but seriously imo thats a tall order for even a well seasoned machinist,

but i would do the bore first then fill the hole with a rod and glue it in or light press fit and do the od , that is the best practical solution i have , or if you have some of that low temp metal stuff that would probably work too anything to stiffen it up

a sharp insert would prob be best , stuff you would use in steel is not ideal

good luck

WHO Quoted that!!!

the guy who didnt have to make it !!! LOL

thanks for the tip Chris,

i've had it setup like that before in the tool def, and stopped doing it bc some of the machines dont have tsc and we use some of the same tools between them, and i found it easier to just use the canned text because usually i'm there to put a m00 in after

thought of this the other day, could i set the machines that don't have tsc to just turn on the flood thru the control def , like if i had a tool defined as having the tsc turned on , and if i use it in a machine that doesn't have it, could i just change the control definition to output a flood coolant?

Jay i opened this file and the tool geo is not flat in respect to the front or the top plane, although it appears flat when viewed from the front plane

ive never had it work when the geo is not perpendicular to z axis of the top plane

i tried to use it as a undefined tool as well and it didn't show up correctly on verify

is there another way your doin this to make this work, if so please fill me in im all about learning new methods

sometimes the canned text "add before, with and after" icons dont work, and this seems to happen randomly, i just cant figure out what makes it happen, ill highlight the canned text i want to use and click before or with or after and nothing happens , ill close the toolpath window re open it and then it works , it also does this on the "edit parameters for selected ops" window

any thoughts?

also there are some rules to that. flip your tool 90deg so that the profile can be seen from the top view,and no junk wireframe only draw what you need to make the tool profile, then when you create a new tool use the undefined tool type and it should open a window to select the file for the tool you drew, and you can also put the tool on a level in your current file if you dont want a seperate file for the tool just use the "from level selection"

either a "x" or a "p"

np

that only works when the toolpath type is set to dynamic

 

For now, I am just going to save the file under another file name and make the necessary changes.

 

yep ive found this is the best thing to do, we run the same jobs on diffrent machines and saving a different file when i change machines is my std

and i also have had many issues with copying ops from machine def to machine def in the same file, tools, holders get messsed , mixed, scrambled and if there are any tool paths the require source ops like k2csq stated they all have to be manually updated

and we do use the warm up cycle its written into the plc from the factory as an alarm , you cant run the machine if you dont run the program

lol well i guess i gotta make the best use of what i got, and i guess thats why makino patented the under race lubrication on their integrated design then huh?

today we put a rebuilt spindle spindle in the newer dhp4000 from northland http://www.northlandtool.com/, and were getting a brand new one as a replacement spare from the factory with a one year warranty from the date its installed so the owner is happy , we didnt get one for free we had previously purchased a spare to have, that was used in another machine then had one rebuilt at northland

im gonna heed your advice about the chiller because i was gonna turn it down some but i guess ill just go about 5deg less then ambient

i looked at the motor when it was out today and the full load amps is 173!!! 10min and 152 continuous duty on the high winding side ,

thats gotta be a crap load of heat,, and the heat on the rotor has to go thru the spindle shaft then thru the bearings to get to the chiller oil (i never though of it before but makes perfect sense now)

we were running a job the does about 20min worth of 14000rpm roughing @ 80-100% im sure thats the bearing cooker right there

im just gonna dial the roughing back to about 11500 max, and if that dosent do it well hopefully then i can convince the owner to buy something with some engineering behind it because this knock off stuff sucks

although everything else seems to be built reasonably well, would you keep your car if the engine blows every 5mos

Are you using Big-Plus CAT40 tool holders?

 

Is this actually a Doosan labeled machine or a Daewoo labeled machine?

Is this the machine in question?

http://www.doosan.co...85542843750.pdf

If it is, check your spindle chiller.

 

I went through this on a 2000 era Johnford VMC.

I agree on the grease packed spindles.

Grease packing is fine if you stay within the specked duty cycle.

No one eve does and its unreasonable to expect that they would.

 

Even on grease packed live tools, the life cycle before rebuild is only 1000 hours.

yes those are the the machines we have, they are labeled doosan

the one hmc thats labeled daewoo is like a 2000 and its dosent have the integral motor spindle its has the inline type and its still has the original spindle cartridge and is used just as hard as the others

yeah and we are using some bp holders when the support is needed, high rpm roughing and large dia boring long end milling etc.

Is it integral motor? Hitachi used to do this (VS50) and we went through 8 spindles on one machine and 6 on the other, in a 2 year period.

Hitachi was crap design because all the heat from the motor was transmitting to the bearings.

