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311  Mach Discussion / VB and the development of wizards / Re: Any new WIZARD ideas to work on ??? on: October 16, 2012, 02:21:24 AM
Found the problem of the part being twisted - had the wrong setting for the A axis steps in Mach3 tuning. See a new one - now perfect. Only problem remaining now is the number of sides cut being wrong. This octagon is cut with the number of sides to 4. I can't find the error in the code, it looks correct to me.

Now regarding the ability to do arcs on a rotary axis, I have a workaround for this. I tried to asign the Y axis to the rotary - works fine only problem is I can't get my head around to figure how to program the arcs. Do you have any idea?

Dan
312  Mach Discussion / VB and the development of wizards / Re: Any new WIZARD ideas to work on ??? on: October 16, 2012, 01:16:54 AM
Hi Terry,

Ah... this was a good idea. I didn't think of changing the rotation axis to Z. Now I see the toolpath more nicely. And for some reason I am seeing it twisted in the Z instead of getting continuously lower. This is probably why the part gets twisted too.

I am using my A axis in revolution mode, as stated in the Gcode heading, not in degrees mode, so 1 in the A DRO means one revolution of the axis. This is why you think it's not rotating all the way around.

Dan
313  Mach Discussion / VB and the development of wizards / Re: Any new WIZARD ideas to work on ??? on: October 15, 2012, 03:03:54 PM
Hi Alex,

You are right the tool has to have a larger clearance angle as the number of flats gets smaller.

Dan
314  Mach Discussion / VB and the development of wizards / Re: Any new WIZARD ideas to work on ??? on: October 15, 2012, 02:59:21 PM
OK. Found the working version. Appears I made some modifications to the code at the machine itself. This one moves the A axis:

G0 G40  G17 G80 G50 G90

(A axis is in revolution mode)
(Program in Diameter mode)

#1 = 4  (number of sides)
#2 = 13 (distance across flats)
#3 = 300 (feed: mm/min)
#4 = 0.2 (Z feed per revolution)
#9 = 2 (length along Z)
#17 = 50 (resolution - number of segments in half flat size)

#5 =  [360/#1] (root angle)
#6 =  [2*[0.5*#2]/cos[0.5*#5]] (distance across corners)
#7 =  [[0.5*#2]*tan[0.5*#5]]  (half side length)
#10 = [[0.5*#5]/360] (single segment revolution amount of A axis)
#11 = [#10/#17] (single rotation fraction of A)
#16 = 0
#12 = [[-1*[#4/[#1*2]]]/#17] (Z advance per segment)
#13 = #12

G0 X[#2+1] A0
G0 Z1
G1 X#2 Z.1 F#3

#14 = [-1*[#4/#1]] (Z advance per main subroutine execution)

#15 = FIX[#9/#14] (Number of subroutine executions required - 'L')

#18 = #11

M98 P100 L100;#15

G0 X[#6+3]
G0 Z1 A0
M30

O100

M98 P101 L#17
#16 = 0
#18 = [#18 + [0.5*#5/360]]

M98 P102 L#17
#16 = 0
M99

O101
G1 X[2*[0.5*#2]/cos[#16*360]] A#18 Z#13
#16 = [#16 + #11]
#13 = [#13 + #12]
#18 = [#18 + #11]
M99

O102
G1 X[2*[0.5*#2]/cos[0.5*#5-#16*360]] A#18 Z#13
#16 = [#16 + #11]
#13 = [#13 + #12]
#18 = [#18 + #11]
M99
%

Just tested it on a piece of delrin and the concept works - see attached picture. Flats seem perfectly straight with resolution variable set to 50 and corners are sharp. Only thing is it's still twisted along Z. And the code has some problems with the variables as it cut the octagon in the pic with the flats number set to 4. If I set it to 3 it cuts two flats and if 5 it appears to cut 10 flats. But at least it shows that the concept works. Just requires some more thought and refinement. See if you find what's the problem.

Dan
315  Mach Discussion / VB and the development of wizards / Re: Any new WIZARD ideas to work on ??? on: October 15, 2012, 01:53:32 PM
Hmm... strange, you are right it doesn't rotate the part and actually does some odd moves here too. Could be that I had a different version of the code on the machine itself, may be I modified it there though I can't see something wrong with this one. Will check later if I have a different version there as it did work and produce the above.

Yes, seems like arcs would make it a lot easier. A bit hard to visualise, but it makes sense.

Dan
316  Mach Discussion / VB and the development of wizards / Re: Any new WIZARD ideas to work on ??? on: October 15, 2012, 01:16:51 PM
No. I think we are on the same page. My code works exactly like in this video. In the picture above, the square rotates counterclockwise so at first I start from point A and go outwards towards point B and as I go past point B, I start to move inwards. This is why I have to subs in the code - O101 for the first and O102 for the second.

What's interesting is that in the end of the video they show the white plastic parts and their square looks pretty similar to mine - with corners rounded and flats not being flat but rather a bit concave in the middle (see attached photo. Not the best quality, but you can see what I mean). Only difference is that mine was twisted in the Z in addition to this (again see the picture). Then what's interesting is that on the next photo they show perfect polygons in metal which don't look like have been made on this machine.

