[SCzEngrgGroup]

With that processor I'd do atleast 45k

At 4060 steps/inch, there is ZERO benefit to increasing the Mach3 kernel speed above 25 kHz, and it often causes problems, even on fast machines. 25kHz is fast enough to run well over 300 IPM.

Regards,
Ray L.

[BAMCNC.COM]

I guess I'd stop the Porn watching while machining then.... Haha

I run 8000+ steps at 45k.

[Smertrios]

Maybe there are processes in the background running and using up CPU time? Ctrl+Alt+Del to open Task Manager then click the "processes" tab then the CPU column to sort it and see whats running much or even at all above 0%.

"clicking" reminds me of a busy computer when trying to run my TAIG with Mach3.

[ChrisAttebery]

I tried using a pulse width of 10us and kernal at 25k but it did not help. I also reran the driver test and was able to go all the way up to 100k without any problems. I don't think there is anything running on the PC that would cause slowdowns. It was a fresh install and I did all of the PC setup tips from Mach.

[cjsamples]

Chris,
I know this is a long shot but I found this problem a few years after I had gutted an older computer. This computer developed a mind of its own and would shut down on its own, just die. I pulled the power supply to make a bench power supply and when I opened it, I noticed the capacitors had ruptured and were leaking. Quick Google search and I found out about the cap problems on some of the older power supplies. Only certain years were an issue but that computer started doing some crazy things.
Might want to google power supply capacitor leaking and see if your power supply for the computer might be dropping out somewhere. Maybe not the main power but one of the lesser volt supplies might be dropping somewhere causing the train to slow down.

Might want to see if your CNC power supply is drooping under load as well. Since there hasn't been any new post I figure people are out of suggestions. The motor soulds like it is stalling out like you said and I wonder if voltage is an issue.
I just got my first cnc project so I will be dipping a toe into the great world of cnc. Nice big router table needing new electronics.

Chris

[ChrisAttebery]

FOUND IT!!!

I talked to Automation Technologies this week and they suggested I try setting the drivers to 1/8 stepping. That did seem to help either.

This mornign I looked at the PC and went through the XP Optimization document one more time. There was a section about ACPI. I tried setting the computer to "Standard" from "ACPI" and suddently the glitches were gone. :cheers:

Here's a video of the machine at 300IPM:
[ame=http://www.youtube.com/watch?v=Od9Pr1nlmnQ]G0704 steppers at 300 inches per minute - YouTube[/ame]

I'm waiting on CNC Fusion to send me a new Z screw and mount so that I can finish assembling the machine. I also received my treadmill motor this week, so I'll start looking at how to mount it up.


Chris

[ChrisAttebery]

I'm still waiting to get my new Z screw and mount from CNC Fusion. It was supposed to ship on Wednesday, but they haven't sent me the tracking number yet.

I decided to put the column and head back on the machine. After some tinkering I got the head trammed. I'm dying to make some parts on this thing and I have the oiler mount drawn up, so I'm going to try cutting it 2D with manual Z moves this weekend.

I needed a chamfer mill so I stopped by the tool shop this morning. I've been wanting to try an aluminum specific end mill so while I was there I picked up a "Best Carbide" 3/8 3F 45 degree EM. We'll see how it works out.

It's supposed to rain all weekend here, so I'll have plenty of time to tinker in the shop.


Chris

[BAMCNC.COM]

Is it ZRN coated? If so, you bought a great endmill, 3Flute all the way!

[ChrisAttebery]

No ZRN. I'm sure it will be much better than the cheap HSS EMs that I have been using though.

[SCzEngrgGroup]

No ZRN. I'm sure it will be much better than the cheap HSS EMs that I have been using though.

Actually, used properly, a good HSS 2-flute will provide all the performance your machine can support, and at a much lower cost that carbide. You're going to be limited by spindle RPM, power, and machine rigidity, all of which will prevent you from getting any real benefit from carbide, and force you down into RPMs and feedrate that HSS can easily handle.

A 3/8" 3-flute carbide running 0.1" DOC slotting wants to be spinning at 15K RPM, and feeding at 150 IPM in 6061,and your spindle will have to be putting out close to 2HP to do that. And you'll need a GOOD coolant and chip removal system. Can your machine handle that? I know my knee mill won't do it.

