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What did you do Today 2018

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Grotto31/08/2018 08:12:01
66 forum posts
31 photos

Got my 3 phase converter (rotary?) installed today. Had done all the cabling but needed a qualified electrician to hook it up.

I was expecting the converter to be a bit noisy, but you can hardly hear it running.

I can now use my mill which has been sitting for a week, unbelievably pleased, it far exceeds all my expectations. I really need to get it into position (it’s currently sitting on a pallet in the middle of the garage) but that can wait a day or two.

Can also put the 3 phase motor back on my Myford (have been running a pretty dodgy single phase which sparks a bit).

Overall an exceptionally good day

Perko731/08/2018 09:31:52
214 forum posts
22 photos
Posted by David Taylor on 26/08/2018 07:46:53:

Following my recent theme of stress in the workshop and being sick of moving machines, this is what I did today. Hopefully the only damage is to the electrical box. A club member who knows about moving things said he'd come and help me get it back on its feet tomorrow.

Note the hardwood blocks under the lathe stand cabinets to raise the working height. What's the opinion on that?

Will they be strong enough, or will they or the cabinet sag? I made a hell of a mess dressing them so they're the same height, give or take 0.5mm, as well as you can with wood. The floor probably has more variation than that!

David.

img_20180826_163029x.jpg

img_20180826_163037x.jpg

Hi David, IMO provided the footprint of the support provided by the hardwood blocks is no smaller than that of the stands themselves then all should be ok. I've used sections of 70x70 SHS under mine to raise the height, and sat the whole thing on 70x70x6 thick rubber feet cut from a floor mat to sit on a concrete floor. It's been that way for 2 years now and has never shown any sign of falling over despite much use and abuse.

Geoff P.

Andrew Johnston31/08/2018 10:35:12
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4155 forum posts
502 photos
Posted by Alan Vos on 30/08/2018 18:34:21:

That nameplate on an Ultimaker 3. 0.4mm nozzle, 0.06mm layers (best). No tweaks.

That looks pretty good, especially since the lettering widths are on the order of 0.5mm. Thanks for giving it a trial. thumbs up

Andrew

Andrew Johnston02/09/2018 21:32:49
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4155 forum posts
502 photos

Weeded one half of the drive early this morning. sad

Then I made a balanced valve and body in aluminium as test pieces for the traction engine governor:

balanced valve and body me.jpg

The balanced valve was a mix of manual turning and CNC milling. The valve body was all manual turning and milling. I learnt a few things about making the balanced valve which I will carry forward when I make the final items in bronze.

Andrew

bricky03/09/2018 06:59:03
320 forum posts
41 photos

Spent yesterday afternoon scraping the rocker arm and con rods on the Rockerblock engine I am building.The push rods needed shortening to get the cams in.The water jacket is next and I am not looking forewards to it.

Frank

David Taylor03/09/2018 08:27:50
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125 forum posts
39 photos

I moved the milling machine. Couldn't find a better place for it so I'll try this.

Thanks Perko. It wobbles at the moment so needs shimming under the cabinets. But it also needs to move towards the camera in the photo below now the milling machine has been placed. The bench needs to come towards the camera too, the vice is barely usable now and I'm left-handed.

img_20180903_152457x.jpg

I also did some work on the 5" mogul and tried an example file in Cut2D. The Tormach post-processor has something nasty in the preamble code that plunged my slot drill right through my workpiece, which luckily was thick wood, hanging off the end of the vice! I copied the preamble from a Fusion generated file and things got better. I still didn't get to the E-stop in time, even though I was expecting trouble and had slowed the machine moves down... I think the problem is you don't want to wait forever so set the moving height to say 20mm, but that doesn't give you enough time to kill it if it continues to rapid move down.

Andrew Johnston03/09/2018 09:16:09
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4155 forum posts
502 photos
Posted by David Taylor on 03/09/2018 08:27:50:

The Tormach post-processor has something nasty in the preamble code that plunged my slot drill right through my workpiece, which luckily was thick wood, hanging off the end of the vice! I copied the preamble from a Fusion generated file and things got better. I still didn't get to the E-stop in time, even though I was expecting trouble and had slowed the machine moves down... I think the problem is you don't want to wait forever so set the moving height to say 20mm, but that doesn't give you enough time to kill it if it continues to rapid move down.