Dan
317  General CNC Chat / Show"N"Tell ( Your Machines) / Re: Chiron FZ12 on its way sometime soon(ish) on: October 15, 2012, 10:06:56 AM
Looks like it just fits there. Are you going to rotate it or leave it that way, facing the gate, so you have access to the cabinet?

I too didn't realise the table didn't move at all. You posted it earlier, but I thought the column was only moving in the Y and the table was doing the X. It is interesting to have a closer look at the mechanism and especially the guards.

Dan
318  Mach Discussion / VB and the development of wizards / Re: Any new WIZARD ideas to work on ??? on: October 15, 2012, 08:51:59 AM
Hi Terry,

Took a look at the code. Since the X axis has to change speed as the A rotates (since tangential speed changes as you change distance from centre) I broke the X axis moves into fractions and used a sub to repeat it. Please see attached screenshot, I hope it will clarify what I meant. In the picture, a, is my X variable and it changes with the angle. I call in the code the ABsegment as single segment and this is then broken into smaller segments depending on the resolution.

I have also made a couple of changes to the code so it will match the sketch and be more readable. Here is the revised one:

%
G0 G49 G40  G17 G80 G50 G90

(A axis is in revolution mode)
(Program in Diameter mode)

#1 = 6   (number of sides)
#2 = 10  (distance across flats)
#3 = 120 (feed: mm/min)
#4 = 0.1 (Z feed per revolution)
#9 = 10 (length along Z)
#17 = 10 (resolution - number of segments in half flat size)

#5 =  [360/#1] (root angle)
#6 =  [2*[0.5*#2]/cos[0.5*#5]] (distance across corners)
; Not used #7 =  [[0.5*#2]*tan[0.5*#5]]  (half side length)
#10 = [0.5*#5] (single segment revolution angle of A axis)
#11 = [#10/#17] (single rotation fraction angle of A)
#16 = #11
#12 = [[-1*[#4/[#1*2]]]/#17] (Z advance per segment)
#13 = #12

G0 X[#2+1] A0
G0 Z1
G1 X#2 Z.1 F#3

#14 = [-1*[#4/#1]] (Z advance per main subroutine execution)

#15 = FIX[#9/#14] (Number of subroutine executions required - 'L')

M98 P100 L#15

M30

O100
M98 P101 L#17
#16 = #11
M98 P102 L#17
M99

O101
G1 X[2*[0.5*#2]/cos[#16]] A#16/360 Z#13 (A converted fromdegrees to revolutions)
#16 = [#16 + #11]
#13 = [#13 + #12]
M99

O102
G1 X[2*[0.5*#2]/cos[0.5*#5-#16]] A#16/360 Z#13  (A converted fromdegrees to revolutions)
#16 = [#16 + #11]
#13 = [#13 + #12]
M99
%   
319  Mach Discussion / VB and the development of wizards / Re: Any new WIZARD ideas to work on ??? on: October 15, 2012, 03:18:30 AM
Terry,

The code cuts all sides per revolution - spindles rotates continuously in one direction only. I will have a look later and try to refresh my memory of the math I did.

I wouldn't trust the toolpath display either. I was experimenting with a delrin bar and it was cutting the shape, but the corners were getting rounded and it was getting twisted along Z.

Dan
320  Mach Discussion / VB and the development of wizards / Re: Any new WIZARD ideas to work on ??? on: October 14, 2012, 10:41:40 AM
Hi Terry,

I didn't really care it being slow. Sometimes it's better leaving it for 15 minutes to do its job than switching for a second operation on the mill.

Here is what I had:

%
G0 G49 G40  G17 G80 G50 G90

(A axis is in revolution mode)
(Program in Diameter mode)

#1 = 6   (number of sides)
#2 = 10  (distance across flats)
#3 = 120 (feed: mm/min)
#4 = 0.1 (Z feed per revolution)
#9 = 10 (length along Z)
#17 = 10 (resolution - number of segments in half flat size)

#5 =  [360/#1] (root angle)
#6 =  [2*[0.5*#2]/cos[0.5*#5]] (distance across corners)
#7 =  [[0.5*#2]*tan[0.5*#5]]  (half side length)
#10 = [[0.5*#5]/360] (single segment revolution amount of A axis)
#11 = [#10/#17] (single rotation fraction of A)
#16 = #11
#12 = [[-1*[#4/[#1*2]]]/#17] (Z advance per segment)
#13 = #12

G0 X[#2+1] A0
G0 Z1
G1 X#2 Z.1 F#3

#14 = [-1*[#4/#1]] (Z advance per main subroutine execution)

#15 = FIX[#9/#14] (Number of subroutine executions required - 'L')

M98 P100 L#15

M30

O100
M98 P101 L#17
#16 = #11
M98 P102 L#17
M99

O101
G1 X[2*[0.5*#2]/cos[#16*360]] A#16 Z#13
#16 = [#16 + #11]
#13 = [#13 + #12]
M99

O102
G1 X[2*[0.5*#2]/cos[0.5*#5-#16*360]] A#16 Z#13
#16 = [#16 + #11]
#13 = [#13 + #12]
M99
%

See if you can read it. It has been sometime since I wrote it and it will take me sometime to understand what I meant myself Wink

Dan
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