Help needed: Software setup for 4-axis tangential stone cutter (Mesa)

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27 Aug 2026 20:05 - 27 Aug 2026 20:08 #349060 by souh-hil
Hi everyone,
I’m building a 4-axis CNC machine to cut marble and granite slabs. It uses a large vertical diamond disk, and the A-axis swivels the blade to follow the cut direction . I’m using a Mesa 7i92 for the control.
I’ve built several  plasma tables before, so I can completely handle the mechanical and electrical sides of this build. However, I have no idea about the software side of it. I’ve always just relied on the Pncconf wizard and have never manually edited HAL or INI files.
Could someone point me in the right direction for the software setup? Specifically:
  1. How to configure LinuxCNC " A-axis that automatically follows the X/Y path"
  2. How to set up the CAM software  so  the cut is perfectly to size without the top of the blade overcutting the part.

    Any  examples, component recommendations, or guides would be hugely appreciated. Thanks in advance!
Last edit: 27 Aug 2026 20:08 by souh-hil.

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27 Aug 2026 21:02 #349065 by tommylight
1 No.
2 No. but...
If i understand correctly, it is a bridge type CNC that turns the head where the circular saw is mounted, so that strictly implies no A axis moves while the head is down into material.
Basically, it can not cut curves or rounded corners.
It should be easier to just use a text editor and do gcode manually, or if you have repeatable dimensions, do a VCP panel with a choice of cuts preprogrammed.
Also strictly requires interlocks to prevent anything (auto, manual, MDI) to turn the head if the head is under a certain value where the material can be, those saws cost a lot, and forcibly stopping such big motors is never healthy as you have about 2-15 seconds before it permanently retires. With smoke.

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27 Aug 2026 22:46 #349066 by souh-hil
Thank you for the response. I have an idea, but it is difficult for me to make it a reality.I thought that if the A-axis rotates very slowly, we could use it to cut the outside corners of almost any shape. My main problem, however, was cutting inside corners, for example, on an L-shaped countertop. For that reason, I wanted to use a bit to cut the inside corners and rounded parts.Let me try to explain my idea.The blade will be in the same plane as the Z-axis. The assembly will also have a bit mounted near the tip of the motor or spindle. The entire assembly will rotate so that the bit can become perpendicular to the slab, while the diamond disk becomes parallel to the slab.Both tools will be mounted on the same motor or spindle. The rotating assembly will not be considered another machining axis. Instead, I would treat it as a tool-changing mechanism:
  • Tool 1: Diamond disk for straight cuts
  • Tool 2: 45-degree diamond disk for bevels and angled cuts
  • Tool 3: Milling bit for inside corners and rounded parts
Once I solve all of these mechanical and machining problems, my next goal is to make the machine very user-friendly.I will not be the person operating the machine every day. Workshop workers will use it, so the control system must be simple and intuitive. Ideally, the operator should be able to load a countertop design, select the material and tools, and start the job without needing advanced CAD/CAM knowledge.Thank you in advance for your help.
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28 Aug 2026 03:09 #349067 by tommylight
That is a nice idea, till physics stick their nose into it and ruin everything! :)
The saw will spin at probably 1500-2500RPM (based on size maybe slower), and that is way to low for any end mill for hard stones, usually diamond coated.
Having said that, it will work, but it will be very, very slow.
Also, another advice that comes to mind, everything should be cut from the back side as the saw will eat into the part to make the cuts, so they remain on the back and not visible.
This will greatly depend on the material thickness, though, so that should be also taken into account.

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28 Aug 2026 05:06 - 28 Aug 2026 05:15 #349070 by timo
It seems a bit odd. I am reasonably sure that you cannot tilt the blade during the cut.
How much do those blades wander when you engage asymmetrical?
I have no idea, but I would be skeptical if outside contours are doable.
I saw that one in the Interweb.stylecnc.com/stone-carving-machine/4+1-automatic-stone-cnc-bridge-saw.html
For the price I would probably just buy it :-) if not a hobby project.
The rpm problematic on said machine is obviously solved by using two separate spindles. (one vertical) one 90° tilted that can rotate around a pivot.
For square cutouts it cannot be all to complicated to figure out how to manually program the thing.
.... I think I need a wood panel saw with router.....
How capable is a water jet machine? 
How about a diamond coated steel rope? Seems there are options for that as well. The plate is vertical and the machines run around like one of those hot wire foam cutters. 
 
Last edit: 28 Aug 2026 05:15 by timo.

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28 Aug 2026 05:21 #349071 by rodw
Master branch solves the A Axis alignment because I added some new motion.interp.* pins to it. One of them is motion.interp.heading which is the tangential heading or direction in real time. Look for motion interpreter Metadata Pins in this documentation link
linuxcnc.org/docs/devel/html/en/man/man9/motion.9.html 

I had envisaged there would be a companion component that dealt with knife alignment probably with external offsets with a setting that paused motion and lifted the knife if the next segment changed more than a certain angle (0 degrees in the case of the saw)

But I would look closely at FreeCAD CAM because one of their CAM developers Brad Collette (aka Siptronic) has done a bit of work with CAM for tangential cutters.There might be a ready made CAM solution.
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