Need help with rough cut

[duramaxer]

my machine has been cutting pretty rough any idea what it could be ? It's a home built machine with nema 23 motors and a powermax45 here is a picture of the problem im having any tips will help ... mach3 and sheetcam

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[warrenb]

When is the last time you changed the consumables?

[duramaxer]

thats with a brand new consumable and electrode

[duramaxer]

i have also checked for play in the gantry changed air pressure cut speed . cv mode is on the distance tolerance is set at 200 and the g100 adaptive nubscv is on aswell i tried holding the torch as its cutting to see if i feel any jerking but just cant seem to find the issue

[Simonh1959]

Have you changed the swirl ring as we had similar problems with our Powermax 105 a few years ago.

[DirtBound]

What kind of drive system, V bearings and direct rack and pinion?

[duramaxer]

What kind of drive system, V bearings and direct rack and pinion?

Yes v bearings and rack and pinion

[DirtBound]

my bet is that's the gear vibrations. My old table did the same thing, no matter what I did there was a bit of roughness.

[duramaxer]

thats what i was thinking did you ever fix it or just learn to deal with it ? you know of any decently priced ball screw rails out there

[jimcolt]

If you put your hand on the torch when it is cutting and feel any vibration....the vibration will show in the cut edge as pictured:

1. Cut a rectangle about 3" x 3". Mark the orientation and then inspect the four sides. If the roughness is exactly even on all four sides.....then it is probably something mechanically loose in the torch carriage or torch mount. If the vibration is isolated to either x+ and X- or Y+ and Y-, then look at the mechanics on that axis.....something has some backlash....or perhaps the motor tuning is too tight, back off on acceleration or gains to correct.
2. If the vibration is on all four sides.....shut the z axis height control off and cut another square with the torch at a fixed height. oscillation in the z axis will cause this type of cut.

More info about your machine will help....as well as pics of the cuts around a perimeter....not just two sides as your pics show. Process power level and settings for speed and height will help...and pics of the consumables (nozzle and shield orifices) will help us help you. Jim Colt Hypertherm