After installing new drives, I changed my plastic belt reduction plates with mechmate made aluminium ones, the results are more than satisfying. No more vibration at all from motors, and they seem to use the aluminium plate as heatsink :)

This is where the new setup fascinated me, I cut rib pieces for a toboggan mold. Curved section was split in three pieces 2.7m long divided by 16 rib sections, and straight part is some 4.2m long divided into 21 ribs. They were cut in half for less waste. The curves are fantastic with very litter chatter here and there mainly because I did not optimize starting point to be somewhere else and not on the curve. Model was made using Rhinoceros.

http://cnc.rs/mechmate/tobogan_mdf1.jpg
http://cnc.rs/mechmate/tobogan_mdf2.jpg
http://cnc.rs/mechmate/tobogan_mdf3.jpg
http://cnc.rs/mechmate/tobogan_mdf4.jpg
http://cnc.rs/mechmate/tobogan_mdf5.jpg

After finishing this I am off to vacation, Greece is the destination.
When I come back first thing to do is to install dedicated dust management, inspired by some others I am finishing my Bill Pentz cyclone.

will be interesting to see end result. Take care in Greece... Viel spass!:D

Vac clamping here we come
 

New additions, will be making some sort of vacuum hold down. Bought this pump

http://cnc.rs/mechmate/ROTACIONA-VAK..._O_1195238.jpg

Its 8.3 cfm 235.1 l/min and 26.0 in.Hg -881 mbar rotary vane, looks fairly in good condition, when it arrives tomorrow I will try to machine some small pods for test.

Anyone has a suggestion for pod pattern or construction? Purpose for now would be to hold 800x200mm 30mm thick beech? how about porosity of beech?

I had something like this in my mind

http://www.cncsupport.co.uk/wp-conte...ac-pod-bed.jpg
http://www.cabinetmakerfdm.com/uploa...cts/PD8508.jpg
http://www.cabinetmakerfdm.com/uploa...cts/PD7723.jpg



Also I think that making a reservoir is a good idea, this one is the same pump as mine and its mounted to a reservoir
http://www.westauction.com/user_images2/7159238.jpg

I would like to get into a detailed build out of a vacuum hold down like this so we can have a good list of parts that can be used to move our MechMate folks to a standard typ hold down system like this one.

Will post all about it when its finished

Danilo,

You might look at this site for you vacuum interests.

http://www.joewoodworker.com/veneering/welcome.htm

Pendent
 

Lets see more of your pendent

Pics and functions

you are doing some fine work here



MAC

http://cnc.rs/mechmate/newpendant.jpg

this is the photo at assembly. It has not changed much from there,

I got , start, stop, feedhold, rewind, Z up, Z down, XY zero, Z zero,
MPG/joystick switch (MPG for Z and joystick for XY) RESET,
feedrate pot, and spindle speed pot, as well as LCD with all the info.

Its a bit large, but it was only way to make it a custom look.
Pokeys now has a new device with faster processor so it should get
bit better response from commands, this one is ok but has a bit of lag.

Help with G-code
 

Hi Danilom
nice work' I downloaded the MDF clamp file but is having trouble converting the DXF file to g-code. Would appreciate any advice on how to import DXF file to make g-code
Gary

It depends on what software are you using?
For start I could make you some gcode, if you give me the cutter diameter and feeds.

If you need some free CAM to use and generate gcode yourself, and try you can look at these
http://www.gsimple.eu/index.html
http://www.cambam.info/ (go at download you have a free version at the bottom)

The software i am using is g-simple and the tool bit is a 1/4 inch straight router bit. I have just started cutting and has not paid attention to the feeds. I just received serial #87 yesterday and is a newbe. Thanks for the help i downloaded the DXF file but was unable to get g-simple to generate g-code keep getting ID connection error. Anything to help is greatly appreciated.
Gary

Hi Gary, When I got my machine up and running I also could not get going. I downloaded all the free CAM evaluation programs. Only when I tried the VECTRIC products that I really took off. It will cost you some money, but worth it in my opinion.
I got going within 5 minutes with CUT2D from Vectric.com.
Just my 2c worth.
I upgraded every now and then until I got to Aspire..The more you do the more you want out of the software...keep this in mind.
I thought Cut2D will be fine. It was for 2 months. Then I upgraded to V-Carve Pro...that was fine for a while...Now I am happy with Aspire and the Free upgrades helps...can't wait for Aspire V3.5 releasing soon.

CUT2D is just too basic, its like evaluation version of some bigger software.
For any serious work it won't be enough. Start with VCarve atleast

If I get time today will look at using gsimple so I can help you

Hi Kobus that's exactly what i did downloaded every free cam evaluation software and settled on g-simple just because i had the best results with g-simple. thanks for the advice if it was not for this forum i would really be lost.

Today i plan on learning more about g-code and importing DXF files once i learn more about what i am doing i will settle on what software to purchase.

Thanks for the good suggestions and the help.
Gary

Some recent work, I'll post some pictures once the numbers are assembled and finished.

http://www.youtube.com/watch?v=SC2zUE5nXNM

Bits arrived, will test them soon, its heaviest bit I held and its only 1/2" or 12.7mm

http://cnc.rs/mechmate/compression.jpg

Minimum recommended feedrate 650 IPM or 16m/min at 18k RPM :) GULP!

yep...that looks aggressive. Show us some chips! Really, I'm interested in the chip load?

