Latest news...on 3d cut resolution
 

Some update !

Last time, I was seeking for some advice in order to improve 3D resolution work !
Lots as been done & learned since as I’m more & more making some of this type of commissioning work!

One MAJOR point I skipped all this time was…. Wear & tear !
Since my built first cuts, I never had issue with….missing / skipping steps !
While on one of the lattes work I was trying to get going as I was making test cuts before hand, I could not get….consistent cuts !
“flabbergasted”….. I suddenly saw, at a “lucky micro-second"….( lucky I say that) a…”hick-up” from my blue beauty !
Long story shorten….. I was missing some steps due to this :

Attachment 14449

Black one = new Boston gears
Steel one = old STD-SI ones

Wear on gears !!
When I relocated my beast early on this year, I did not “adjust” properly the motors support “tension” and did not / forgotten to re-tuned some points !
Gears with too much spring tension created this accelerated wear !

Some other pics from this work

Attachment 14450

Attachment 14451

Thought I may share this !

Later, Robert ;)

Too much spring tension !

A warning not to overengineer or overtighten.

Maybe you should reference this
http://www.mechmate.com/forums/showthread.php?t=593

I am glad it was mechanical, that is much easier to repair.

Make sure you are using an appropriate lube for the contact surfaces of the gear and rack and not running them dry. The only thing the design does not take into account for is grease spray from the pinion to the table on the Y traverse. I had to make a tray to capture the minute amount of splatter from hitting the work pieces.

Example
http://farm4.staticflickr.com/3716/8...3ffda715_z.jpg
Grease tray for Y Motor on Flickr

Making trany prototype !
 

Hi all….
Some update on my beast !
After my gear wear episode a mo ago, I gave myself the objective to “finally” go ahead with my trany upgrade…..long overdue, specially it was drawn, planed and all parts in hand over 3yr ago !!

First step I decided to is making some prototype in MDF !
After some preliminary test, all seem fine….aside some little correction !
Why prototyping is fun…correcting before final output !

Hers a few pics !

Attachment 14528

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Attachment 14530

More to come when final assy will be made !
Enjoy a great seasons holiday !
Later ;)

Ohh...BTW !

Could search for a few....hrs :rolleyes:.....but easier to ask ;)

For those who are running with a 4:1 ratio...
What is your "motor tuning" specs in Mach3 ( Velocety & accel ) ?
Thks ;)

Hi Robert ,looking good ,how does it work with the mdf model? What are you going to make the real one with?

I have run 500 and 50 (IPM) on my single 4:1 axis.

Interesting Pete !
Few test so fare, but no sign of "abuse" out of my testing at 750 & 45 !!
Not cutting at those specs, but rapids are !!
not sure to what I can "push" the cutting ??
are you cutting at 500 & 50 ??

NORM !!
Salut @_@
the mdf has more....flex, but aside this and being fragile, all seems fine at this point ( only +/- 6-8hrs at test )
Did those ( in mdf 1st) to satisfy my curiosity on....fitment, machined file & assembly....and obviously....see if any correction could be needed !
Final version....not decided yet, debating between.....some black acetal or T6 alu ??

The 4:1 is on the Z, the velocity and acceleration were set to that. It ran fine at that setting.

How durable do you think the MDF is when using it for reducers housing. If it works I think I over did it with the steel. The one thing that is nice about using MDF is the ability to machine it, I almost have my first Mach up done. I used 1/4 hot rolled steel plate.

Hurshy, MDF can’t replace the advantages & the rigidity of steel or aluminium !
In my opinion & experience, keep MDF for mach ups or woodworking projects, not the material for a “good” solid, working CNC.
MDF is just too unstable, absorb humidity and brittle for this task.
On the other hand, many have machined steel and/or aluminium with their blue beast. It is very “do-able”!!
¼” steel does not qualify in the “over doing it”….keep you transmission housing project as planned, and mdf as a cheap alternative material !
I used it as “prototype” meanwhile….only !
Hope this helps, Later, Robert ;)

Robert, thanks for the answer. Do you think that 1/4 aluminum plate is sufficient for the back plates. I have finished my mock up using 1/4 steel plate. It worked but hot rolled steel is not fun machining. Good luck on your build and Happy New Year.

Hurshy….Personally, I would not “improvise” myself competent enough to measure / recommend what is the limit in thickness for alu, but on the easy side…..why not going with, say 3/8’’ or better yet, 1/2” ??

As for steel....I have the same opinion as you....but in defense, did not search nor can I remember who did it, but I can tell you some one here, a few yrs back, did machine some steel for his trany plates....with his beast !

Thank for you wishes…..all the best to you also !
PS….by build was done some years back...:p
Robert ;)

It is to late now. I completed cutting out all of the blanks. I picked up a pair of machinist gloves at the steel store. It really cut down on the cuts and splinters. I have a couple of splinters that are buried so deep. Back to the topic, tomorrow I will do the lay out on the pieces and start machining. I worked up a protocol sheet of all the machining tasks to resolve all the errors I made up on the first set. The most tricky part of all the tasks is centering and boring the bearing hole to the correct size. They call the process boring for a reason. The largest bit I currently have is 5/8. So I have to step bore this hole from .725 to 1.119-1.125 in .10 increments. Can't wait for the large set of bits I ordered to show up. Anyway, another day and one small step completed.

Cutting hardrock maple.....from Lac-Brome
 

Hi all....

Some update was needed !
Been too long since I've “captured” some work done by the beast.....in its new location !
Here you’ll see a little production run for a local designer, making some “cocktail” plates.
Attachment 15044
Attachment 15045

Lots of fun and great occasion to confirm the new trany are running as per expected....fine !

