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Messages - chad

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General Mach Discussion / Re: How fast is your G00 Rapids?
« on: July 22, 2007, 02:50:58 PM »
Hi, I also use the elrod stuff on my bp clone, really nice. I have a grex and baldor ac servos on it. I have tested it at 350 ipm but it is positively scary at those speeds. The entire machine shakes and and the y being so short just scars the hell out of me. The other problem is the soft limits don't work on the grex.

I have the rapid set at 150 ipm and that seems about fast enough for this machine, at least that is as fast as I am comfortable running it.  ;D


There are some pics here..


General Mach Discussion / Re: Galil - from art
« on: July 22, 2007, 02:16:29 PM »

You know what they say, good news travels fast  :P


General Mach Discussion / Galil - from art
« on: July 22, 2007, 01:48:20 PM »
Hi Guys:

We just heard from Galil they have done a white paper on Mach3's usage with Galil controllers.
We will announce a location for it when they post it. Its a big step to get accepted to that level by Galil,
so hats off to Brian for all the hard work in the connection to Galil controllers..


Promote and discuss your product / Re: UK cnc router site
« on: July 16, 2007, 03:39:46 PM »
That link is broken for me..


Paul is correct, there is no separate license file for the frequency setting. The rule of thumb for the frequency: If your velocity slider is all the way maxed, move up to the next highest frequency setting. If you are only of capable of 22khz on your hardware 45khz will not do anything but take away processor cycles.

Leeway. Sometimes mach can be a little strange on inputing numbers. Make sure after you enter a value be sure to hit return or apply if it is there. I have done the same thing entering a number hitting ok and mach didn't save it..


General Mach Discussion / Re: Update post from Art
« on: July 07, 2007, 04:26:18 PM »
Vmax is totally correct.  I had the same problem with my bp clone running ac servos 2500 per rev encoders. I had to get a grex to be able to get any speed out of it. Now ith the faster kernel speed those with a higher encoder count don't have to use a external box. 

If you are running fine as is, don't change anything.


Tangent Corner / Stumbled on this today thought it was funny
« on: July 06, 2007, 07:12:30 PM »

I have 2 dogs & I was buying a large bag of Pal at Big W and standing inline at the check out.

A woman behind me asked if I had a dog.

On impulse, I told her that no, I was starting The Pal Diet again although I probably shouldn't because I'd ended up in the hospital last time, but that I'd lost 50 pounds before I awakened in an intensive care ward with tubes coming out of most of my orifices and IV's in both arms.

I told her that it was essentially a perfect diet and that the way that it works is to load your pants pockets with Pal nuggets and simply eat one or two every time you feel hungry & that the food is nutritionally complete so I was going to try it again.

I have to mention here that practically everyone in the line was by now enthralled with my story, particularly a guy who was behind her.

Horrified, she asked if I'd ended up in the hospital in that condition because I had been poisoned. I told her no; it was because I'd been sitting in the street licking my balls and a car hit me.

I thought one guy was going to have a heart attack he was laughing so hard as he staggered out the door.

Stupid bitch...why else would I buy dog food??


That Looks awesome! Nice work.


General Mach Discussion / Update post from Art
« on: July 06, 2007, 05:50:17 PM »
Hi All:

Version 2.01 is online and is the new lockdown (Mach3 Suite). It incorporates all bug fixes to date, add the tool length comp to the
toolpath display and has the new lazycam . It also has a new Mach3 flash screen which can be loaded
from the /Flash folder. Flash screens may now be stretched to any size, with the full screen being used.
Oh, and I more than doubled Mach3's speed since we're near done with the printer driver.

You may now select 25K, 35K, 45K, 60K, 65K, 75K or 100Khz as your base frequencies. A few notes..

This does not mean you should be the "cool" guy and use 100khz because you can. :) , remember at all times the rule,
if your velocity slider is maxed out in one kernal and you know you can go faster, then you may bump to the next level. It
takes a fair amount of cpu to run 100khz. My 1.2Ghz single core just manages it. Remember that windows slows as mach3
increases in kernal speed, so keeping it as low as possible makes the gui work better and such. I wont have much
sympathy for the guy reporting jitter or lost steps at 100khz when switching window screens. Specially if his motor maxes
out at 8khz. Keep the kernal as low as you need, but if you need 100khz, then fine, go fer it. It seems to work here fine
and even 200khz was pretty stable for me. ( And no, I wont send you a 200khz version, youll just have to trust me. :-) )

That having been said, over the last 2 years, CPU's have sped up, not to moores law's dictates, but quite a bit. Those with
dual core cpu's and such deserve to get as much as they can, so in thet vein I have increased mach3 to 100khz.
For those curious about such things, I have run successfully at 230khz, but barely, any my computer locks up at 300khz output,
the theoretical limit is about 333Khz with no pulse stretching, but I doubt Ill ever see it. I have locked it to 100khz
because I like to have it half the speed I can run, thus meaning most could run at that speed if they had to. Expect a 4 second
frequency lock in time at very high kernal frequencies when starting the program.

