New version 4.90.03 -- 4th axis

[ArtF]

Hi All:

  A new video at http://www.youtube.com/watch?v=UndFcWc38Wk illustrates the usage of the newly released
4th axis Gcode module. The dev version has now been updated to match the video as well. You can attempt any
type of gear tooth cutting, but as the video says..its early days so the algorithms will change as required over
the next while as we find its strengths and weaknesses.

  I have cut a spur for validation of the code, but only a spur, so be carefull if you get more complex till Ive had
a chance to cut other types.

Have fun, let me know your thoughts and how it works for you..

Art

[John S]

Good god man , couldn't you have split the video up.
Don't you realise just how hard it is to skive off for a whole 47 minutes and 16 seconds ?

Looking forward to watching it eagerly, thanks Art.

[ArtF]

lol.. yeah, that IS pushing it. I will probably be redoing it, I wasnt real happy with it to be honest, but I wanted to have some context
to the new module, its actually quite complex internally to make it seem easy externally.. but it takes a bit of artistic temperment to use it most efficiently..

Art

[Ya-Nvr-No]

Thanks, good timing I have some large XL pulleys to cut. But have a couple of issues.

Noticed the time and path display does not get reset, every time I hit gen paths it keeps adding to the values
Need a way to control the speed of the message displayed way too fast, I guess I don't read that well, lol
could be if i ran this on a larger monitor it would be easier to read, but this laptop makes the text hard to read.

And maybe I missed this somewhere:

1:/How do I control climb and conventional directions of cuts on 4th axis fly cuts?

2:/How do I control the part Z0 on the center of the pulley?
If I use a slitting type saw I want to be on center line on Z 0      Y radius plus cutter radius and clearance
If I use a profile end mill I need to be on Y 0.                            Z radius plus clearance


Clip of output for the 3" fly cutter

(Gearotic Thoughts Version 1.03 )
(Object Name:  Pulley-XL-1 )
(4th axis gear generation: Blank Radius: 6.36  Thickness of Blank:1.00 )
(Max Depth of cut for this file: 0.00 )
(Depth Per Pass: 1.00 )
(Spindle Speed: 3500  Feedrate: 10.00 )
(Tool Diameter: 3.0000 )
(Tangental shaving with involute shaped saw-flycutter.)

G20 S3500 T1 M6
          (Prolog Begins)

(  No Epilog set )

          (Program Begins)

G0        X 2.3000  Y 0.5000 Z 0.0000  A0.0000
          X 2.3000  Y -0.0654 Z 0.0000  A0.0000
G1 F10.0X -2.3000  Y -0.0654 Z 0.0000 A 0.0000
G0        X -2.3000  Y 0.5000 Z 0.0000  A0.0000
          X 2.3000  Y 0.5000 Z 0.0000  A1.8000
          X 2.3000  Y -0.0654 Z 0.0000  A1.8000
G1 F10.0X -2.3000  Y -0.0654 Z 0.0000 A 1.8000
G0        X -2.3000  Y 0.5000 Z 0.0000  A1.8000
          X 2.3000  Y 0.5000 Z 0.0000  A3.6000

[ArtF]

>>>Noticed the time and path display does not get reset, every time I hit gen paths it keeps adding to the values

  Thx, on my bug list, probably be fixed today or tomorrow..

>>Need a way to control the speed of the message displayed way too fast, I guess I don't read that well, lol

  Also on my list, be fixed same time.

>>1:/How do I control climb and conventional direction s of cuts on 4th axis fly cuts?

  You cant at the moment, it cuts back and forth, lowering each time. I will be adding options for various
things such as cutting in only one direction, but in this preliminary release, only the basic option of dual direction
cutting is implemented.

>>if I use a slitting type saw I want to be on center line on Z 0
>>If I use a profile end mill I need to be on Y 0.

  No matter which ( saw or bit), you zero at the spot shown on the screen. Zero all axis. The program will put out code appropriate for the saw, or flute, tangental
or fly positioning. It will take care of the conversion for all axis configurations as well, but at the moment you cannot swap sides for the saw, it always assumes the
position on the zero degree point, the saw cannot be at 180 degrees on the blank. ( luckily this matches the majority of configurations, but will appear as an option
eventually. ).

