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PM932 CNC Build

Discussion in 'MACHINE BUILD LOGS' started by jbolt, Mar 11, 2014.

  1. jbolt

    jbolt United States Active User H-M Supporter-Premium

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    More progress. Getting close to completion. Finished all the electrical wiring and managed not to let any of the magic blue smoke escape.

    Got the home/limit switches installed. I originally planed on using optical switches in sealed enclosures but decided to install inductive proximity switches simply because the install was simpler. These may be temporary or permanent depending on performance. The z and x switch are out of the way or protected from coolant and chips but I still need to make a cover and wiper for the y switch.

    Coolant system (pond pump in a bucket) is hooked up and running via a switch on the control panel. For now the coolant pump will be switched manually but I have provisions to run it from Mach3 if I decide to do so in the future.

    The lights on the machine are Malibu 20w halogen garden lights run by a 12vac power supply in the control box. Lights are on magnetic bases so they can be moved around for better positioning depending on the work piece. I have used the same lights on my Smithy Granite for the last 10 years with great success.

    Started on the coolant enclosure today. The framework is installed, just need to finish hanging the rest of the shower curtain liners.

    Next step is o make the protective covers for the x and y motors and belts.

    All three axis have been powered up and jogged back and forth. It's really satisfying to finally see things moving.

    Jay

    20140426_PM932_014.JPG 20140426_PM932_013.JPG 20140426_PM932_004.JPG 20140426_PM932_005.JPG 20140426_PM932_006.JPG 20140426_PM932_007.JPG 20140426_PM932_008.JPG 20140426_PM932_009.JPG 20140426_PM932_003.JPG 20140426_PM932_011.JPG 20140426_PM932_010.JPG 20140426_PM932_012.JPG 20140426_PM932_015.JPG 20140426_PM932_002.JPG 20140426_PM932_001.JPG

    20140426_PM932_001.JPG 20140426_PM932_002.JPG 20140426_PM932_003.JPG 20140426_PM932_004.JPG 20140426_PM932_005.JPG 20140426_PM932_006.JPG 20140426_PM932_007.JPG 20140426_PM932_008.JPG 20140426_PM932_009.JPG 20140426_PM932_010.JPG 20140426_PM932_011.JPG 20140426_PM932_012.JPG 20140426_PM932_013.JPG 20140426_PM932_014.JPG 20140426_PM932_015.JPG IMG_0001.JPG IMG_0002.JPG IMG_0003.JPG IMG_0004.JPG IMG_0005.JPG IMG_0006.JPG IMG_0007.JPG IMG_0008.JPG IMG_0009.JPG IMG_0010.JPG IMG_0011.JPG IMG_0012.JPG IMG_0013.JPG IMG_0014.JPG IMG_0015.JPG
     
  2. Boswell

    Boswell United States Hobby Machinist since 2010 H-M Supporter-Premium

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    Very Impressive Jbolt. Thanks for all the pictures. I really like the chip pan.
     
  3. bvd1940

    bvd1940 United States Active User Active Member

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    No, found out there on a slow boat from China lol.:nuts:
    Oh well that gives me some time to get a few things ready.
     
  4. jbolt

    jbolt United States Active User H-M Supporter-Premium

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    Woo Hoo! It"s ALIVE!

    Ran my first test part today. I don't have the motor splash guards made yet so I ran some plastic sheet. Made the drawing in Solidworks and saved it as a dxf file. Imported the dxf into d2nc for the g-code. The circles came out spot on but the outside is 0.002" under size. Not sure if this is due to running the plastic dry, backlash or the motors need more tuning.

    Jay

    20140430_PM932_CNC_002.JPG

    20140430_PM932_CNC_002.JPG
     
  5. jbolt

    jbolt United States Active User H-M Supporter-Premium

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    Spent some time today making mock ups of the lower motor cover. I could have just done it in CAD but sometimes I find it easier to do physical mock ups to see how parts interact in real tine. Once I had the mock up done to my satisfaction I then did them in CAD. Solidworks has a sheet metal tool set which allows you to flatten the part and make a template. All the parts are cut out ready to bend this weekend when I can get into the robotics lab to use the brake.

