Re: [Emc-users] Youtube 5axis cutting an impeller

2013-04-15 Thread Rudy du Preez
Thanks for all the interest.

I used Mastercam at a friend of mine. The impeller CAD model was fetched
somewhere from the Internet. I wrote my own post processor in Delphi - it
reads the NCI file that Mastercam creates. This file has the tip and tail 3D
coordinates of the tool in the toolpath in world or part coordinates. From
this it was easy to determine the A and C angles for the 4th and 5th axis in
part coordinates. The XYZAXkins that I wrote expects part coordinates. For
the impeller the part coordinates' origin is in the center of the blank on
the top surface. The post-processor also displays the toolpath and tool
vector in 3D, but with the tool fixed in space and the part moving (opposite
to what AXIS shows).

The setup is just a test - two rotary tables fitted with stepper motors. The
bigger rotary table (red) is fitted on the machine's table with its axis
parallel to the machine's X-axis (provides the A-axis). The smaller rotary
table is fitted on an angle plate which is fitted to the bigger rotary table
so the its axis is vertical parallel to the spindle axis or z-axis when in
the A = zero position. It provides the C-axis.

The machine is a Hermle 780. Its spindle is fixed and the table moves
up-down, left-right, and forward-backward. In the movies it may look as if
the spindle is moving up-down - this is not the case, the camera was mounted
on the table.

Backlash was adjusted as best I could - the rotary tables are not the best
quality. I was not concerned about the accuracy, just the functional testing
of the kinematics component. I was only cutting a soft material at
relatively slow speed. The movies were speeded up 200% to shorten their
playing times.

The component actually used 6 axes. The 6th axis is used to do indexing
between the blades of the impeller. The Gcode is provided for preparing the
blank (1st movie) and then to remove the material between the blades at one
indexing station only (2nd movie). The 6th axis adds a rotational increment
for each blade so the Gcode is used over and over again with a relative
indexing C-axis move between blades..

I have designed a complete trunnion table to replace my test setup. This has
a 140mm C-axis rotary table built in to a yoke including a concealed stepper
motor. The yoke is supported at both ends in bearings and is turned at one
end by a larger stepper motor. The trunnion table will be built as soon as I
have completed the conversion of my latest machine, A Hermle PF1000.

If I knew how and where I could post some pictures of the machine used here
and the new trunnion table.

Hope this background answers most of the questions.
Rudy


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Re: [Emc-users] Youtube 5axis cutting an impeller

2013-04-15 Thread jeremy youngs
THANK YOU and great work


On Mon, Apr 15, 2013 at 2:31 AM, Rudy du Preez r...@asmsa.co.za wrote:

 Thanks for all the interest.

 I used Mastercam at a friend of mine. The impeller CAD model was fetched
 somewhere from the Internet. I wrote my own post processor in Delphi - it
 reads the NCI file that Mastercam creates. This file has the tip and tail
 3D
 coordinates of the tool in the toolpath in world or part coordinates. From
 this it was easy to determine the A and C angles for the 4th and 5th axis
 in
 part coordinates. The XYZAXkins that I wrote expects part coordinates. For
 the impeller the part coordinates' origin is in the center of the blank on
 the top surface. The post-processor also displays the toolpath and tool
 vector in 3D, but with the tool fixed in space and the part moving
 (opposite
 to what AXIS shows).

 The setup is just a test - two rotary tables fitted with stepper motors.
 The
 bigger rotary table (red) is fitted on the machine's table with its axis
 parallel to the machine's X-axis (provides the A-axis). The smaller rotary
 table is fitted on an angle plate which is fitted to the bigger rotary
 table
 so the its axis is vertical parallel to the spindle axis or z-axis when in
 the A = zero position. It provides the C-axis.

 The machine is a Hermle 780. Its spindle is fixed and the table moves
 up-down, left-right, and forward-backward. In the movies it may look as if
 the spindle is moving up-down - this is not the case, the camera was
 mounted
 on the table.

 Backlash was adjusted as best I could - the rotary tables are not the best
 quality. I was not concerned about the accuracy, just the functional
 testing
 of the kinematics component. I was only cutting a soft material at
 relatively slow speed. The movies were speeded up 200% to shorten their
 playing times.