Almost certainly a tool change problem. It's normal to set X, Y and Z zeros using tool 0, the master tool. When you change to tool 1, say, which is a different length the machine needs to take that into account. With the old Mach3 setup you could tweak the Z postion on the screen. But PathPilot doesn't allow that so you need to account for the different length in the tool table, either manually or automatically.

In the end I got sufficiently pee'd off manually zeroing each tool and typing the numbers in that I bought an electronic tool height setter.

Andrew

Mark Rand03/09/2018 11:22:32
581 forum posts
Posted by David Taylor on 03/09/2018 08:27:50:

The bench needs to come towards the camera too, the vice is barely usable now and I'm left-handed.

Being also left handed, I reasoned that all the vices in the school woodwork shop and apprentice training school were set up for right handed folk. So I put my vice at the other (right) end of the bench in my shed. Works for me smiley.

David Taylor03/09/2018 12:56:02
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125 forum posts
39 photos
Posted by Andrew Johnston on 03/09/2018 09:16:09:

Almost certainly a tool change problem. It's normal to set X, Y and Z zeros using tool 0, the master tool. When you change to tool 1, say, which is a different length the machine needs to take that into account.

I've been looking at the code from Fusion, PP conversational, and Cut2D. I think the problem is that the Cut2D post-processor turns off tool length compensation (G49), then travels to Z20.320 which the post-processor is calling the home Z position. But when there is a tool sticking 70mm out this means it will plunge 50mm into the material! Only after this does it do the G30 like the others. It makes no sense to me, even if I had an empty spindle it is just an unnecessary Z move which will be undone by the G30 so I can put the tool in.

G0 G17 G21 G90 G40 G49 G64 P0.03
G80
G0 Z20.320 <--- Waste of time?
G0 X0.000 Y0.000
G30
T8M6
(End Mill {8 mm})
G43H8

The G0s between G80 and G30 are not required - PP and Fusion don't do them.

Andrew Johnston03/09/2018 16:12:29
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4155 forum posts
502 photos

Here's a snippet of my code with tool heights taken from the table at tool change:

N10 G21
N20 G0 G80 G17 G40 G94 G54 G49 G64 G90
N30 (2 1/2 Axis Profiling - Roughing-1)
N40 M09
N50 T01 G43 H01 M06
N60 S4000 M03
N70 G04 P3
N80 G90
N90 M08
N100 G00 Z1.500
N110 X-4.000 Y-85.100
N120 G01 Z-0.800 F600.0
N130 G01 Y-82.100 F150.0

There are a few oddities in the toolchange code, such as the G90, which is there for historical reasons, must get rid of it sometime. The G04 delay is to allow the spindle to get up to speed before moving axes when machine tapping. The following is the sequence I use after powering up the Tormach:

RESET the controller using the button on the screen

Reference all active axes using the buttons - I reference Z first in case there's anything in the way. This sets the machine co-ordinates using the limit switches

Set Z=0 on the mill table using tool 0, which in my case is a length of silver steel with a ballnose end and longer than any tool I'm likely to use

If I need to fill the tool table I use the electronic tool setter and the offsets screen making sure the tool number box represents the tool I want each time

Once the work is in place I set X=0 and Y=0 on the work, or fixture, according to where I've set the origin in the CAM program

I then set Z=0, using tool 0 with 0 selected in the tool window, on the work or fixture, again according to where the CAM program origin is set

Once that is done putting tool 1 in the spindle,and selecting tool 1 in the box, should give Z=0 at the same origin as set with tool 0

It may not be the most elegant method but it works for me. When I updated to PathPilot I had a disagreement with Tormach about using tool 0. They now recommend using the spindle nose rather than a master tool. But the spindle nose is big and clumsy, and you can't see what you're doing. So I don't use it.

The post-processor is part of the CAM program rather than part of the Tormach controller. It is normal to write ones own. Which is what I did for my CAM program (VisualMill). I've got two, one using tool tables and one not. I use tool tables 95% of the time. But when I use the high speed spindle I don't want to use tables, as the spindle has no repeatable way to swap tools.

Homing for tool changes is something I must sort out. At the moment I simply edit the G-code to put in a G0 Z100.00 to move the spindle up far enough for a manual tool change.

Roll on retirement, then I'll have time to sort out all these little issues!