The new download is 20megs approx. My appologies for that, but Mach3 has grown quite a bit over time, so this lockdown
was bound to be much larger than Mach2. However, I am moving to an update system that will only contain the files needed,
and will then make updateing much faster. This means in future that updates may only be made to a system already running the
latest lockdown version. The lockdown version will rarely change. It is quite stable, and will be only periodically updated to
take into accoutn the files that will appear in the development update installer. I have only a couple minor bugs Im chasing
in areas most dont use.

Have fun, experiences at higher speeds are welcome, Id like to know how the higher kernals affect you, dont blame me for
having to reboot if you push for the moon.. Id recommend a 1.3Ghz fast machien for 100khz, and thats a dead minimum...


General Mach Discussion / Re: Need a motor recommendation
« on: July 06, 2007, 10:00:42 AM »
Ok well I will make some guesses.

If you want to do 20-40 IPM in mild steel .04 deep with (1/8 , 1/16 ,1/4 ,1/32 ,2mm ,4mm, 6mm "rolls dice" 1/8 inch) then you will have to use a spindle running 12000 rpm and higher probably a lot higher. I would recommend good flood cooling, and depending on speed and feed either 2 or 4 flute carbide. Depending on... you are getting into "high speed" machining. The smaller the bits you use the faster they have to turn to keep the chip load reasonable especially at high fees rates like this in steel, especially at that depth. Depending on the size of the bit it might not be at all possible to go that deep in one pass at any ware close to that speed, or at all.  If this were wood there would be no problem but this kind of speed in steel is going to take a lot of experimentation and very high rpm.
For example on our metal mill with a 1/8 inch bit cutting 1/8 deep in 2025 alum with mist cooling with the speed cranked all the way up to 5600 rpm I start breaking mill bits at 12 ipm. If it were mild steel I couldn't go much over 2 or 3 ipm (maybe). 

Cooling is going to be critical! At that kind of rpm and feed any heat = broken bit.

Spindles: http://www.hsd.it/home.asp  or http://www.pdscolombo.com/products.htm

Just found this:

 Fully guarding the machine and offering a remote video system for monitoring performance will also reduce operator fear and anxiety. High-speed milling is quite foreign to many of today's operators, and running a spindle at 25,000 or 30,000 rpm is vastly different from running at the 2,000 or 3,000 rpm that operators understand.

To assist in determining certain feeds and speeds for a selected machine, Tables 1 and 2 are reprinted with permission of the Robb-Jack Corporation and represent their recommendations for using their particular end mills for machining three different materials.

Table : Table 1 - Recommended feed rates for two-flute solid carbide end mills in aluminum (based on unlimited available horsepower).

(INCHES)   PER TOOTH   6,000 RPM      10,000 RPM     20,000 RPM
1/8        0.002             24.0         40.0            80.0
3/16       0.004             48.0         80.0           160.0
1/4        0.008             98.0        160.0           320.0
5/16       0.008             98.0        160.0           320.0
3/8        0.012            140.0        240.0           480.0
1/2        0.016            190.0        320.0           640.0
5/8        0.016            190.0        320.0           640.0
3/4        0.020            240.0        400.0           800.0
1          0.020            240.0        400.0           800.0
1/8        2,000     0.0007     16.8
3/16       8,500     0.0012     20.0
1/4        6,000     0.0017     20.0
5/16       4,900     0.0025     25.0
3/8        4,100     0.003      25.0
1/2        3,000     0.004      24.0

Table 2 - Recommended feed rates for roughing a slot in 6AL titanium (340 Brinell) with a two-flute solid carbide end mill (up to 5/16-inch diameter) at 400 sfpm. These recommendations apply to a depth of cut not to exceed one half of the cutter diameter. For cutters over 5/16 inch in diameter, depth of cut should not exceed one quarter of the diameter. For finishing cuts or profiling operations, use a four-flute end mill at double the listed feed rates.


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