 The component actually used 6 axes. The 6th axis is used to do indexing
 between the blades of the impeller. The Gcode is provided for preparing the
 blank (1st movie) and then to remove the material between the blades at one
 indexing station only (2nd movie). The 6th axis adds a rotational increment
 for each blade so the Gcode is used over and over again with a relative
 indexing C-axis move between blades..

 I have designed a complete trunnion table to replace my test setup. This
 has
 a 140mm C-axis rotary table built in to a yoke including a concealed
 stepper
 motor. The yoke is supported at both ends in bearings and is turned at one
 end by a larger stepper motor. The trunnion table will be built as soon as
 I
 have completed the conversion of my latest machine, A Hermle PF1000.

 If I knew how and where I could post some pictures of the machine used here
 and the new trunnion table.

 Hope this background answers most of the questions.
 Rudy



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Re: [Emc-users] Youtube 5axis cutting an impeller

2013-04-14 Thread Tomaz T .
Here is also my test of running heavy 5axis code on linuxcnc. 
Code was generated by NX.

At 1 min it shows up embedded screen of linuxcnc ruining it.

I tried also final passes, but executing it was way to slow... anyway, this 
issue is already discussed in other topic.

http://www.youtube.com/watch?v=iy1Mb6G_VJ0feature=youtu.be 
  
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Re: [Emc-users] Youtube 5axis cutting an impeller

2013-04-14 Thread dave
On Sun, 2013-04-14 at 11:55 +, Tomaz T. wrote:
 Here is also my test of running heavy 5axis code on linuxcnc. 
 Code was generated by NX.
 
 At 1 min it shows up embedded screen of linuxcnc ruining it.
 
 I tried also final passes, but executing it was way to slow... anyway, this 
 issue is already discussed in other topic.
 
 http://www.youtube.com/watch?v=iy1Mb6G_VJ0feature=youtu.be   
   

Hi tomaz, 
Nice video! What kind of plastic are you machining?

Dave


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Re: [Emc-users] Youtube 5axis cutting an impeller

2013-04-14 Thread Andrew
2013/4/14 Tomaz T. tomaz_...@hotmail.com

 Here is also my test of running heavy 5axis code on linuxcnc.


Great! But the rotary spindle is not seen well, I'd like to look at the
design.


 Code was generated by NX.


Which postprocessor was used?


 At 1 min it shows up embedded screen of linuxcnc ruining it.

 I tried also final passes, but executing it was way to slow... anyway,
 this issue is already discussed in other topic.


I must have missed it, can you point to that topic?


 http://www.youtube.com/watch?v=iy1Mb6G_VJ0feature=youtu.be

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Re: [Emc-users] Youtube 5axis cutting an impeller

2013-04-14 Thread Tomaz T .
rotary head is produced by this guy, I only reinforced it for my needs... 
http://www.doughtydrive.com/

Postprocessor is slightly modified one of the native 5axis post in NX.


Topic about execution speed is named Poor CV




 Great! But the rotary spindle is not seen well, I'd like to look at the
 design.


 Code was generated by NX.


 Which postprocessor was used?


 At 1 min it shows up embedded screen of linuxcnc ruining it.

 I tried also final passes, but executing it was way to slow... anyway,
 this issue is already discussed in other topic.


 I must have missed it, can you point to that topic?


 http://www.youtube.com/watch?v=iy1Mb6G_VJ0feature=youtu.be  
   
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Re: [Emc-users] Youtube 5axis cutting an impeller

2013-04-14 Thread Andrew
2013/4/14 Tomaz T. tomaz_...@hotmail.com

 rotary head is produced by this guy, I only reinforced it for my needs...
 http://www.doughtydrive.com/

 Oh, I've seen those heads on the net. Just wonder what's inside - some
belts or kind of harmonic reducer?


 Postprocessor is slightly modified one of the native 5axis post in NX.

Topic about execution speed is named Poor CV


Thanks!



 
 
  Great! But the rotary spindle is not seen well, I'd like to look at the
  design.
 
 
  Code was generated by NX.
 
 
  Which postprocessor was used?
 
 
  At 1 min it shows up embedded screen of linuxcnc ruining it.
 
  I tried also final passes, but executing it was way to slow... anyway,
  this issue is already discussed in other topic.
 
