On Tue, 2009-09-29 at 17:04 +0100, Andy Pugh wrote:
... snip
> 
> > http://www.youtube.com/watch?v=NDA48nLdbiI
> 
> More data after a long discussion on the IRC channel:
> HAL setup: http://www.pastebin.ca/1581821
> Halscope grabs:
> http://www.atp.pwp.blueyonder.co.uk/G76.png
> http://www.atp.pwp.blueyonder.co.uk/g76b.png
> 
> It seems to be related to the index pulse rate. But there is no trace
> of the index pulse in the input to motion.spindle-revs
> 
> --
> atp

I have only read the original post and watched the video, so I may be
off base here. I had the same symptoms on my lathe. I believe the thread
pitch and spindle RPM are at a rate that is beyond the Z axis abilities
to accelerate. I slowed my spindle RPM down and allowed for a fair
amount of air cutting to allow Z to stabilize before reaching the real
threading. I also tried to optimize my acceleration settings. Too high
of an acceleration number created following errors, so it's a
compromise. Basically your Z cannot instantly accelerate to match the
spindle RPM. It's like trying to grab onto a moving carousel. It just
came to mind, I wonder if changing the spindle RPM would help -- slow at
first, fast in the middle or the tread, then slow again at the end?
-- 
Kirk Wallace
http://www.wallacecompany.com/machine_shop/
http://www.wallacecompany.com/E45/index.html
California, USA


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