BP-High-Priests..please help me with the following.....
Been working on making PET blowing molds last 3 month, with very interesting and good results in terms of accuracy and surface finishing on aluminum.
Machine is a BP-Series 2, ex Boss 6, rigid-ram and currently running under Mach-3, HillBillys BOB, all X,Y,and Z original finned stepper motors and boards yet,,,,, and Mastercam X3 for the CAD-CAM stuff, since 2006, with no visible problems...
Right now machining the first half cavity for the future 1.5 liter container...and here is where the nightmare begins....
Never had any problem with the semi-finishing as well as the finishing machining process before, but at the "roughing" machining, and after 2 or 2 and a half hours running the mill, a sudden erratic and non programmed toolpath took place and ruined the stock of material...mostly in straight line and over X axis.
At that moment, mill was running fine with all the stuff...plenty of propper coolant..spindle speed of 3200 rpm at 32 IPM (800m.m./min) aprox of feed rate with a down plunge step of no more than 0.040 each pass...suddenly and without any warning..X axis increased its routine and in straight line, towards the positive side in 1 inch and more, as I hitted the emergency-stop button.
Checked and re-checked the program...simulated it once again...made some air cutting again....nothing wrong were found...end of story.
Only thing I could noted -if this helps somehow- at that moment, was the X stepper motor temperature... after 2 1/2 hours of machining...you couldnt hardly put your hands on it, but remember, at that time, X motor was doing most of the job, due the block position along X axis...so Z and Y motor were only working for the plunge and the step-over.
Comments will be higly appreciated.!!!
(sorry about the bad english writing).