Smoothing Help update with video

[Pitka_Guru]

Thanks to everyone's help, including the guys at CAMTOOL in Windsor I've managed to get our Haas VF4-ss running fairly decent. Here is a video running at a feedrate of 16510mm/min. (650ipm) using X7 optirough.

 

Anyway, I wanted to know what you guys think of the smoothness and speed.  From what I know the Haas control doesn't tell you what the actual feedrate is just the programmed or overidden value. So for the guys used to running above 300ipm does the speed seem about right? It seems a bit slow to me but over the past few years the machines I've used top out at 200ipm so my experience is limited.

 

What ways would you guys rough this part out? I wanted to try a 12mm endmill with a big d.o.c but it's not something in our inventory as of yet. It's the first video I've taken and edited so laugh all you want, I know I did.

 

Look forward to any feedback.

 

https://www.youtube.com/watch?v=7jquN4UY_zw

 

Cheers!

 

Pitka

 

Guru Pitka: "Rajneesh, I'd like an alligator soup, and make it snappy. Because alligators are snappy, and at the same time, I want it prompt."

[reidmachine]

Nice work!

You have that animal running real smooth.

I would be interested to see what the machine settings and MC parameters are.

[Pitka_Guru]

Thanks! The Haas settings are the defaults.  I've used G187 P1 (rough setting) to override the default smoothness (which is P2 medium)

 

My X7 settings are below 

 

 

And here is how I've set my advanced config. It seems like the more code I have the better and that the machine seems to stutter with small arcs, which is counter intuitive to me. 

 

 

 

 I read your post with crazymillman about feeding your minimill really high. How are your settings compared to mine? I'm not certain these are the best it's just what I have found works so far. 

 

 

[The Cathedral]

That video would not be fun to watch drunk.

[CJep]

That video would not be fun to watch drunk.

 

I don't know about that,.....

 

I was getting dizzy and all I've had to drink is coffee.

[scooke4073]

I don't know about that,.....

 

I was getting dizzy and all I've had to drink is coffee.

 

Yeah.  You can't let Youtube automatically filter and correct your upload....otherwise you can see the result.

[Pitka_Guru]

WOW, sorry guys, I just removed their filtering, that was absolutely terrible, lesson learned. I hope I didn't make anyone too sick lol

[Jayson Kramer]

looks good it is nice to see this machine actully get up and move. the max i have gotten one of there Horziantals to go using optirough a few years ago was about 600ipm then the machine started almost move. lol

[crazy^millman]

Great Video, but maybe I can get you to think a little differently. Look to a 3/4 Endmill like this tool from Helical the one shown is a 1.00 size. Keep your same rpm with a 350 ipm, but go with 200% step down and 10% Step over. I would like to see if there is a time difference between using that tool and the endmill.

[Jrygus]

+1 To Crazy's comment. I have found higher Material removal rates and much less warping, and...The chips come out of the machine easier.

[Chris Rizzo]

The kinematics on the machine look pretty good. I believe there is a debug screen that will show the actual feedrate. (Parameter lock off, Alarm page, and type "debug".

 

I too would go towards crazy's method.    150% stepdown, 15% stepover, 20% rounding radius, as fast as machine will feed.

 

Take a look at my spreadsheet in the link for some ideas. Run some MRR calculations and see what method gives you what.

[Pitka_Guru]

Ron, I wanted to try an End mill but we didn't have anything bigger than 10mm when I ran the part. It's nice to see that many of you believe the endmill method will be quicker so im on the right path. A funny thing I'm noticing with optirough is that the 1st few passes when working from the outside in are a bit jerky but then it smoothes out until it gets very close to the part shape.

 

Some of the moves are so quick it sounds like the machine is lifting itself off the ground so I know what you are speaking of Jay lol.

When running these feeds what types of load values should I avoid for each axis? I have had it up to the theoretical max of 833ipm but in fear of seeing the table come flying out of the machine I slowed it down. It likes to make banging noises at those feeds, not a confidence inspiring thing.

 

I will do some mrr calculations and see where we end up and use the debug to check actual feed. Curious to see what it's running at.

 

Thanks as always, this site is awesome!

[Guyinthedesert]

I'm curious as to how the backplot/verify time compares to the actual cycle time?

[Pitka_Guru]

Surprisingly with 100% rapids, my cycle time was very close to what backplot estimated. Normally if backplot says its 5 minutes, my cycle time is 10 minutes. 

[CJep]

 I have had it up to the theoretical max of 833ipm but in fear of seeing the table come flying out of the machine I slowed it down. It likes to make banging noises at those feeds, not a confidence inspiring thing.

 

 

 

The "banging" that you're hearing could be associated to the acceleration clearances in your machine. If I tell the machine to make a very short move at too high of feedrate the limiters get a bit crazy. I ran into that cutting some small perforation knives .250 x .187 at 60ipm it sounded like the machine wanted to esplode itself, slowed it down to 45ipm and it was good to go.

[left coast lefty]

Pitka, nice video!  What kind of insert cutter is that?

[Pitka_Guru]

thanks! It's a Taegutec 63mm, 5 flute Chase-Alu. High polished, high rake inserts for Aluminum. Iscar has the same tool as its all IMC group of companies but I'm sure everyone makes a similar type tool these days.