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  1. #157
    Registered jakemestre's Avatar
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    Default Re: 10"x12" Scratch built lathe

    So much update! I've almost got the machine running. A couple bumps along the way but everything seems to be working out. I'm really hating and loving LInuxCNC all at once. There is so much you can do with it, but programming everything and learning how to troubleshoot is a seriously steep learning curve. Here are a few photos:
    Pulley Making time: I can't wait to have coolant on a machine again and the ability to break a chip.




    The backside had to be recessed on the mill to allow for the jaws to clamp and jbelt grooves machined.



    This is the spindle encoder I've printed a mount to install and tension. It's a very simple AMT103 encoder from digikey. It reads beautifully in linuxcnc, and I have to say it's really cool to see the spindle number changing when I'm barely rotating the chuck at all.



    I added proximity switches to the turret to both index, and know if the turret has reengaged correctly before cutting starts again. This is the final reassembly photos. I will at some point print some TPU gasket to protect the hirth teeth from chips and coolant.


    I'm using a nema17 stepper with a Mechaduino board to make sure the turret arrives in position.

    Cable chain is installed and a friend was helping me and designed a small junction box that affixes the chains and keeps the cables free from chips.




    The rats nest: I had just switched to a brand new computer to run the machine. The old computer kept having cpu overheat shutdown events and I didn't want that to happen while running a program.
    Also I wanted to use DIN terminals to get signals in and out of the 7i76. It is definitely not a break out board, but rather a signal in/out board. It is really nice once you know what you're doing but power, signal, ground, shield are not broken out together in labeled headers.
    So you have to use these beautiful beautiful diagram that Norbert(newbynobi on the linuxcnc forum) created for the 7i76e. That's the Ethernet version instead of paired with the 5i25 pci card.


    Next up cleanup.

    which is slightly better, nothing like the Grizz but it'll work.

    A little better, and all the 120 outlets are powered and controlled via software.

    I'm waiting on the VFD as the old one had some issues. TECO has been absolutely amazing to work with. Seriously, they are amazing, one of the best companies I've ever done business with.

    I've got the machine moving, homing and each axis controlled with the switches and MPG on the control panel. It was about a 3 day process to figure out why linuxcnc would not work with the MPG. Finally after leaning how to understand what's going wrong with the hal file, the custom.hal I created for jogging was perfect and I could see everything in the halmeter. Turns out the old MPG wasn't outputting signal and the code worked great after all the troubleshooting. It uses a 3position switch to toggle between the x, z or not selected and a rotary 2 position switch to send the bit logic to hal which selects the unit. .0001, 001 .01 or .05 I find that using it at the .01 is great for direct jogging. At anything greater than .01"/pulse the the speed you're spinning the wheel exceeds the max speed of the closed loop steppers and the machine keeps going after I stop spinning the MPG.



    If anything it makes a good nightlight for the shop...



    As is:


    Up next is get the turret working and changing tools based on what's selected. I need to make some tool holders as well and finish off the enclosure. I think the chip conveyor is going to go on the back burner for a bit and I think at some point I'll build in a touch-off probe.



  2. #158
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    Default Re: 10"x12" Scratch built lathe

    Turret is almost working. Now to figure out how make ClassicLadder execute this gcode simulated toolchange.




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    Default Re: 10"x12" Scratch built lathe

    The other option for the turret is a linuxcnc 'component'. They are just short C programs with connections to hal. That's what I used for my turret. I'm more familiar with C and find the classicladder logic odd / difficult.

    7xCNC.com - CNC info for the minilathe (7x10, 7x12, 7x14, 7x16)


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    Default Re: 10"x12" Scratch built lathe

    Quote Originally Posted by pippin88 View Post
    The other option for the turret is a linuxcnc 'component'. They are just short C programs with connections to hal. That's what I used for my turret. I'm more familiar with C and find the classicladder logic odd / difficult.
    Hey pippin,
    Thanks for the suggestion. I did a little more digging with classic ladder and there's not really a good way to control an axis really with the outputs. Unfortunately I'm not so good with C, so a remap is what I need. Working on that part now. For the moment I'm using the motion.output to control the turret lock, and an A axis coordinate to swing the turret around. I'll post an update in a little while.



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    Default Re: 10"x12" Scratch built lathe

    This is a major update.
    The machine is working!
    I'll start off from the last update. Here's a photo of the crappy, warpy, gluey, recycled stainless that makes up this machine.


    Chopping it up with a Dremel saw that uses cutoff wheels. Mostly because I don't have a sheer.


    Then I flatten it as much as possible and use a hand belt sander to get the brushed finish.


    Afterwards I bend it on my little box break, and weld it with my Dynasty280x I love that tig machine!


    More sheetmetal work.


    I printed a cable dragchain mount that l's off for the x axis chain.


    Unfortunately it was in the way of the connector used on the back of the turret so I had to redesign something that was much more compact.
    I decided black could look a little nicer instead of the blue. I also made a nice little stop for the home switch on the Z.


    That was one tough insert. G0 Y not Z while machining round tool holders.