Also, though it may be interesting to some, made a tempo dust separator inspired by the Phil Thien separator design till I finish installing the cyclone system in the shop !

Attachment 15046


....btw....motors were running at +/- 78° after several few hrs runs....really maxed out I’d say !!

Cheers, Robert ;-)
Ps....
Maybe this can confirm that I’m more in to solid wood making ....than ply !!
Pss.....by the way...I’ve moved 4yr ago from Brossard to Lac-Brome !! ;0)

Looks great. - Just curious, how much difference do you notice using the Thein collector vs a cyclone?

Thks....
No comparison would be fare.....
Cyclone = 7.5 hp
Thein separator to a cheap Arbourfreight (low) 2hp.....:eek:

One thing I can tell....
The Phil Thien separator design is wonderfully working….and saving me time and hassle….but lower the suction (velocity & and air speed):(.

;)

What can I say about Thien Separator, only 30 minute to set one up from scratch with an oil barrel & MM.

Safety first.....
 

Hers what may happen when....less attention !!

The other day I was supervising some cutting and while it was cutting, i was occasionally, getting ahead doing some tab cutting !
End then......oups.....

Attachment 15132

while I was bent over one X rail......collision with the beat !!
Well guess what....the beat took for hostage ( at least my shirt ant under t shirt ) ;0))

Attachment 15133

Attachment 15134

Thanks to mother luck....no harm...no scratch.....aside my ego !!

Moral....this like any other machining....NEVER assume....and be ALERTED !!

Later, ;0)

Glad you are safe... It's not in the plans, but a rail wiper, or just a piece of plex on either side would avoid this danger, always found those exposed v-wheels a bit of a safety hazard in the mm. Excellent place for extension cords and fingers to get caught as well ....

I have those on my thread to keep little fingers out ;)

...I put cow pushers on my #5 too. More for keeping the airborne foam bits from sticking to the rail. Yes, I have had my share of shop rags get run over....and the proxies detected the lift every time and stopped the machine!

yo need some stickers like.

Caution !!
Wear appropriate clothing to manipulate the machine.

Metalhead could sell some 'breakaway CNC jerseys'! :-)

I have a couple shirts that have some holes in them from the same exact thing.

Quasiment perdu ta chemise la. How is that tool to cut the tab? this way you dont have to flip it over like with a router .

O que oui....Heureux d'aweirre un bouton rouge proche :cool:
Love that tool, battery operated, handy & very practical !

Latest work !
 

Hate to admit....prefer to keep out of the spotlight, but never the less, I taught some may appreciate what was the latest work done...& assisted by my best assistant, the big blue !

Cutting one of the tops ( one of 3 )
Attachment 15190
Attachment 15191
Attachment 15192
Attachment 15193

Drawers cut out
Attachment 15194
Attachment 15195

Attachment 15198

Finished & on location ( Local town council )
Attachment 15196
Attachment 15197

Cheers mates ;)

Gorgeous work, my friend.

nice work.

did your assistant manage to break the diy t-slot or was it an operator error ? :D

Very Nice Robert! :)

Brilliant stuff! (and we are not allowed to be shy here Robert :) )

Woaw guys, thks for the compliment !
Shy, moi...na.... ;)

FOX, the t-slot actually gave away as it had a weak lip do to, I made an initial machining mistake ( to thin). So ya, we can say it’s the programmers miss :p

Wow c'est beau pas a peu près. Very inspiring. There is no stopping you now.. Is that oak ? Are you still running with the mdf prototype gears reduction?
Ça me fait beaucoup penser a la cour ,je viens de gagner pour la 6em fois en ligne ,ça commence a être redondant.

Hey Norm, nice to here from you !!
Merci pour les compliments....
"There is no stopping you now.. " better then ever, since I got separated 4 yrs ago :D

Certains ont ds billets de saison pour le Hokey...toi....C'est la Cour....t'es un abonner régulier :p

Gear reduction have been on MDF only for a few trial !!
Since then, there made of ½" black composite

Attachment 15199

Attachment 15200

Cheers ;)

Robert,
Awesome job on the desk! So when are you going to get some Labels on that machine and get a serial number? :)

Heath, thks for the compliments, appreciate !
See, I’ve been around since #2 ( RIP buddy) !
When I started my project, I was aiming for #21......
Since then, I’m still around, acknowledge Gerald great contribution, time ( and some patience :p ) and brag the MechMate rights with respect when I’m ask on the how I did it,....but I’m one of those who has past this numbering issue over 5yrs ago !
Have to admit though, I had a thought about it when I saw the possibility for #121....but opted to leave it !!
Amicalement ;)

Some news
 

Hi all….Some update !!
Well after some +/- 5yr, my bridge rectifier as.... given up ….while running a job.. (/%&*$/$!! ) :mad:
But aside of this, I can still say that my beast is still quite running fine after all ! ;)
O-!!….one other note, during my little stop on this past “short holidays”, I paid my good old PorteCable 7518 some new good new bearings ( advice ; don’t shot on those, good one are still inexpensive).
Let me tell ya, didn’t think much till I fired it up after the change…..BIG DIFFERENCE ! Advice, I would recommend to change those earlier than later, meaning, do not wait for some wear signs, I would say, if wear sign appears, it’s already late, but nothing aside vibration and “loos” shaft may occur…in my opinion !
Total cost for me was – Bearings = 62.40$ + ….+/- an hr of time/labor !!...CHEEP ! :0)

But one “new” concern I’m more….worry about !
Has anyone ever needed to change their gear rack ?
My X axis is not giving me a nice & smooth sound while traveling its axis, and that even as the gears running with my trany are not that old, say less than 50hrs of wear, but the rack…..humm…well over….say…hard to say, but +/- 200hr ??

Later….