0.018 - 0.021 per tooth
for 1xD cutting, for 2xD 25% lower
I think that 12m/min will be possible

That is a mean looking bit! It will be cool to see the MM going about its business at at just "mare" 12m/min! That is like F1 racing car!

Danilo,

I like this style of cutters. I have gone through about 40 sheets using these cutters, and they do really well for keeping burrs to a minimum. The cutters are strong and like a healthy chip load. If the sppeds scare you at 1st try running the cutter at the 12,500-13,500 range but keep the chipload @F.036 per rev to minimize burning the tool. Get your CS Setting right and go for it. Then as you get dialed in, up the rpm to 18,000. I can cut full depth of cut right through 3/4 marine hardwood plywood like nothing with these cutters, trully amazing to watch it go. your dust collecter will fill up in a hurry. Have fun with you new cutter!

But he doesn't have dust collector. :D

He can collect the dust manually :D

Hahaha I knew you would say that digger! :rolleyes:

Anyone has some idea on calculating Horsepower needed for cutting?
I seen somewhere some formulas but it requires the amount of power needed to remove cubic inch of material.
What would be that for MDF or particle board?
Last thing I want is to stall the spindle. Its 2.2kW or 3HP, if someone has some info on power req.
I have pocketed hardwood, beech with 5mm DOC and 18mm endmill, with no problem.

The bit in the picture is left handed. Or is the image mirrored?

On our Morbidelli router at work we cut 3/4" particle board at 950ipm at 16,000rpm with similar bits. It also has a 15HP spindle, and two 25HP vacuum pumps. :)

Ger, remember this thread?: Compression spiral LEFT hand bits

:o Had a feeling it was the same person.

Danilo,
Regarding spindle power for cutting, There are no fix rules for it, it is a compounded result of how deep, how hard you feed the bit into the work & size of the bit. Also, how sharp or how blunt your bit is.

To monitor stalling, The only reliable monitoring I found is the current the spindle draws, Power= Voltage x Current & since Voltage is sort of constant, Current will give a direct indication of the power. I don't know how accurate the Chinese VFD display is but that isn't critical, I only need an indication.
For the 2.2Kw, Working around 4A is very safe as it is about 50% capacity.
Adjust your cutting combo to suit or change a sharp bit when the current start to climb gradually over 5A. you don't want to go over 6A as there will be too little head room for to load variation due to blunt bit, uneven wood/MDF density & other unforeseeable load.
For the 2.2Kw Chinese spindle 8A is THE death zone, I know :(

Monitor by listening is one way but it won't give repeatable result & it is always too late for me to respond to stalling especially with 3D works...

Just finished cutting 40 boards of 18mm plywood and 6 boards 10mm. Its was for a local theater. The astonishing decor is breath taking as some pieces are 17 x 7.2m when assembled. Will post some pictures later when they finish the assembly and final setup.

Mechmate held good and I got more tired from loading boards and unloading pieces then machine from cutting. Only damage... Z axis reduction belt, it was damaged some weeks earlier when I during tramming over tightened the Z axis wheels and jammed the axis. As the motor was stronger then the belt it stretched it a little, which I did not notice until it gave up couple of days ago after the 40 boards :) .
Total bits spent.... 2 spiral upcut bits :) they hold up quite nice, for a price of 6$ , I recommend carbidechiu! The truth is the plywood was poplar and very soft, I cut it in 9mm per pass at 2.8m/min and 16k rpm.

46 boards sounded like some money coming in, but then you said it is for a theater and they don't pay much money :)

Well done!

I forgot to post the pics of the scenery. Here they are! Stage is 17 x 7.5m and scenographer filled it up till the last millimeter.

http://www.cnc.rs/images/stories/pos...ic/a1scena.jpg
http://www.cnc.rs/images/stories/pos...ic/a2scena.jpg
http://www.cnc.rs/images/stories/pos...20(Medium).JPGhttp://www.cnc.rs/images/stories/pos...20(Medium).jpg
http://www.cnc.rs/images/stories/pos...687_resize.JPGhttp://www.cnc.rs/images/stories/pos...688_resize.JPG
http://www.cnc.rs/images/stories/pos...699_resize.JPGhttp://www.cnc.rs/images/stories/pos...698_resize.JPG
http://www.cnc.rs/images/stories/pos...700_resize.JPGhttp://www.cnc.rs/images/stories/pos...702_resize.JPG
http://www.cnc.rs/images/stories/pos...709_resize.JPGhttp://www.cnc.rs/images/stories/pos...715_resize.JPG
http://www.cnc.rs/images/stories/pos...712_resize.JPG

Danilo. VERY NICE!!.. I want to be like you when I grow up :). I am impressed.!!!

Whole scene produced in 19 days, with help of their woodworkers and others

Very nice. Check PM

Very impressive!

Wow, very nice!

That looks like a lot of dust.... Well done

Finger leaking good!!!

Nice job.

What do you have in the space normally give for the MechMate logo?
I recognize the 'kreutz' but the first part is covered...
http://www.cnc.rs/images/stories/pos...20(Medium).JPG