    Here's one of the internals of the turret. I ended up using a Leadshine closed loop nema17 stepper instead. The original stepper wasn't powerful enough to make it all happen with only 1.2A max current. I tried a 5:1 geared stepper but then there was too much backlash and the turret was missing the teeth for engagement. I also printed a really tightly toleranced pulley and there's only about 1 degree of lash now.


    Round holders are finished and I drilled/bored the hole on the lathe itself.


    The seal is printed in a TPU and very flexible. It'll be hard for chips to make their way into the hirth I think. The top of the turret was blindingly shiny I had to cover it with a little vinyl.


    The router had a really really hard time cutting the 300 stainless. Even with MQL spray, perfect chip calculation it was really hard to get a clean cut.


    It's really starting to look like a machinetool!


    I successfully implemented an M6 remap today and the turret works perfectly. It even errors if it doesn't make it to position.
    I'll be posting my complete config files for linuxcnc with a 5i25_7i76 setup. That will probably happen over on the linuxcnc forum so if you're interested I'll link it when I get that done.
    That's all for now.
    Next steps are to cut some metal for the coolant system. Then learn how to turn parts via fusion360.



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    Default Re: 10"x12" Scratch built lathe

    Oh, forgot the photo of the cleaned up control box.


    I've also got to fab some way covers. Telescoping style......



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    Default Re: 10"x12" Scratch built lathe

    Wow Jake,you've really got it going you way! I really envy your Linux skills. That's why I had to go with the Centroid Acorn. The smart stuff comes pre-programmed on its onboard Beagle Bone.

    I just noticed your encoder setup in an earlier post. Were you able to get LinuxCNC to correctly index the spindle for threading without a 1:1 pulley ratio? That's pretty awesome. Centroid is absolute in requiring that the encoder is driven at a 1:1 ratio for threading & rigid tapping.

    Milton in Tennessee ya'll!


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    Default Re: 10"x12" Scratch built lathe

    Quick update:
    Things are running pretty well!
    Here's a shot of the current machine. I fixed the door so it slides perfectly now and opens up wide.


    I love how it looks at night. Sort of spaceshipish.


    I've made my first parts! Coolant nozzles for the machine. lol


    And one purely fun project.


    In Linuxcnc it seems to me that threading is really down to making sure that one revolution is exactly one revolution and that there's not accumulated error. I opened up a halmeter and looked at the revs counter directly. Then I put a test indicator on a jaw at 0 revs, moved the test indicator off the jaw with the z axis and rotated one revolution. That got me the rough the encoder scale for a single revolution but I needed to make sure that after say 20 revolutions I would reed 20 not 20.1 for the revs counter. It took a little while but I got threading down. If I remember correctly this was an M4 thread.


    This a replacement part for one of the worm gears in my 3D printer. The nylon was wearing out much too fast, and I wanted a 2 start thread to speed up the output gear.


    I found a screaming deal on a little power chuck, but no through hole is a challenge for prototype parts.


    It seems like there's a never ending list of things to still do to this machine but that list is slowly shrinking. I still need to add cycle start/stop/feedhold to the buttons, and fab some waycovers, but otherwise the machine is pretty functional. And it's rigid! Way more rigid than I had hoped.

    Here are a video of cuts.




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    Default Re: 10"x12" Scratch built lathe

    Regarding spindle encoder: yep, very important that the scale is perfect.
    The easiest way it to have the encoder on the spindle, the index pulse at least will always be correct.

    7xCNC.com - CNC info for the minilathe (7x10, 7x12, 7x14, 7x16)


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    Default Re: 10"x12" Scratch built lathe

    Quote Originally Posted by jakemestre View Post
    I successfully implemented an M6 remap today and the turret works perfectly. It even errors if it doesn't make it to position.
    I'll be posting my complete config files for linuxcnc with a 5i25_7i76 setup. That will probably happen over on the linuxcnc forum so if you're interested I'll link it when I get that done.
    That's all for now.
    Next steps are to cut some metal for the coolant system. Then learn how to turn parts via fusion360.
    If you have that link for the Linuxcnc configs I'd like to see them. I have a 7i76E and the config would be similar (assuming the same functions).
    Also - do share tips on using Fusion360 - especially the turning bits.
    I have a tiny emco compact 5 with tool changer I'm using to learn with before I cnc a bigger machine.
    I managed to hack up my toolchanger so its works with an open loop stepper (goes past the ratchet and backs up against it - sounds horrible when operating!)
    Mike



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    Default

    A couple quick questions:
    First, this thread started in 2013. Was the time to cutting the pulls because of other endevours, funding, or something else? Or did it take this long?

    Second: why the welds at the beginning? I’d imagine it wasn’t simply to raise the guides up a little. Was it machine constraints? (As in the machine that did the drilling and tapping)?

    Third: I’m definitely not up on lathe turret work holding. I figured I’d read up a bit. You said you didn’t want to release your design which is fine, my question is way more basic. Are the parts holding the tools wedge shaped? I can’t see how the parts are retained otherwise but figured I’d ask.

    I’m in the very early planning stages of what I’m going to do for a lathe. Your build is quite helpful



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