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Messages - lcvette

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11
General Mach Discussion / Spindle index slot dimension question..
« on: December 28, 2015, 01:28:28 PM »
Hey all,

I am Installing a new motor on my mill and it doesn't have an encoder like my BLDC did so I am making a single slot disk and using an optical sensor to read the single pulse per revolution.  I have done alot of research but haven't found hard data on the slot size itself.

Can anyone guide me on the slot size?  I have read it should be painted flat black to avoid reflection issues so I will paint it flat black.  The disk diameter is 2.9" and .1000" thick which gives it clearance but still fills the gap of the optical sensor about ~80%.  Any information on those who are running succesfully the single slot setup and their disk dimensions is greatly appreciated. Trying to do this once the right way..

I attached a screenshot of the disk with dimensions.. Tying to cut this today to move forward with installing the new motor so any guidance is greatly appreciated!

Chris





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12
LazyTurn /
« on: September 10, 2015, 10:08:46 AM »
Yes...  I see many easy ways to oops..lol.

I agree that the lathe could be significantly more dangerous, especially being the spindle is a large spinning mass verse an endmill.  I ALWAYS get nervous when the tool starts getting close to the chuck.. I watch the sims and know it will stop, but it is still a bit of a pucker factor no matter how many times I see it safely clear..hahaha

I did notice that grooving works great with a zig zag option I found in Camworks especially if it's a wide groove. It goes in a set depth then moves axially to the other edge and goes in the set depth again and back the other way and continues to the part geometry depth in X.  Definitely helps with the chatter.

I did find that 600rpm is perfect speed for grooving and parting off, excellent advice Hood!  I set feed for .001 FPR and it still chatters a little but but not nearly as bad.

I also found that parting off close to the chuck really makes a big difference. Almost eliminates all chatter and I was running .004 FPR with a nice smooth material peel.  I think it is because of several factors on my machine, for one the table mounted tool post is closest to the base so there is less deflection of the table and the material is closest to its mounting point.

All in all I call it a success..  Now I'm just digging deeper into the CAM software to find all of its nifty secrets, and there are quite a few.

The technology database has taken some time to figure out but now that I see how it works it is very powerful, and I love that it is completely configurable.  So for example, for ID Profiles, it has cored or solid parameters and for every various diameter o the ID profile it allows a configuration to be defined.  So for a 1" ID hole, I can program the auto feature recognition to call strategy #********* which has a center drill strategy with tool X, a drill strategy with tool Y, a bore rough strategy with tool Z, and a Bore Finish strategy with tool A. All of which pull from cutting parameters for each of those strategies.  Once you define those strategies for your machine but automatically recognizes the ID feature, generates an operation plan with all of the above strategies and then kicks out a tool path.  So it completely builds the machining plan and if all your setting are properly entered, it is done and ready to spit out a post.

Obviously setting all of the configurations takes time. But the tech database does have a wonderful copy function that allows you to copy a finished strategy parameter and paste it to another operation so it isn't too bad.  But for now I find it is easiest to set them up as I get to parts with features i haven't had before.



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13
LazyTurn /
« on: September 04, 2015, 12:19:14 PM »
I bored first because I was afraid the small remaining material inboard would become problematic.  It would have only been about 0.11"  wall thickness supporting the part.  So as you suggested, I did my internal operations first.

I was using the boring bar that I crashed with, had an oops.. I checked everything on my design computer with a copy of machturn and it was fine but on my machine computer I had missed checking the box in the ports and pins config to reverse arc movements...  So it tried to make a loop into the interior part wall the first I, K move it got too... I found the tooling insert was chipped on the outer most edge near the back of the angle of the corner radius.  So the front radius was fine making a nice cut on the reducing slant wall where it was contacting the unchipped portion but on the straight in wall it was cutting partially on the chipped edge which probably didn't help... So new insert is now installed... Live and learn..lol



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14
LazyTurn /
« on: September 04, 2015, 01:50:16 AM »
Yeah I doubt it is rigid enough, it is actually not a lathe but my grizzly G0704 mill setup like a lathe with the head tilted sideways and a custom QTC tool post mounted on the end of the table and a R8  4" 3 jaw chuck. 