If you have an integral motor, check your chiller has no air bubbles and is working/set correctly.

HTH

yep integral motor

it is grease,

was it northland that rebuilt it? they have rebuilt one thats in our dhp5000, its running good so far been in there for about 8months

i took em a few trys to get it right but they found something that seems to work better then the factory

every time one burns up its usually the rear bearing that supports the motor shaft, you would think they would try something different instead of just fixing it over and over

im pretty much set on just dialing every thing back a notch or two on roughing aluminum that seems to be where they lack in reliability but it does suck not being able to use 30hp

the job we had running was 100cuin removal in some areas

well we dont have a balancer, all of out holders are g2.5@25,000 we dont run tools that aren't symmetrical at high rpm, and if we do feel vibration on the spindle head we lower the rpm until it stops or switch tool holders, gauge lengths etc, were not letting things run at 14000 if its vibrating, you really cant even run a tool @14000 if its vibrating because the tool chatters and the surface finish and tolerance sucks so im really sure its not vibration

anybody else have the 4000 and/or 5100 model with the 30hp 40taper 14,000rpm motor spindle cartridge? we have 4 of these and have had new/rebuilt spindles in every one of them some have had more than one replaced

anybody else have the same machine and having the same issue?

we have a 2001 doosan dhp400 , which is not an integral motor spindle and its the original spindle and still 14000 rpm, and its been crashed a few times now and still keep on gettin it 24/6..

we have okuma vertical mills and a kitamura horizontal, the cutting performance is about the same , the maintenance is not, the kit requires about 5x more attention then the okuma's, and the kit also leaks all over the floor badly , because of poor sheet metal design inside , rtv works for about a week or two, so id go okuma all the way

any opitions for different tool holder ? ilike a er16 or a er20? they would prob work better for a smaller tool, and get more of shorter lengths ex. 2xd 6xd 8xd 10xd of tools and do it in steps leaving the 12xd to do only the deepest, not gonna get away from deflection take smaller doc to reduce cutting forces

static tool runout less then .0002 at tip , and max spindle speed is not always the best,

find a speed that produces the least amount of vibration at the spindle head , this will help protect the cutting edge and ensure there is not any dynamic runout out from vibration

pretty much all i have to offer

Will any of the 2D dynamic toolpaths kick in cutter comp on the last pass?

NOPE, the only real drawback to 2d hs paths is no cutter comp available, not sure why not either, im always kicking out new roughing paths for reground solid carb em's

what I would normally do here is make the core path first leaving a bit for finishing then do a contour 2d path with the force tool change box checkd , so the operator can rerun the part if there's a size issue without having to rerun the entire roughing path again

throwing in my 2, id use 2d dynamic core, pick both chains and it will do the rest, you may have to increse the stock chain diameter bigger then the part chain it looks from the pic they meet each other at both ends

howd u ,make out on that lug dealy, u get the ht process figured out? and cut that support out without massive warping?

dang! never had the opportunity to program a machine with that many available, but i see where that would be a complete mess

my bad i totally forgot i modded that 54-59 in the post (its been so long since i did it) , so that 54-59 outputs a g54-g59 and 1-48 is p1-p48

sorry for the bad info

in mpfan typing in 54-59 outputs a g54-g59, entering a 1-48 outputs a g54.1p1-g54.1 p48, also theres a misc value to be set as well cant remember off the top of my head , goto that page in the tool path window its pretty self explanitory, i think is misc value #1 and you set it to a value of 2

as far the machine goes just look at the work offset page if there a p1-p48 listed beyond the g54-g59 then you have the extended work offsets

as fas programming seems you are already using the 54-59 just type in a g54.1 p1 instead of a g54, this would call extended work offset "p1"

and fyi if you type in a G54 or a G54.1 with a "P" its using the extended work offset denoted by the p value

if you do not have the extended you could always use the g10 code to change the 54-59 thru the program then youll have basically unlimited work offsets

there are usually two things that cause that, one the machine cant process the g code into motion fast enough, or the acc dec settings are not set correctly in the machine parameters,

to suppress this at the machine , most controllers have high speed g codes that enable the cnc to smoothly accelerate and decelerate at high feed rates

what kind of machine controller are you using? fanuc mazak etc? either way theres info about it in the users manual

in mastercam this is what i use for older machines

total tol set to .003in

then in refine toolpath window

ncprgm length + short

surface quality + good

calc time + normal

line arc filter checked

smoothing not checked

xy xz yz all checked

one way not checked

and maximal tol val for both

minimum arc .005 in

max arc 100. in