[Lathe] Fanuc OT to DC_CNC conversion

Another update:

I did make the first chips a couple of days ago, but it really doesn't count. I just took a light skin cut on a piece of stock using the MPG as part of getting the axis calibration and offsets figured out. Needed to figure where the spindle centerline was relative to the turret face and relative to the X home position and the tool setter. Figuring out exactly where everything is at on a CNC lathe is a lot more complex than a mill, I'm on a bit of a learning curve here.

I have all of the sheet metal back on so was able to test the coolant pumps. They work fine and are under computer control.

The next step is to get all of the offsets figured out in the software so it's operator friendly. When done, I'll be able to index through all of the turret positions and set all of the tool offsets from the tool setter. You can approach the tool setter from either side and is also useful for finding the exact width of a parting or grooving tool as well as locating the exact center of a drill bit.

Tool setter in the stored position
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Setting the X axis position. According to the manufacturer literature, the tool setter switches are good for +/- 1 micron. Close enough for me. :)
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And setting the Z axis position
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Lookin' great Jim.

MANY moons ago, I tried a toolsetter, much cheaper version. Did not have good results, or at least the needed accuracy. At the time, I thought the problem was as much my 30 year old lathe as it was the probe. Anyway, I'm back to making test cuts when accurate setting is required. Even after this, there is often a thou or so adjustment on part one. I will watch to see if yours does better.
 
Jim- awesome- now I see what you guys were chatting about in my thread w the Galil and box of Bugatti parts- awesome to see the work! From a rank hand-file and hacksaw level fellow looking at your work- looks awesome and thanks for sharing!
 
This is quite a complex project and your steady progress is inspiring. (still looking for video :) )
 
Karl_T said:
Lookin' great Jim.

MANY moons ago, I tried a toolsetter, much cheaper version. Did not have good results, or at least the needed accuracy. At the time, I thought the problem was as much my 30 year old lathe as it was the probe. Anyway, I'm back to making test cuts when accurate setting is required. Even after this, there is often a thou or so adjustment on part one. I will watch to see if yours does better.
Click to expand...

Thank you Karl. I expect the tool setter will be useful for rough setting even though it is supposed to be high accuracy. The tool bit will never approach the tool setter the same way it approaches the work, so I assume that some fine tuning will be needed when turning parts.

silverforgestudio said:
Jim- awesome- now I see what you guys were chatting about in my thread w the Galil and box of Bugatti parts- awesome to see the work! From a rank hand-file and hacksaw level fellow looking at your work- looks awesome and thanks for sharing!
Click to expand...

Thank you for the kind words. The Galil card is a very flexible motion controller and with a little planning can be used to run anything that needs to move accurately. I have been using them in projects for the last 20 years. I have proabaly installed about 70 or 80 of them in various machines all over the world, mostly in machines for the wood products industry.

Boswell said:
This is quite a complex project and your steady progress is inspiring. (still looking for video :) )
Click to expand...

Thank you. The video is coming soon. I have to pull off of this project for today and get some milled parts out the door. Actually will be a nice break, I've been over taxing my poor old brain trying to figure out all of the logic for the lathe systems. :)
 
I reached a new milestone today, I cut piles of air chips :grin:.

I finally got the tool offsets correct after realizing I was using the currently loaded tool offsets for all of the tools when I loaded the G-code, rather than applying the correct offsets for the planned tool for the operation. :mad: A little programming error. o_O I thought there was a problem with my math or machine calibration, but it turned out to be a problem with my program logic and order of operation. I was looking for the problem everywhere but where the actual problem was. Took about 30 seconds to fix it once I found it, just a quick change to 2 lines of code.:rolleyes:

Once I had that little problem solved (about a weeks worth of head banging:bang head: ), I was able to get a number of other little operational problems resolved like getting the spindle to run at the right time and turning the coolant off rather than on when it was supposed to be off and a few other minor housekeeping chores. So overall it was a good day.

Hopefully by the weekend I can start converting the 1000 lbs, or so, of aluminum and stainless bar stock that's sitting on the floor into useful parts. So the plan for tomorrow is to do a little fine tuning of the servos and make some real chips :)

Hopefully there will be a video tomorrow. It's been a long arduous journey to get to this point but I can now see the light at the end of the tunnel. :encourage:
 
Congratulations. Anyone that has done much programing knows exactly what you went through!
 
wow, I've never seen a pre 95 cnc with a tool eye. Pre 90's CNC's I have ran but I guess employers get cheap. Sounds familiar today even. Looking at that pick with the turning tool reminds me tool room lathe with just tool post. Is it 90 or 60 slant.
 
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