The same cut, using a HSS 2-flute, wants to run 6600 RPM, 44 IPM, and 0.5HP. Still almost certainly beyond the RPM and rigidity limits of your machine, but not by nearly as much.

High-quality, US-made (Putnam, Greenfield, Atrax, Hertel, and others) HSS 2-flutes (I typically buy 1/2 HSS endmills for about $12 each) are not only more than adequate for small machines, but will generally last longer, as carbide is much more easily damaged by re-cutting chips, spindle runout, thermal shock and many other factors.

Regards,
Ray L.

[ChrisAttebery]

Thanks Ray. I will keep than in mind. Unfortunately, the local machine tool supplier mostly caters to the big CNC shops. The have a very limited selection of HSS. I'll try ordering a few name brand USA end mills when I get the chance.

BTW: Where do you buy your tooling?

[waltpermenter]

Actually, used properly, a good HSS 2-flute will provide all the performance your machine can support, and at a much lower cost that carbide. You're going to be limited by spindle RPM, power, and machine rigidity, all of which will prevent you from getting any real benefit from carbide, and force you down into RPMs and feedrate that HSS can easily handle.

A 3/8" 3-flute carbide running 0.1" DOC slotting wants to be spinning at 15K RPM, and feeding at 150 IPM in 6061,and your spindle will have to be putting out close to 2HP to do that. And you'll need a GOOD coolant and chip removal system. Can your machine handle that? I know my knee mill won't do it.

The same cut, using a HSS 2-flute, wants to run 6600 RPM, 44 IPM, and 0.5HP. Still almost certainly beyond the RPM and rigidity limits of your machine, but not by nearly as much.

High-quality, US-made (Putnam, Greenfield, Atrax, Hertel, and others) HSS 2-flutes (I typically buy 1/2 HSS endmills for about $12 each) are not only more than adequate for small machines, but will generally last longer, as carbide is much more easily damaged by re-cutting chips, spindle runout, thermal shock and many other factors.

Regards,
Ray L.

what butt did you pull those numbers from? gwizard gives 7500 rpm, 67ipm and .53hp for your carbide 3fl at .100 slot. your hss specs are way beyond extreme too even using the vmc machine. Chris, get gwizard and get real speeds and feeds for your machine and don't listen to someone trying to scare you.
walt

[SCzEngrgGroup]

Thanks Ray. I will keep than in mind. Unfortunately, the local machine tool supplier mostly caters to the big CNC shops. The have a very limited selection of HSS. I'll try ordering a few name brand USA end mills when I get the chance.

BTW: Where do you buy your tooling?

I get most of my tooling from either Enco or MSC. Get on their e-mail lists, and wait for a 30% off sale, then stock up.

Regards,
Ray L.

[SuperFlyLoser]

I agree with Walt. Get Gwizard! I wanted to just solve everything on my own to include speeds and feeds. Its not that I didn't have the money just thought it was an easy mathematical equation that I would easily tackle. Well it ended up costing me the amount of a 1yr subscription to Gwizard in broken tooling or lost material.

I remember Ray posting a link to a free speeds and feeds calculator somewhere. I'm sure you could search for it. But I haven't compared it against Gwizard so I couldn't give you a review on it.

SFL

[BAMCNC.COM]

GWizard....I guess if you want to pay for it, over and over and over..

This is what I use. http://zero-divide.net/index.php

[zero_divide]

what butt did you pull those numbers from? gwizard gives 7500 rpm, 67ipm and .53hp for your carbide 3fl at .100 slot. your hss specs are way beyond extreme too even using the vmc machine. Chris, get gwizard and get real speeds and feeds for your machine and don't listen to someone trying to scare you.
walt

He gave you speeds-feeds for a carbide tool. And i assure you i have bushed them harder than that.

Here->FSWizardfor a 0.5" 3Fl HScobalt End mill recommends about 6000 RPM, 90IPM for full slot at 0.1" deep. Should pull 1.5 HP.

On a HAAS VMC i ran the same end mill at the same 6000@90 speed/feed 0.25 Deep !
Tool lasted for a week.

Carbide tool with the same settings lasted for 2 months.

for a 3/8 HSCO FEM it gives 7700RPM at 81 IPM when slotting 0.1 deep.

