Help with determining spindle noise

December 24, 2013, 9:26 am

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I have a spindle that started to make noise at 10,000 rpm. This noise can be heard at the 22 second mark of the following youtube link.
Awea spindle noise at 10,000 rpm - YouTube
Any suggestions would be appreciated.
Thanks
Howard

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4th axis PVC pipe asymmetry mapping

December 24, 2013, 9:52 am

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I want to work with PVC pipe (3" dia.) on a 4th axis. My problem is the PVC pipe is not 100% round. My question is can I map the asymmetry (out of roundness) of the PVC pipe and modify my gcode in some software program to compensate for the out of round PVC pipe before I mill it? I was thinking of measuring each line before the mill passes and somehow creating a zero or baseline for the z-axis relative to the x-axis. I saw this Aussie machinist struggle with making lithophanes on PVC pipe with several attempts to get one without cutting all the way through. Thanks.

Involute Programming Verification - G02.2 / G03.2

December 24, 2013, 2:34 pm

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Hello,

I am trying to program an involute shape for a grinder with a Fanuc 31i controller. I am told you can use the G02.2 and G03.2 commands to do this.

I have access to Vericut, but can't seem to find a machine model that can recognize this command. Does anyone have one available? If not, is there a way I can add this to one of the existing sample models?

If not, is there a way of verifying that I am making the correct shape without testing it directly on the machine?

Best place to buy CT40 tooling for new haas VF3?

December 24, 2013, 5:19 pm

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Hi,

I am in the process of tooling up my new Haas VF3 w/ 4th axis.

What is the best supplier for cost effective tool holders?

I have been looking at Parlec and Techniks tool holders from ebay or Marshall Tool and Supply, does anyone have any better recommendations or suggestions?

My initial budget for tooling is $3-4k to start.

Horrid Loud BANG! Knew I shouldn't be working on Christmas Eve....

December 24, 2013, 10:48 pm

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Ah well, trying to wrap up the end of the year stuff, and now I have another problem. Perhaps one of you fine folks can steer me in the right direction and give me a bit of advice.

22.25" x 10" x 2" thick slab of 6061 improperly clamped; came loose when hit by a 3.86" diameter tool spinning at 5250 RPM, travelling at 155IPM on a mellow .144 Depth of cut. Part slid into adjacent part... Popped up and was torn loose and thrown off the table. Machine alarmed out.

Investigating the cause of the loud bang I noticed a couple alarms related to the ESTOP that cleared, while a EX1032 MAG SENSOR ERROR alarm remained. The cutter body is damaged, mostly because an insert screw let go and wiped out the pocket. Both drive keys disappeared and the screws holding them in place are sheared off. The tool holder itself has ripped loose material around both drive keys and it appears to have spun in the spindle, as there is evidence of scarring as seen in the photos below.



I was able to clear the Magazine Sensor Alarm (man this is the second time in a couple weeks I'm going to have to reload the magazine though... did I mention I'm beginning to develop a dislike for random pocket tool changers...) but for the life of me I can't get the tool out of the spindle.

I've bumped up the air pressure as far as I can, and whilst having someone hold the tool release button I've tried prying the tool out, and/or gently tapping the tool holder with a dead blow hammer. Short of the brute force method, and of you guys have a trick for getting out the stuck tool holder after the tool has spun?

The spindle fires up just fine and still sounds fine. Once I get the tool holder out, how do I repair the damage to the spindle? Can it be reground in place, or does it need to be removed to be ground. It's just a CAT40, no dual contact spindle. My 14 hour workdays are going to get longer still, since I'll need to swap over to a smaller machine to keep going, so getting this machine going quickly is going to be a high priority. Any help would be greatly appreciated.

Once the tool is gone I'll get to work on removing the stuck screws. Working overhead, that will be fun, I'm sure. At least there's plenty of room on the table and I can always bring the spindle down to a comfortable work height.

And Merry Christmas as well.

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How to activate G15/G16 Polar coordinate in Fanuc 21i-M

December 25, 2013, 6:41 am

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Hi there,

I have Cincinnati milacron VMC with Fanuc 21i-M controller. I want to use G15/G16 Polar co-ordinate in bolt circle program. But I got the message 010 improper G Code. Please let me know how to activate parameters for polar co-ordinate.

Ashish

fanuc-0 Mold Machining very slow..?

December 25, 2013, 1:37 pm

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I'm playing with some new software and for the fun of it, I made small and simple 3D mold pattern with some curvy surfaces. The software makes it very easy to design complex surfaces...then make tool paths to machine it. I'm new to this type of machining and I'm using a Fanuc-O controlled 40X20 VMC. I'm drip feeding the program...

