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Check the difference in height between the puck and the spoil board. You may need to do some calibration. Or just 0 off of the spoil board.

The only problem with plasma is the edge hardening. If you can work around that, then you should be fine. Water jet would be my first choice if available.



That's odd, normally solid carbide...

No, not suitable at all for your proposed application. It would work on the control wiring of your VFD, but not the power input wiring.

The switches are rated for ''pilot duty'' only, and can not...

Hardinge stocks an amazing amount of mechanical parts for older machines. So mechanical parts are most likely available. On a control failure, I would just replace the original controls with modern...

I would use 0.2505 for easy removal. I would not expect the hole to get larger.

If I have a base, many times I would use a 0.2500 for the base hole for a tight fit, then would use a 0.2505 in the...

Look for a setting that says something like Arc Center Mode. When that is set incorrectly or doesn't agree with the G code it can cause the circles that you are seeing.

Is the ''crunchy'' feel coming from the ball nut, the thrust bearing, or the motor? I guess I would lube things up a bit, disconnect the motor from the screw and test again.

Some pictures would...

When I replaced my O-T control, I replaced the servos with modern hardware (DMM Tech), and powered the spindle motor (6S, 7.5kW) with a VFD. I gave up trying to interface with the original Fanuc...

For $10K I would pass, I would think about it at maybe $500 or so.

I have installed one on my lathe. Flashing Red = E-stop, or error. Green = Job running. Flashing Green = Job Complete

Like you, my keyboard normally sits on an extension shelf bolted to the mill table. I buy only the finest $5 keyboards and toss them when they no longer are useful. I normally get a year or better...

That seems reasonable. I just adjusted mine so I couldn't detect any movement by eye. I think your method might be more accurate.



With encoder feedback the controller is looking for some...

Maybe try reseating the CPU?

Renting a forklift might be a good option. If it really only weighs 2500 lbs. then good pallet jack could be used to move it around, also available for rent. At 2500 lbs, I would want a minimum of...

Yes, the Galil controller is very flexible and easy to use. It can output analog, step & direction, and PWM command signals. My preference when using them with modern AC servos is to set the drive...

Yes


Good question, it depends on the required torque for the operation


Yes. That type of motor should produce near full torque from 0 to near max RPM.


With the right controller it...

That's awesome! Wish you were closer to me, could have given you some work a few days ago.

It really depends on your control system (''brain''). Today I don't think it makes a lot of difference if you close the loop at the controller (''brain'') or the drive. The old way of doing it was...

Another vote for Fusion 360

Read the GS3 manual

The base speed for this motor is 1500 RPM. The minimum speed is about 10 RPM, effectively 0. This motor is virtually identical to my Fanuc.
...

On the GS3 the Max Hz is calculated from the Base Hz, Base RPM, and Max RPM. You don't set a Max Hz

First I would set Factory Defaults on the drive. P9.08 = 99

Then this is the way I would set it up. This should get it turning.

P0.00 = 200 Volts
P0.01 = 39 Amps
P0.02 = 50 Hz
P0.03 = 1500...

I would use Sensorless Vector mode, gives you constant torque at low speed. Setting the base frequency at 50Hz is fine, set the voltage for 200V, set the amps per the motor nameplate. At 50 Hz I...

By definition all servos are closed loop, the loop can be closed at the drive or the controller.

Every servo drive I have seen has an error (fault) output. Most have a settable encoder error...

Of course it's advertizing, and their tooling and possibly the machines are free to them.. But I was making a point. You can push a little harder and find the sweet spot for your application. The...

4130 will work harden also. It takes adjusting your mindset to start making some major chips.

Maybe this will help :D Titans of CNC has a lot of videos about how to increase production.

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Normally breakage like that is due to dull tools. 7 hours is not bad, but you might increase tool life by speeding things up a bit. You have plenty of machine there, why don't you try running at...

I just took a look at your last posted part. It seems that the heights need to be adjusted to get it to cut correctly. Note the Bottom Height, this could be done differently. I would normally...

Try selecting only the outside chain. Seems to work for me. Now why it doesn't work like before, I have no idea.