Andrew

mechman4803/09/2018 19:17:09
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2140 forum posts
352 photos

Yesterday actually; replaced a defunct cooker hood fan that decided to stop working last week. managed to find a 'generic' replacement on 't'internet from electrical spares provider so with the aid of a builder friend & some fiddly manoeuvring managed to swap it out. Tested out fine before replacing hood on wall so job done, in the same context has anyone done the same /similar, & would any one know if these motors are repairable as it seem a waste to throw it out if it can be repaired, the replacement aint what I would call cheap, but a lot cheaper than buying a complete new hood.

TIA

George.

Neil Wyatt03/09/2018 21:30:04
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Moderator
14723 forum posts
628 photos
72 articles

I tried my first experiment with anodising today.

Just a rough-finished block that I had knocked up as a temporary telescope dovetail clamp, as it was the right size. Don't judge the workmanship!

The result was a very impressive colour, although I had to microwave the (industrial) dye to get it to work and yes it faithfully kept all the original machining marks. I can run a hardened steel screwdriver ove the finish with light pressure and it doesn't mark it, which is good.

More noticeable was where I had filled some wrongly placed holes with Alutite - they went black in the caustic soda, didn't anodise and didn't take any die. They look like JB Weld but aren't!

Tomorrow I will try a couple of 'proper' parts.

anodising test.jpg

Mark Rand03/09/2018 23:07:01
581 forum posts

I'm not sure I really want a finishing process that highlights all of my 'design changes'!

Sam Stones03/09/2018 23:50:37
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569 forum posts
188 photos

George (mechman48) ... I sent you a PM.

Regards,

Sam

Neil Wyatt04/09/2018 08:49:12
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Moderator
14723 forum posts
628 photos
72 articles
Posted by Mark Rand on 03/09/2018 23:07:01:

I'm not sure I really want a finishing process that highlights all of my 'design changes'!

The block has been repurposed at least twice - that's why I had to change the placement/size of holes.

It also shows the scratched and dings unanodised alloys collect when left rattling around for a year or two.

Neil

Robin04/09/2018 09:16:07
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294 forum posts
Posted by Neil Wyatt on 03/09/2018 21:30:04:

The result was a very impressive colour, although I had to microwave the (industrial) dye to get it to work and yes it faithfully kept all the original machining marks. I can run a hardened steel screwdriver ove the finish with light pressure and it doesn't mark it, which is good.

My one attempt at anodising preserved the metal most wondrously but I could not get the colour to penetrate.

Controlling the current using an auto bulb meant it took a lot longer than expected to convert and I thought that was the problem.

Please explain this microwaving thing if you have time. I thought hot water sealed the surface.

duncan webster04/09/2018 10:18:28
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1704 forum posts
10 photos

I trust we're to look forward to an article in MEW about anodising. I'm making some bits in ally which would look a lot better black.

Edited By duncan webster on 04/09/2018 10:18:47

Neil Wyatt04/09/2018 11:12:03
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Moderator
14723 forum posts
628 photos
72 articles
Posted by Robin on 04/09/2018 09:16:07:

Please explain this microwaving thing if you have time. I thought hot water sealed the surface.

It does, but the dye I'm using is optimised for 40-60C with lower temperatures giving a less intense colour.

Unlike most anodising dyes it's a chemical process based on ferric oxylate which reacts with the oxidised layer and the solution is bright green.

I'm following an industrial process which also means sealing in a cold seal solution then finishing with a simmer.

Neil

Neil Wyatt04/09/2018 11:14:03
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Moderator
14723 forum posts
628 photos
72 articles
Posted by duncan webster on 04/09/2018 10:18:28:

I trust we're to look forward to an article in MEW about anodising. I'm making some bits in ally which would look a lot better black.

Edited By duncan webster on 04/09/2018 10:18:47

Yes, I'm hoping for one, but it's unlikely to be written by me.

Out of interest, that Alutite has gone 'porous' on the surface - my guess is that zinc has leached out. If scratched it shows bright silver.

Neil

mechman4804/09/2018 14:21:42
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2140 forum posts
352 photos
Posted by Sam Stones on 03/09/2018 23:50:37:

George (mechman48) ... I sent you a PM.

Regards,

Sam

Thanks, replied via pm...

Geo.

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