Workshop
Just Getting Better
The parts breaking seem to be behind me for now. I have run several very long 3D projects with no qualms from the HB2. It has just been rolling along doing it thing at fairly high speed (at least to me).
I have increased the MACH3 frequency to 60,000 Hz and now been able to run the steppers as high as 200 fpm (1000 rpm on the steppers) but not reliably. My rapids are now set at 150 IPM and that is as good as I’ll probably need. I was running the roughing at 100 IPM and the 2 hour finish passes were running at 70 IPM. Working just fine.
Ahhh… Life is good!
Going For Broke
Well, dumb me again. Sometimes I just have to learn by experience and just blame myself. I actually like problem shooting and it is something I usually do quite well. I should have been a CSI or some kind of forensic engineer.
My problem is I broke another coupling on the HB2. Same place and I am certain the same reason. There is nothing wrong with the selection or type of coupling. They are perfect for the work they were selected to do. Actually, the helical beam is one of the most rugged, with the highest torque and deflection ratings of the couplings I have researched.
My problem is shaft alignment. I am using the original slotted aluminum tubes around the couplers as debris covers. They have no affect on spacing or alignment. However, they did prevent me from clearly seeing, thus correcting my real problem on the Y axis steppers.
The first two axis I set up were X and Z. They were the easiest for me to measure and eyeball. They both have run super smooth. The double Y axis drive is what I did last and has been more of a problem. Since X and Z aligned so well, I ASSUMED assembling Y would be a no brainer. I put them together with the covers on and the open slot down. That made it extremely difficult for me to see the shaft misalignment. I used a mirror so I didn’t have to stand on my head to look up. However I couldn’t see the vertical alignment problem, only the horizontal which was fine. (The assume part.)
All the other work, end play, screw/guide alignment, was on the right track but not the major issue.
I am an energy and HVAC engineer. Motor coupling alignment is a major… Continue reading
Broke Beamer
I have just had a interesting development with the HB2 router. Most of my readers realize I push my inventions to the limit, actually breaking things from time to time. The Proxxon lathe is but one example. Not saying that I plan to break things but how else do I know where the break points are?
This one is a bit curious as what I broke this time was one, actually both of the helical beam clamp-on shaft couplings for the dual drive Y axis. One of the couplings totally failed (broke in two pieces) so that really caught my attention. The other had a clicking sound. Actually both had the clicking sound but I was not sure what the reason was. Now I know.
The dual drive was the hardest to get fine tuned (alignment and sticking spots) and suffered some abuse. No not the large mallet I joked about in another report. There were many times when I stalled the steppers trying to go too fast. It is pretty hard on the works when one motor stops and the other keeps going. I was also getting aggressive with short ramp times and was certainly slamming the couplings on several other occasions. Top speed at 4000 SPI on 5 TPI screws is 150 IPM. I’ll probably run my rapids at 100-125.
But Hey! That’s what it is all about when you make your own. No manufacturer to blame. I love it!
The HB2 is much larger and heavier than the Taig mill I have been playing with for years. There is more mass in motion. Therefore I have to pay more attention to Newton’s laws of physics. The hard Part is the MACH3 stepper tune up instructions say to set the motor speed and ramp times until they sound… Continue reading
The Creation
With HB2 running it has been fun refining MACH3. There are just so many things that software can do that I am always experimenting with settings. Thank goodness everything can be saved under various setup names. I have two main versions, one for the little Taig CNC mill and the other for HB2.
I am also spending time with the Vectric Aspire software. This is a serious program that works very well at composing very nice projects. I hesitate at saying it creates very nice projects as I feel that is still a human function. Aspire is simply a tool.
I am making signs and nameplates. I am looking for the “killer app” that will be something I can make in suitable volume for sale to others. Gross profits after taxes will go into a building fund to eventually find or build a better shop. That is my long term goal.
The replacement metal gears I sell have been a good sideline but the lack of inventory is killing me. My import person is also beside himself wondering what is going on. I can only think there has been a breakdown somewhere in the shipping process. I can’t sell from an empty basket or without finished product of my own design.
All in all, I am still excited HB2 is a success. Now to put it to work.
HB2 First Project
HB2 has been brought to full functioning life with sounds not much unlike a trim router. I am kind of alluding here to a new baby cries when first born.
I am not one to choose an easy project for the very first run. What you see here is the Aztec calendar with a lot of detail. I set the design up in Vectric Aspire V2 and sized it for a 12 inch diameter. The process is known as V-Carving.
I used a 90 degree V-Carve bit. I discovered I should have used a 60 or perhaps 45 degree V-Carve bit. I would have deeper cuts and wouldn’t have had the dropout in several areas due to board warpage.
But all in all, not too shabby for a first run. I and HB2 can only get better. Enjoy the pictures.
See Video -> V-Carve Action