around the rails, and they will stay in the right place.

Lars

Hi Lars,

To late unfortunately. I'e already done it! The steel plate is set on a bed of concrete with rebar welded sitting it to the plate. I used 6mm plate in the end. The level of flatness I've quickly measures is overall around 0.2mm over a 0.5m2 area so not to bad i don't think considering the plate was warped to hell. It' gonna save me a lot of shimming and the rails are now almost within tolerance of height according to the hiwin specs! So I'm happy with that.

Thanks for your reply though. All seems to be going smoothly.