Hello everyone,
It seemed like it was going to be a promising week starting Monday when I finally started after months of preparation cutting my prototype product. I cannot say what the product is as of now, only the problems I am experiencing.
Let me start off by saying here are my specs:
Gecko 540
Keling 7.3 Amp;48 volt PS
Keling KL23H276-30-8B- Bipolar (Parallel) which is 4.2 Amps Per Phase
I have a 3.2K Set risistor on ea' axis.
***NOTE***Ok before I go on, to clarify I can push against my table as hard as I can and I can't get the motors to stall when jogging at 24 IPM Per axi. Seems like there is way to much power****nOTE*****
So my table has mounted a 7x5x.75 block of aluminum and using CUT 3D as my CAM for this 3d object. Work began all day monday. Monday was my first cut which consisted of a rough cut at:
.1875 endmill
15 IPm cutting
7 IPM plunge
1.5 mm doc
24 IPM Rapids all axis.
The rough cuts uses a Z-axis Rasta cut and then profiles the part for smoothness. The rough cut at first glance on Monday looked perfect! Until yesterday, I seemed to noticed that it had seemed to lose steps in the why because the part start a little head each time it x-axis down. (However, this is very minimal and with a total depth cut from 0mm-9mm it has progressed about 2mm which is not good but not the biggest problems here). So thats that.
I would like to note, that during this rough cut, the Z-axis retracts probably over two dozen times to cut different areas of my product. Make note.
So the rough cut was ok, now came what I thought would be the last of it; the Finishing Pass.
Specs:
.1875 Ball nose
20 Ipm
16 plunge Ipm
.40 mm DOC
24 IPm all rapids.
On the finishing pass, the z-axis only picks up about 5 times and moves to another area. It does not do the part in one pass because because I do not have it on a RASTA where it would try to cut the entire stock which would be a waste of time! My initial finish cut was done at a 45 degree angle. Everything at first looked great! Until I came back over and hour later and found the machine in the z-axis cutting just ABOVE THE STOCK. The x and Y axis seemed to be in the right area both on machine and screen. But the z-axis was above the stock not touching the metal, in fact it was over the stock about 3 to 4 mm moving but never touching the material. This resulted in my prototype not being properly finished and cut oddly. The basic shape was there, but the finish pass left smooth curves and stock rough cut to be untouched.
So after this, I ran numerous tests! I ran the finish pass again and again and again with a 135 degree angle, back to 45, then to a 90 and every time, in certain areas. The cutter was above the surface!!!!!! Some areas cut and then no areas cut and some areas from normal surface height to higher and higher to stock height of the material.
Then I said ok, maybe it's the speed. So I dropped the velocity on all axis on rapids, I dropped all cutting speeds. In fact! I even went so far to drop the Cutting IPM AT 6 INCHES A MINUTE! <------This turned out the worst!!!! I came back to see the cutter was about .50-.75 inches above the cutter in certain areas. The same areas that did not get cut over the past 5 times I ran the finish pass.
So again, I said WTF to myself! I ripped off my aluminum, I ripped off my jig and I slapped on some wood! I wasn't going to flip the wood after the cut because it was only a test to see if it would work; so no alignment jig needed with dowel pins! I redid some programming, figure I was in wood and could up the speed since 6 IPM on the finish pass showed no gooood! So I now ran the BOTTOM portion of the part which is identical to the top (Hence why I use a jig, so when it's flipped, it's right on 0,0). Anyway, I decided to do the rough cut on the bottom and proceeded with:
.1875 endmill
18 IPM
9 IPM plunge
24 IPM all rapids.
1.5 mm DOC
First layer all good, so I left. Came back. Y axis was out of wack, the part looked like steps. It started here, the here, then here, then here. So the part was useless.
Ran the file again on a new piece of wood! This time I dropped the program file from 100% down to 95% of speed. Left and came back and knew there was trouble. I saw my endmill was broken! Z-axis seemed to get stuck in wood and the table decided to move and snapped the tool! That just shows how much torque I must have. for that to happen! This part did the same thing; started here, then here, then here, then here. The x-axis every rough cut seemed fine, the y axis was off much more in WOOD then in Aluminum.
I have lost sleep over this, i thought after all the months of prepping the machine, new electronics, software upgrades, tweaking, jig making, that Monday the protype of my part was going to be made! (nuts)(nuts)(nuts)(nuts)(nuts)(nuts) I can keep going now.....(nuts)(nuts)(nuts)
I thought that this was at first software problem with Vectric cut3d, but changing the value of the Rapids seemed to mess everything up. So i assume this is machine/electronics error.
Here is why i posted this in the Gecko forum. My steppers are rated for 4.2 amps, the way they are wired. When I do a rough cut, there is less movement with all three axis. The z-axis sets it's depth in a plunge and then the the x and y do the work.
On the finish pass all three axis move together when making contours on edges etc. Lots of movement, maybe much more amps being drawn! I thought that maybe because I only have the 3.2 K resistor on ea' axis instead of a 3.5 K resistor, the steppers are not at efficient as they can be.
This all confuses me because everything seems to contradict itself. Cutting in aluminum at the initial test was bad, but not the worst. Figuring lowering the speeds would help, the z-axis ended up higher then originally thought. Cutting in would at the normal speed of the rough cut end up WAY worse then cutting in the aluminum.(nuts)
I am so exhausted from this week, frustrated and sad! I have prepped so long, was so excited and am dealing with such crap.
I have no idea what to do at this point. So maybe it's my resistors or maybe not enough amps for ea' axis to consume from only a 7.3 amp PS. ?????
Please for the love of god, help me members! Help!
-Jason