    20140430_PM932_CNC_003.JPG 20140430_PM932_CNC_004.JPG 20140430_PM932_CNC_005.JPG 20140430_PM932_CNC_006.JPG motor_cover.png 20140430_PM932_CNC_007.JPG 20140430_PM932_CNC_008.JPG

    20140430_PM932_CNC_003.JPG 20140430_PM932_CNC_004.JPG 20140430_PM932_CNC_005.JPG 20140430_PM932_CNC_006.JPG 20140430_PM932_CNC_007.JPG 20140430_PM932_CNC_008.JPG motor_cover.png
     
  6. fatphatboy88

    fatphatboy88 United States Iron Registered Member

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    Looks great Jbolt. Also about the plastic you cut being under size. Have you measured your end mills to see exactly what their true size is and are you running any cutter compensation? I ran into that problem at work where outside profiles were coming out +.003" and inside pockets were -.003". Turned out my 1/2" cutter was .006" under sized at .494". If that isn't it then you can always run machine compensation to make up the difference.
     
  7. jbolt

    jbolt United States Active User H-M Supporter-Premium

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    Finished the motor covers and got them installed. Decided to make a vise speed handle as a first project. The plastic part is a test part I ran prior to having splash guards on. The g-code for plastic part was done in D2NC. The aluminum parts g-code was generated from HSM Express which is a free 2.5D CAM software that is used from within Solidworks. HSM is a lot more difficult to use out of the box but I like the fact that integrates with Solidowks. I'm having trouble with the post processing code not matching what I see in the CAM simulations. So far I have done the drilling ops, the hex holes and a fixture to hold the parts to do the outer contour. I also plan on doing a chamfer on the edges. Video is the end of the final profiling pass on the fixture.

    20140504_PM932_001.JPG 20140504_PM932_002.JPG [video=youtube;D5uw1u6N960]https://www.youtube.com/watch?v=D5uw1u6N960[/video]

    20140504_PM932_001.JPG 20140504_PM932_002.JPG
     
  8. jbolt

    jbolt United States Active User H-M Supporter-Premium

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    Finished up the vise handle. Tried using hsm express but kept running into post processing problems with Mach3 so I finished with D2NC.

    20140505_PM932_001.JPG

    20140505_PM932_001.JPG
     
  9. JimDawson

    JimDawson Global Moderator Staff Member Director

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    Nice job. Congratulations on your first successful run.
     
  10. jbolt

    jbolt United States Active User H-M Supporter-Premium

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    Thanks Jim. Thanks for your help on the wiring.
     
  11. bvd1940

    bvd1940 United States Active User Active Member

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    Nice:)) I are still lurking waiting for my ballscrews that are hung up in customs:angry:
     
  12. jumps4

    jumps4 Global Moderator Staff Member Active Member

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  13. jbolt

    jbolt United States Active User H-M Supporter-Premium

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    Bill, next time tell them not to mark the package "Radioactive" !!!!!!!!
     
  14. jbolt

    jbolt United States Active User H-M Supporter-Premium

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    HSM comes with a Mach2 & 3 post processor My problem has been the learning curve of the program (and impatience on my part). I have a difficult time understanding new concepts just by reading when I have no background to pull from. I learn better by example.

    It amazes me sometimes how the simplest tasks are the most difficult to figure out how to do. I must have spent 4 hours trying to create the tool paths for a double step down on one straight edge of a part. I could get the first step to work but not the second. Hours of searching and reading yielded nothing. I finally gave up and wrote the code by hand in less than 10 minutes.
     
  15. jumps4

    jumps4 Global Moderator Staff Member Active Member

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  16. bvd1940

    bvd1940 United States Active User Active Member

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    Ya think that would work :roflmao:
    Typical government bureaucratic bull :angry:
     
  17. jbolt

    jbolt United States Active User H-M Supporter-Premium

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    BBWWWAAAAAAAA!!! My controller pc died in the middle of a parts run that needs to be done by Monday. :angry:. Something on the MB or CPU is toast.

    Last year I purged most of my spare PC parts and kept this box because it had been reliable. Now I have to scrabble to get something put together to get these parts done by Monday. I have new Zotac mini-itx MB I was saving to use to run a remote weather site. All it needs is a CPU and a stick of memory. I ordered those from NewEgg yesterday and expedited the shipping. The memory will be here today. The CPU got miss-labeled and is on its way to Pennsylvania!!!!!! Hopefully NewEgg will come through on correcting the situation.

    I have a spare laptop I could scrape and reload the OS but it only runs properly on Vista or win 7, no proper drivers for XP. I'm leery due to all the problems I've read about trying to run mach3 on a laptop. Fortunately I had backed up my Mach3 settings.

    Sometimes I really hate technology.

    J~
     
  18. JimDawson

    JimDawson Global Moderator Staff Member Director

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    You're in Silicon Valley, there has got to be some parts around. There is always the quick run to the corner Fry's.
     
