[Goose80]

Hello.
I was using my router for a almost 2 years now. But after I moved machine in the new shop I got a strange problem.
Every time I try to cut outside circle I get a circle axacly 0,2mm bigger. Every time I try to cut inner circle (hole) I get 0,2mm smaller. When I cut a square outside I get 0,3mm bigger.


So When I cut a circle with ø10mm on the outside I get 10,2mm. When I cut a hole ø3mm I get 2,8mm. When I cut a square 7x7mm I get 7,3x7,3mm.


My setup is:
Windows XP with 3ghz cpu.
Ethernet SmoothStepper
PMDG-122 Brakeout board
KL-8070 Stepper Drivers
2Nm Nema 23 motors (8-leads)
48V PSU capable of delivering 24A constant
Kress FME 1050W
ø16mm 1605 Ballscred an all axis
ø16mm Shafts with SMUU bearings


What I have tried:
1. I changed location of all cables.
2. I changed location of spindle cable.
3. Changes back and forth microsteps.
4. Calibrating steps per. But this is weird as it worked before.
5. Reinstalling (everything with newest drivers and versions)and setting up Mach3 and SmoothStepper for skratch.
6. Tried 3 different PCs included Laptop with Win7 64-bit. Each time new setup.
7. Screaming at whole system
8. Curse at whole system


What i suspect:
My new location has a little mote humility.
1. Maybe PMDX-122 is going crazy?
2. Maybe SmoothStepper is going crazy?
3. Maybe Stepper Motor Drivers are going crazy??
4. Some kind of Noise doing it? But noise is never so consistent.


Any more ideas?

[Dylwad]

What machine?
Big temp difference between the old and new place? Have you checked backlash?

Even with an all aluminum and steel machine, I have to re calibrate steps per inch for summer and winter to hold tolerances. Not as bad as .2mm though, more like .05mm.


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[Goose80]

Hey thx for answer but before I had like 23degC now I have like 18-22degC.
My machine is self made:
Attachment 195344Attachment 195346Attachment 195348Attachment 195350

I have done some more tests.
Using ø1,5 flat end mill and this program genereted from HSM Works:

(2D CONTOUR1)
(T1  D=1.5 CR=0. - ZMIN=-1.5 - FLAT END MILL)
G90 G94 G40 G49 G17
G21
G28 G91 Z0.
G90

(2D CONTOUR1)
M9
T1 M6
S10500 M3
G54
M9
G0 X-0.75 Y3.5
G43 Z15. H1
Z1.
G1 Z-1.5 F150.
Y7. F300.
G2 X0. Y7.75 I0.75 J0.
G1 X7.
G2 X7.75 Y7. I0. J-0.75
G1 Y0.
G2 X7. Y-0.75 I-0.75 J0.
G1 X0.
G2 X-0.75 Y0. I0. J0.75
G1 Y3.5
G0 Z15.

M9
G28 G91 Z0.
G28 X0. Y0.
M30

After cuting it, I get X: 7,3mm Y:10,4mm

I done the same test without SmoothStepper. Same result.
I also checked steps per and it is correct. It has to be some kind of noise...?

More test tomorrow:
1. I got 4 stepper drivers and I am going to change the one on X axis to the one that is not used.
2. I am going to use a owen and warm up case with stearing to 23degC, just to see if there is a difference.

If that not helps. I probably have to buy new Breakout board to check if all is fine with it.

Any other suggestions?