MACH3
Project Tessa
In case you missed this, here is a picture of a project I made on the HB2 router. I published it over on the Ramblin’ Dan blog too.
The layout was designed in Vectric Aspire and output for the MACH3 controller. Of course it is MACH3 that runs the steppers on the HB2.
Four files and three tool bits were required. One file cuts the outline using a 1/4 inch flat router bit. It leaves tabs for support so I did this first. Next was the roughing file again with the 1/4 flat bit in 1/8 inch steps. The third pass was the finish (detailed) pass using a 1/8 inch ball nose bit with very shallow step over.
The last file was the V-Carve for the name and date.
Total run time on the HB2 was about 2.5 hours. Speeds were 100 IPM for the roughing and 70 IPM for the finish. The HB2 handled them all just fine.
I actually made three runs. The first one is where the coupling broke, the second I spelled Tessa’a middle name as Daniel (Horrors!) and then the final fully successful ran you see here. At least I had a test piece to practice the finish work (and I did).
Three coats of shellac gave the oak the color you see here (no stain). Then the color painting. Last a final coat of clear lacquer.
I also used a table router to cut a T slot in the back for hanging on the wall.
Oh yes, the date is correct. Tessa is one year old!
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!
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
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
Heat Sinks Added to The HB2 Web Pages
The complete story on the construction and installation of the HB2 stepper motor mounts has just been posted to the THMShop web site. Click on “What’s New” in the first (left) menu “Site Tools” drop down. Then click on “HB2 Construction Section 4” The picture here gives some idea how good this project turned out. I am pleased with the results and I hope you like what you see.
I mention in one section of the web site display that I thought I might make these for sale. That is not the case now. At least not the way I made these. Far too much time is invested in these prototypes. If there is a real demand, they will have to be made from casting to get the cost down.