So yeah that 7500 RPM at 67ipm is in the range.

If FSWizard shows overload on power you should reduce depth of cut rather than feerdate. This way tool will do more work before it gets dull.
FSWizard may be free but experience and math put into are not worse that other paid-for software.

hey BamCNC thanks for shout-out!

[waltpermenter]

He gave you speeds-feeds for a carbide tool.

the specs i gave were for carbide too according to gwizard, even yours with a 3/8 carbide maxed doesn't come close to rays typical over exaggerations. my point to chris is to get the info for himself. there are tons of free s&f calcs on the web. gwizard isn't free but it comes with far more than feeds and speed. thanks for the link to your freebie.
walt

[SCzEngrgGroup]

He gave you speeds-feeds for a carbide tool. And i assure you i have bushed them harder than that.

Here->FSWizardfor a 0.5" 3Fl HScobalt End mill recommends about 6000 RPM, 90IPM for full slot at 0.1" deep. Should pull 1.5 HP.

On a HAAS VMC i ran the same end mill at the same 6000@90 speed/feed 0.25 Deep !
Tool lasted for a week.

Carbide tool with the same settings lasted for 2 months.

for a 3/8 HSCO FEM it gives 7700RPM at 81 IPM when slotting 0.1 deep.

So yeah that 7500 RPM at 67ipm is in the range.

If FSWizard shows overload on power you should reduce depth of cut rather than feerdate. This way tool will do more work before it gets dull.
FSWizard may be free but experience and math put into are not worse that other paid-for software.

hey BamCNC thanks for shout-out!

zero_divide,

Please don't waste your time responding to WaltP. He is by far the worst troll on all of CNCZone, as he's never once made a useful, helpful, or constructive post - only criticisms, snide insults, and nasty personal attacks. His only goal is to stir up trouble for his own sick amusement. Based on his posts, I very much doubt he has any actual machining experience at all. He will, of course, claim otherwise, but has never posted anything that would in any way provide back up for his claims. If he did know anything, you'd think he would have been able to contribute SOMETHING of value in his 92 posts to date, but he never once has. Most people here have had to learn to just ignore him, in the hopes that he'll eventually take the hint, get bored and go away, as most trolls eventually do when others stop "taking their bait". But he seems to be a slow learner....

Regards,
Ray L.

[zero_divide]

the specs i gave were for carbide too according to gwizard, even yours with a 3/8 carbide maxed doesn't come close to rays typical over exaggerations. my point to chris is to get the info for himself. there are tons of free s&f calcs on the web. gwizard isn't free but it comes with far more than feeds and speed. thanks for the link to your freebie.
walt

You are welcome.
..
No, No. He meant that for slow flimsy machines there is no reason to buy carbide tooling. That's all.
You will max out RPM long before you can realize the carbide tool's potential.

IE: At my work we have a HAAS. I run 1/2" 3Fl 2" long Hi-Helix EM at 10000RPM and 170 IPM and 0.25" depth of cut when slotting. And i go 250IPM for slotting at 0.125 deep.

If all i had was 5000 RPM i would go with HSCobalt or HSS just because i will never be able to utilize all of carbide potential at 5000RPM

BTW there ere not many free online/standalone calcs like FSWizard. in fact i dont know any.

@HimyKabibble
Hello Himy.
I dont ignore anybody and i am always willing to pick up a fight.

But thanks for warning

[waltpermenter]

You are welcome.
..
No, No. He meant that for slow flimsy machines there is no reason to buy carbide tooling. That's all.
You will max out RPM long before you can realize the carbide tool's potential.

IE: At my work we have a HAAS. I run 1/2" 3Fl 2" long Hi-Helix EM at 10000RPM and 170 IPM and 0.25" depth of cut when slotting.

If all i had was 5000 RPM i would go with HSCobalt or HSS just because i will never be able to utilize all of carbide potential at 5000RPM

Yes i agree these benchtop machines aren't Haas's and one would be foolish to expect similar performance. tools have a range of recommended sfms so running at the low end of the range does put it within the realm of some benchtops. only giving a newbie the maxed out specs is of little value. again he needs to get the info himself with the aide of a good calc like yours.
some people don't like to be questioned and have to resort to rants and name calling, pity.
walt