 
  I must have missed it, can you point to that topic?
 
 
  http://www.youtube.com/watch?v=iy1Mb6G_VJ0feature=youtu.be

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Re: [Emc-users] Youtube 5axis cutting an impeller

2013-04-14 Thread Tomaz T .

  rotary head is produced by this guy, I only reinforced it for my needs...
  http://www.doughtydrive.com/
 
  Oh, I've seen those heads on the net. Just wonder what's inside - some
 belts or kind of harmonic reducer?


Combination of belt and spur gear stage reduction, and it gives you 30:1 ratio. 
  
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Re: [Emc-users] Youtube 5axis cutting an impeller

2013-04-14 Thread Dave
Is that the NX Cam from Siemens?

Dave

On 4/14/2013 10:55 AM, Andrew wrote:
 2013/4/14 Tomaz T.tomaz_...@hotmail.com


 rotary head is produced by this guy, I only reinforced it for my needs...
 http://www.doughtydrive.com/

 Oh, I've seen those heads on the net. Just wonder what's inside - some
  
 belts or kind of harmonic reducer?



 Postprocessor is slightly modified one of the native 5axis post in NX.

  
 Topic about execution speed is named Poor CV

  
 Thanks!



  
  
 Great! But the rotary spindle is not seen well, I'd like to look at the
 design.



 Code was generated by NX.

  
 Which postprocessor was used?



 At 1 min it shows up embedded screen of linuxcnc ruining it.

 I tried also final passes, but executing it was way to slow... anyway,
 this issue is already discussed in other topic.

  
 I must have missed it, can you point to that topic?


 http://www.youtube.com/watch?v=iy1Mb6G_VJ0feature=youtu.be
  
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Re: [Emc-users] Youtube 5axis cutting an impeller

2013-04-14 Thread Tomaz T .

 Is that the NX Cam from Siemens?


Yep
http://youtu.be/opxo2KxRLDw?t=40s 
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Re: [Emc-users] Youtube 5axis cutting an impeller

2013-04-14 Thread Dave
Any idea what they want for that software?

Dave

On 4/14/2013 1:56 PM, Tomaz T. wrote:
 Is that the NX Cam from Siemens?

  
 Yep
 http://youtu.be/opxo2KxRLDw?t=40s 
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Re: [Emc-users] Youtube 5axis cutting an impeller

2013-04-12 Thread Rudy du Preez
I have uploaded to videos on YouTube showing the cutting of an impeller with
Linuxcnc using the XYZACkins that I wrote (on the Wiki). 

The videos are not very professional, and the 5axis setup is just a test of
functionality, using two rotary tables, one mounted on the other. The
machine is a converted 3-axis Hermle 780.

If you google for XYZACkins you should find it.

Rudy


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Re: [Emc-users] Youtube 5axis cutting an impeller

2013-04-12 Thread Andrew
Great!
What is your CAM?

Andrew

Andrew
http://parallelrobots.blogspot.com/


2013/4/12 Rudy du Preez r...@asmsa.co.za

 I have uploaded to videos on YouTube showing the cutting of an impeller
 with
 Linuxcnc using the XYZACkins that I wrote (on the Wiki).

 The videos are not very professional, and the 5axis setup is just a test of
 functionality, using two rotary tables, one mounted on the other. The
 machine is a converted 3-axis Hermle 780.

 If you google for XYZACkins you should find it.

 Rudy



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Re: [Emc-users] Youtube 5axis cutting an impeller

2013-04-12 Thread Sebastian Kuzminsky
On 04/12/2013 12:12 AM, Rudy du Preez wrote:
 I have uploaded to videos on YouTube showing the cutting of an impeller with
 Linuxcnc using the XYZACkins that I wrote (on the Wiki).

 The videos are not very professional, and the 5axis setup is just a test of
 functionality, using two rotary tables, one mounted on the other. The
 machine is a converted 3-axis Hermle 780.

 If you google for XYZACkins you should find it.

Very cool Rudy!  How did you generate the gcode for this?  Some big 
commercial CAD/CAM package?

Here's the videos for the lazyweb:

https://www.youtube.com/watch?v=x-OYB5KCrqk
https://www.youtube.com/watch?v=Oh9eCupbsso


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Re: [Emc-users] Youtube 5axis cutting an impeller

2013-04-12 Thread jeremy youngs
did backlash cause any issues with the rotaty tables?