    This module is pretty preliminary , but will be developed slowly in conjunction with the other modules as they require extra power. Its being released now as I think
people need a way to cut the gears in 4th axis which has the ability to show graphically whats going to happen, GM's limitation in that regard bothered me quite a bit
as it required faith in the path, I prefer some verification graphic so your on the same page as I am. :)

Art


Art

[Ya-Nvr-No]

oops I was editing my last post as you posted a reply, :P
sorry

I understand now thanks, Looking forward to GT development because like you mentioned, was fighting a way to do this in GM

Just added a 4th axis 10" rotary table and 8 tool changer to my large table router so looking forward to swinging some large pieces (24" diameter 100" long).

Regards and thanks
Craig

[ArtF]

Craig:

  Ill be uploading a new version in 5 minutoes or so, so you should update. There is now in the options a time setting for the system messages
and the path times shoudl now reset. I didnt mention in the video you need to set your rapid rate so the times will at least be close on your system.


Be interesting to see how you make out, let me know what you see..all this will probably take quite a bit of refining to get it working as wel las it can.
There really isnt much 4th axis cad out there thats reasonable in price, so its all hard to compare to anything..

Art

[ArtF]

Craig:

  New version online ..should read 4.90.05 during install. Check options for time setting of messages.. Path times should reset now as well.

Art

[Ya-Nvr-No]

I assume the rapids are in mm per minute?

the other issue is I dont see what you show in your video. watched the movie after I last posted, learned a few things should have watched it before I posted. Sorry
No 4th axis, no cutters, no real definitive paths.

think because my default is in inches it could be why I am seeing screen issues. Or it could be this laptop. Might try installing on a workstation to see if thats it.

Regen works for the times but the Gen paths still add the times.

thanks for the added message timer option.

note: it's not an inch issue still same display problem in mm

Also I have 5axis MadCam and FeatureCam have not tried this gear cutting with them, another thing to do.

[Ya-Nvr-No]

Installed on a 64 bit system and graphics are all there, so it must be the 32 bit issue.

I guess I still dont understand how to orient the tools. They seem to be in line and on center with the gear shaft.

Noticed a bug, if I try to cancel out of an unnamed "post code" cnc output file it still creates a folder and file as untitled.

Craig

[Mooselake]

Art, from watching the first half or so of the video (sorry, got too late and too tired) it looks like it might be possible to build a gear machine that only needs driven X, Z, and A axis, and neither X or Z need a very big range.  Y, the displacement of the A center, could be manual since it doesn't change.  Is this true?

Kirk

[ArtF]

Kirk:

  Actually, in tangental cutting you need all 4 axis to move, the Y moves for tangental motion, the X to cut across the blank,
and the Z for depth...then a for rotation.. all 4 at once at times.. ( though only small motion of x,y,z are possible )

Art

[ArtF]

Craig:

Good point, as you know I use only metric,  I will run inch this afternoon to correct any issues..

Art

[Mooselake]

I'd already taken another look and realized I was wrong  :(  It'd still be a fun project.  I need a 110 tooth #40 chain sprocket for my hay mower, the price from the dealer is almost enough to build a machine to make one, and the project has been on a mental back burner for a couple years.  Openbuild extrusion and plates might make if fairly easy.

I'm stuck in a knee CPM machine for the next few weeks, lots of time to plan while I'm sitting around.

Kirk

[ArtF]

Kirk:

  Well, on the bright side you can now do sprockets on 4th axis, but due to the way the arcs in a sprocket work the rooting is fairly nasty, BUT with a very small depth per pass , it will actually do a pretty decent job at a sprocket, just some dressing with a file
I suspect.. In most 4th axis work under the new system, you can get alias artifacts on all but involutes, that will be typically approximately the size of the depth per pass settings and can be dressed away Id think....This is why I never allowed sprockets
and such in the past, but then as someone pointed out to me, better to have it half or 3/4 ass'ed than not at all.. :)


Art