I will be running more parts tomorrow z a bit more complex, I will play with the feedrate for grooving and parting and report back with what I get to work...  I think I found part of the problem, the cutoff operation had an option for adding a chamfer and I Think the angle was a bit too aggressive.  I managed to do a successful groove today, it made a little bit of noise but then smoothed out and a nice stream of little square chips started flying out.  It then did great to widen the groove by using a 50% step over to wide the groove.

It did very well side cutting up to about 3/4 the length of the widened cutting tip, very smooth and very good surface finish.

Think I will just need to play with it and find out what the machine and cutter are happy with.  For now I will avoid the chamfer until after its made an initial groove instead of trying to cut into the stock by making a chamfer move... Think that's a bit too much for this machine.

Thanks again Hood!

Chris

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15
LazyTurn / Gcode Request for a part
« on: September 02, 2015, 09:07:44 PM »
Oh and here is a picture of the finished test part.






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16
LazyTurn /
« on: September 02, 2015, 09:03:48 PM »
Ok, ran my first part, came out great but I ran into some issues with parting it off. stalled the motor with a horrendous shudder shortly after starting to cut.  I ended up manually parting it off running at 500 rpm and bumping in .001" at a time.

I was using 1000rpm and .0005" fpr...  What is a good rpm and feedrate for a parting tool?  It seemed to like 500rpm, but I'd like to get some experienced input.  I'm ready to start running parts now that everything is finally up and running, just need to dial in the part off.

Thanks Hood!

Chris

17
LazyTurn /
« on: September 01, 2015, 11:59:22 PM »
Hood,

Excellent, that is exactly how I decided to set Camworks up as well.  It handles tool paths based on the tool models I designed and the zero point being the center of the tool tip nose radius so it is outputting true tool paths and I do the the X and Z offsets in mach3.  I have a part chucked up and am just tweaking the tool paths bit plan on hitting the go button tomorrow. 

I had been wrestling with the post trying to change the feed option between ipm and fpr and was stumped because the post template I was using, (fanuc generic) called for g98 or g99. finally out of the blue I saw a small check box on the fanuc source code in the universal post generator that asked if I wanted post style A, B, or C. Apparently B and C output that command as G94 and G95 which was what mach needs...  So now I'm in business and think the post is 100% mach compatible at least for anything I have test posted so far..lol

So thanks so much hood for the confirmation!  It also allowed me to run the same safety line up top without tripping error codes!

Double bonus!

Chris

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18
LazyTurn / Re: Gcode Request for a part
« on: August 31, 2015, 06:56:02 PM »
Ok,  I am glad i got confused because it forced me too look a little deeper and even with my cam package set for CNC Compensation off, it is still accounting for the tool tip radius.  I am using tools with a 1/64 (.015625") radius tip and it is showing the X going to X -0.156 on facing operations.. glad i caught that or it would have been doubled by mach if i entered the tool radius into the tool table.  so I know I can go back in and fix all of the tools I drew for Camworks and set the tool tip radius as a zero point and it will spit out unadulterated code and then have mach handle it, but it seems to me that letting the cam do it may be better?  keeps mach from having to do the calculations?  however, i need to now figure out what else this is going to effect such as part zeroing etc.  it appear there is a gauge offset in the camworks tooling table for both the X and Z in the tooling page.  it wants to set the offsets off of the flat of the square bar portion of the tool holder (the clamped section) for the Z and for the X it wants to offset from the rear edge of the tool.  when i zero them out it shows the offset to be the tool tip radius center point.  I wonder if I need to set the offset so the point shows the tool tip where it would be if there was no radius and the tip came to a point?  thoughts?

Soo confusing!

19
LazyTurn /
« on: August 31, 2015, 05:53:18 PM »
Hood,

I'm confused again..lol

I was reading the mach manual and it suggested letting the cam software handle the tool offsets?  Is that correct?

This is easy I'm sure, but I am terrified to crash this thing.  Do you let mach handle the offsets or your cam package?

Thanks!

Chris

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20
General Mach Discussion /
« on: August 30, 2015, 01:18:04 AM »
Your z lowest point should be a negative number as well..

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