On Fri, Apr 12, 2013 at 2:12 AM, Rudy du Preez r...@asmsa.co.za wrote:

 I have uploaded to videos on YouTube showing the cutting of an impeller
 with
 Linuxcnc using the XYZACkins that I wrote (on the Wiki).

 The videos are not very professional, and the 5axis setup is just a test of
 functionality, using two rotary tables, one mounted on the other. The
 machine is a converted 3-axis Hermle 780.

 If you google for XYZACkins you should find it.

 Rudy



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Re: [Emc-users] Youtube 5axis cutting an impeller

2013-04-12 Thread Marius Liebenberg
I see Rudy is not answering. As far as I know he used Mastercam for the 
CAM generation.

On 2013/04/12 08:32 AM, Andrew wrote:
 Great!
 What is your CAM?

 Andrew

 Andrew
 http://parallelrobots.blogspot.com/


 2013/4/12 Rudy du Preez r...@asmsa.co.za

 I have uploaded to videos on YouTube showing the cutting of an impeller
 with
 Linuxcnc using the XYZACkins that I wrote (on the Wiki).

 The videos are not very professional, and the 5axis setup is just a test of
 functionality, using two rotary tables, one mounted on the other. The
 machine is a converted 3-axis Hermle 780.

 If you google for XYZACkins you should find it.

 Rudy



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Re: [Emc-users] Youtube 5axis cutting an impeller

2013-04-12 Thread Andrew
2013/4/12 Marius Liebenberg
mar...@mastercut.co.zahttps://mail.google.com/mail/?view=cmfs=1tf=1to=mar...@mastercut.co.za


 I see Rudy is not answering. As far as I know he used Mastercam for the
 CAM generation.

 Marius, thanks for your reply!
The next question is which post was used.
It's not confirmed here http://wiki.linuxcnc.org/cgi-bin/wiki.pl?Cam_Post that
Mastercam post can do 5axis.



 On 2013/04/12 08:32 AM, Andrew wrote:
  Great!
  What is your CAM?
 
  Andrew
 
  Andrew
  http://parallelrobots.blogspot.com/
 
 
  2013/4/12 Rudy du Preez 
  r...@asmsa.co.zahttps://mail.google.com/mail/?view=cmfs=1tf=1to=r...@asmsa.co.za
 
 
  I have uploaded to videos on YouTube showing the cutting of an impeller
  with
  Linuxcnc using the XYZACkins that I wrote (on the Wiki).
 
  The videos are not very professional, and the 5axis setup is just a
 test of
  functionality, using two rotary tables, one mounted on the other. The
  machine is a converted 3-axis Hermle 780.
 
  If you google for XYZACkins you should find it.
 
  Rudy
 
 
 
 
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 building
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Re: [Emc-users] Youtube 5axis cutting an impeller

2013-04-12 Thread Stuart Stevenson
Yes, Master cam post can do 5 axis.
On Apr 12, 2013 3:27 PM, Andrew parallel.kinemat...@gmail.com wrote:

 2013/4/12 Marius Liebenberg
 mar...@mastercut.co.za
 https://mail.google.com/mail/?view=cmfs=1tf=1to=mar...@mastercut.co.za
 

  I see Rudy is not answering. As far as I know he used Mastercam for the
  CAM generation.
 
  Marius, thanks for your reply!
 The next question is which post was used.
 It's not confirmed here http://wiki.linuxcnc.org/cgi-bin/wiki.pl?Cam_Postthat
 Mastercam post can do 5axis.



  On 2013/04/12 08:32 AM, Andrew wrote:
   Great!
   What is your CAM?
  
   Andrew
  
   Andrew
   http://parallelrobots.blogspot.com/
  
  
   2013/4/12 Rudy du Preez r...@asmsa.co.za
 https://mail.google.com/mail/?view=cmfs=1tf=1to=r...@asmsa.co.za
  
  
   I have uploaded to videos on YouTube showing the cutting of an
 impeller
   with
   Linuxcnc using the XYZACkins that I wrote (on the Wiki).
  
   The videos are not very professional, and the 5axis setup is just a
  test of
   functionality, using two rotary tables, one mounted on the other. The
   machine is a converted 3-axis Hermle 780.
  
   If you google for XYZACkins you should find it.
  
   Rudy
  
  
  
  
 
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