When running the finishing passes with a ball mill, I notice that the machine slows down (feedrate)...way below the programmed federate. The feed nearly stops at it moves thru the complex 3d contours. I looked at the program and see that the tool path is written in thousands of little linear moves. Is there something that I can set or check to increase the speed of the machine. Like "exact stop" or some other parameter that might be bogging down the processor with an overload of streaming data....?

Like I said, this is new to me....I'm very comfortable with 2D stuff.....

Thoughts?

Cnc conversion

December 25, 2013, 3:41 pm

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Not sure if this is the right forum , am thinking of converting a 1340 Victor to cnc . Any opinions or web site advise?

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Heidenhain iTNC530 small question about "NC Stop" button.

December 25, 2013, 11:44 pm

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Hello everybody!
The button "NC Stop" is highlighted red anytime expect while "NC Start" is pressed or NC programm runs.

Is it correct?

Thanks in advance.

Soft limits on HH iTC 530

December 26, 2013, 5:12 am

≫ Next: Help desperately needed! Sinumerik 3T/Monforts RNC

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I am not very familiar with this control.
The machine X axis is equiped with linear scale length 3240 mm. The default axis travel is 3100 mm. Customer is playing with the soft limits to
define working areas for particular jobs.
Question: is there a set of "higher level" parameters (not accessable for machine operator) in which the default settings of maximum travel
are saved, to avoid the mistaken setting of soft limit beyond extreme values ?

Help desperately needed! Sinumerik 3T/Monforts RNC

December 26, 2013, 6:44 am

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Hi, we bought a used Monforts from 1984 and have had a nightmare trying to get it into service. Please can someone help?!

The control is a Sinumerik 3T. We are just a start up company and bought a machine with the promise that it worked. No such luck... After 9 months of slogging through various problems we are approaching the finish line but have lots of trouble finding help. The machine was bankrupt stock and was really badly uninstalled. Cables were just chopped with bolt cutters, etc. All this happened after we paid of course... We have cleared all the hardware alarms, everything from the chuck to the tailstock, and even had the machine running very briefly and it was beautiful.

The last problem we fixed was the contour monitoring problem, which we eventually found was down to some bad relays on one of the boards. After swapping them around we had the machine running. Finished, great! Such a happy few hours. I took out the board with the dodgy relays and sourced a replacement board and also some new relays. So we would have 2 of them.

I left the board out of the machine over night, and the next day completely forgot this and stupidly tried to fire it up without the board in. The machine's fans spun up, then down, then back up again. No idea if this was related to the missing board, or a power outage or something.

Now, we have the PLC/computer turning on as normal. But, now the main relay no longer comes on and none of the other familiar clicks that used to signal the machine powering up. We still have the original parameters of the machine, we have tried many procedures to restart the PLC, and now I wonder if I accidentally wiped the parameters, but even then, the control panel should come on...

Can anyone please, please give an idea where to look for whatever we just did. We really need this machine to work, unlike the jerk we bought it off I cannot in good conscience just palm this off on someone else, and we can't afford to scrap it. The most frustrating thing is, this machine is built like a tank and the few hours we had it running, it was like silk.

Ballscrew rebuild cost ? 40mm diameter

December 26, 2013, 11:42 am

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One at aprox 32" long and two at aprox 20" long. Any vague notion of cost to rebuild ? It if matters, this on early 90's VMC. No serious damage just screws a little noisier than I'd like. May be mostly thrust bearings but in case not, some idea of ball screw repair costs would be helpful. Could also need linear way work but will cross that bridge when it comes.

Fanuc Macro B... confused about looking at the Diagnostic or Ladder inputs?

December 26, 2013, 6:16 pm

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Hello, I would really like to try and write into one of my macros to look at a particular diagnostic input (10.4) or ladder (X010.4). Part of the macro might be { IF [10.4]=1 THEN #nnnn=0}. I see where where there are #1000-#1015 and #1100-#1115, though I do not think these are what I am looking for.

Can have a Macro at the Ladder or Diagnostic inputs?

Any insight would be great, thanks!

Manually Step Through Toolchange, Fanuc Omc?

December 26, 2013, 11:55 pm

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So I foolishly hit the reset button on my mill mid-toolchange (makino FNC-60, fanuc omc). I pressed the mechanical releases on the toolchange arm and have safely removed the tools from the arm, but now I need to send the arm back to home position in order to reset the toolchanger. There is a manual control panel on the side of the machine which has buttons to actuate this (B>A, A>B, etc), however this panel is completely unresponsive. Is there some sort of atc interlock button or manual override I need to press on the control in order to make these buttons respond? Is there a special mode to make these buttons respond or another way to home the toolchanger?