  19. jbolt

    jbolt United States Active User H-M Supporter-Premium

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    You would think. Unfortunately I need an older"ish" CPU for the board I have. I may have tracked one down, I'll know in the morning. My CS experience today with Newegg was absolutely unbelievable. Enough so I will never do business with them in the future.
     
  20. John Hasler

    John Hasler United States Active User H-M Supporter-Premium

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    What CPU do you need?
     
  21. jbolt

    jbolt United States Active User H-M Supporter-Premium

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    Socket 775
     
  22. JimDawson

    JimDawson Global Moderator Staff Member Director

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    If you were a bit closer, I would give a you MB. I have 6 or 7 of them sitting in my computer grave yard, just about in arms reach, and I think most of them work.

    Best of luck
     
  23. jbolt

    jbolt United States Active User H-M Supporter-Premium

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    Thanks for the offer Jim! Me and the wife did pass through your part of the country last year. Toward the end of a 2 week road trip we drove around Mt Hood then took 211 down toward Salem. Pretty country.
     
  24. jbolt

    jbolt United States Active User H-M Supporter-Premium

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    I was able to source a used CPU from a local computer repair shop and got my system back up and running last Friday in time to get the parts I needed done by Monday. Phew!!!

    Monday I started on the power drawbar parts. For some reason on these parts I ran into finish problems on the outer contours. I'm assuming it is from chip buildup in the slot. I ran these parts with a 1/4" 2-flute end mill at 10in/min at 2000rpm with 0.025" DOC. Coolant was on full. I did not employ any finishing passes. Other parts in thicker material with 3/8" and 1/2" end mills did not have this problem so I was somewhat surprised. Either I need more coolant pressure/volume, run finishing passes or both?

    Jay 20140519_PM932_001.JPG 20140519_PM932_002.JPG 20140519_PM932_003.JPG

    20140519_PM932_001.JPG 20140519_PM932_002.JPG 20140519_PM932_003.JPG
     
  25. JimDawson

    JimDawson Global Moderator Staff Member Director

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    That looks like chip buildup, I have the same problem sometimes. More flood coolant might help, but my preferred method in aluminum is to use my spray mist system with WD-40, with lots of air flow to blow the chips out. A climb finish pass should pretty much eliminate the problem, I usually leave 0.015 for a full depth finish pass.
     
  26. jumps4

    jumps4 Global Moderator Staff Member Active Member

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    I was having the same finish problem at times, what I started doing was to tell d2nc my cutter was a few thousands larger than it is for the outside profiles and I'd do the offset then I would reopen the file and make another offset to do a final pass at full depth and tell d2nc the correct cutter size. It finishes the entire part at full depth in one pass just removing a few thousandths.
    steve
     
  27. jbolt

    jbolt United States Active User H-M Supporter-Premium

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    Today I got air installed on the machine and the power drawbar finished. I replaced the stock drawbar with a one piece replacement drawbar for a bridgeport mill. The new drawbar is 1.25" longer so I turned a spacer to make up the difference. Air is supplied by a small compressor under the chip tray. Also added an air nozzle though I dont use these much.

    Also added a selector switch and rewired the control box to have mach3 turn on the spindle and coolant or they can be run in manual mode.

    20140525_PM932_001.JPG 20140525_PM932_002.JPG 20140525_PM932_003.JPG 20140525_PM932_004.JPG 20140525_PM932_005.JPG 20140525_PM932_006.JPG

    20140525_PM932_001.JPG 20140525_PM932_002.JPG 20140525_PM932_003.JPG 20140525_PM932_004.JPG 20140525_PM932_005.JPG 20140525_PM932_006.JPG
     
  28. JimDawson

    JimDawson Global Moderator Staff Member Director

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    Looking good!
     
    Last edited: Jan 21, 2017
  29. jbolt

    jbolt United States Active User H-M Supporter-Premium

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    Tonights project is a lathe stop. I tried doing the operation using tabs to hold the part but I made them too thin and I think the placement of the tabs was poor. The part came out okay but was not rigid enough for the finishing passes. I'm going to try this again using a fixture to hold the part through the holes for the magnets.


    photo 1.JPG photo 3.JPG

    photo 1.JPG photo 3.JPG
     
  30. zmotorsports

    zmotorsports United States H-M Supporter - Premium Content Staff Member H-M Supporter-Premium

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    Very nice setup and beautiful work.

    Thanks for sharing.

    Mike.
     

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