I would really appreciate any help. Of course none of us ever has time for a machine to be down, and my situation is no exception. On the upside, there are no mechanical or electrical issues, I just don't know the proper key sequence to manually home the toolchanger.

Mazak Lathe question; EWS VDI 40 live tooling compatibility

December 27, 2013, 6:53 am

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Hi guys. I've got a mazak qtn msy 200 and I'm looking to buy some radial live tooling for it. Found a VDI 40 from a company called EWS. First of all, will it fit? The shanks for the tools in my machine right now are 40mm so I'm assuming they should be good. Secondly, are they worthy tools or should I look elsewhere. It's a used pair for about a thousand. I know used tooling is tough to gauge, therefore, would you buy them if they were new compared to other brands?

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Lathe

December 27, 2013, 7:58 am

≫ Next: Looking for best PEEK supplier?

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Looking for suggestions on a decent cnc lathe to make wood baseball bats

Looking for best PEEK supplier?

December 27, 2013, 10:54 am

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Seems I'm doing a lot more with this material than I ever have and I wanted to check to see if my pricing was in the ball park.

110 pieces

1.00” x 1.10” x 1.375” PEEK

$8.85 each

Anyone else have a connection for good pricing on PEEK?

3D Printing

December 27, 2013, 12:00 pm

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Anyone have one? If so how are they? How do you like them?
3D Printing: Make anything you want - YouTube

2 Year old Haas VM2 trying to crash itself.... Sudden unexpected rapid movement...

December 27, 2013, 1:45 pm

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Hi Guys;

So, once again we will need your help with a very serious issue we ran into with our not even 2 year old Haas VM2.

The machine has been down since December 19th 2013 and we seem to be having some issues to get this properly addressed through Haas.

Here are the events the way they unfolded:




12/18/2013:

We are doing some very light milling on a 6061 Aluminum part with a 10mm endmill - 2.5mm stepover and 1mm down. On the second tool 5 passes inwards the machine out of nowhere switches from feed (4500mm/Min) to a rapid motion, continues to feed, breaks the cutter and alarms out with a 103 X Servo Error too large error. The cutter ended up nearly 1" away from the original toolpath and nearly crashed the machine during a rapid movement!

Please see a picture of the part attached to this email - it tells a very clear story of what happened.

12/18/2013:

We raise the issue with our HFO and ask them to notify Haas and to get feedback on what could have caused this and what needs to be done to fix it and make sure it doesn't happen again.

12/20/2013:

Even though our HFO did not receive feedback from Haas a technician updated the software. Unfortunately, he ran into several issues with the update and suspected the maincon to need replacement. We put a hold on the repair until we have official feedback from Haas explaining what could have caused this very severe error.

After the software update we are dealing with the following issues:

- Each and everytime we load a program from memory we get "Program Integrity Error"
- VQC will throw "Program Integrity Errors"
- Ethernet interface not working
- Spindle RPM limited to 177 RPM
- RS-232 Framing Error
- Setting CRC Error

Both HFO techs advised us that they wouldn't run the machine in its current condition and that the maincon needs to be replaced.

12/27/2013:

After one week of no feedback from Haas (not to us and not to our HFO) we try to escalate the issue with Haas. Even though our HFO advised that the maincon needs replacement Haas is now telling us that once the errors are cleared we should put the machine back to use. Haas does acknowledge that they have never seen an issue like this before, are unsure about what caused it and it looks like they simply want the customer to assume physical and financial risk in case the machine decides to rapid move again and crash into the next best fixture.

The one thing that Haas did see is that our code exceeded the 1000 BPS limit. At the same time, they acknowledge that this probably did not cause the issue we experienced. Personally, we are well aware of what happens when the controller is starved and this issue was clearly very different.




We are disappointed about the poor support, Haas not taking a much more pro- active approach to getting to the bottom of this and Haas simply wanting us to assume all risks with putting the machine back to use. We do not feel that this issue received proper attention and troubleshooting efforts were poor at best.

Even though we have talked to over a dozen experienced local machininsts nobody has ever seen an error like this before. Everyone is surprised about the approach Haas is taking and everyone is telling us that they wouldn't put the machine back to use unless the source of the error has been found and corrected.

Any advise on how to best handle this issue would be much appreciated.

Thanks as always!

Chad

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Fanuc OT a, b or c? How can I tell

December 27, 2013, 4:41 pm

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I am looking for a manual for my control. I am having a few issues programming stuff and I am sure I am just programing it slightly wrong. So I want to buy a manual. I have seen some for sale. But the say Fanuc OT-b or a. How do I know what control I have?

Any one know of a source for a manual? I have look all over the net and not had much luck finding what I am looking for.

Thanks ZachN