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Hi everyone, 

I have posted before and got a lot of help setting up my CNC machine. 

Now I am working on a hacked/bolt on component for said machine.  I am in desperate need of drilling some very small (.5-.8mm) holes in inconel of high aspect ratio.  I was able to do it with PCB drills but I break more drills then I succeed. So I want to use edm.  I would really appreciate it if anyone who knows about these things could weigh in on the probability of success.

Here is the plan:

I can buy a edm drill head from aliexpress that handles high pressure. I can use a low pressure pump to pump the dielectric through a water filter. Then I can tap the fluid to an airless paint sprayer to pressurize the dielectric fluid to send to the drilling head (the drilling rods are hollow for flushing debris away). I will also tap off from the pump to return to the fluid container (but first it will be directed at the cut as my work piece will not be submerged).  I am ok with replacing filters often. 

All of this was taken from Applied Science YouTube channel. Here is a link: 


What I am doing different from him and am more worried about:

For starters I am using oil as the dielectric.  I am doing this because I already have oil set up for doing traditional machining with. 

The biggest thing I am worried about is the power supply. You can buy these cheap EDM machines form aliexpress that are built for broken tap extraction.  I have a couple of concerns with this. First, is I am not sure if the power supply output power can be reduced low enough to drill very small holes.  I believe it is necessary to lower amperage for smaller holes.  Second, I would not have a feedback to know if the arc has shorted. My thought with this is that I could simply run my feedrate low enough that a short is unlikely to occur. Alternatively, I believe the power supply comes with a drill head on it that does not have through coolant so I would not use it.  However this drill head does have a servo on it and I think that it has feedback to detect a short and it retracts the drill if this occurs.  I could probably workout how to sense when this is ocurring and feed this into my control board. This would require me to modify my LinuxCNC to reverse if a short is detected, but I am sure this could be done? 

Alternatively, I could use the Powercore from RackRobotics.  This power supply seems more versatile and controllable. But I do not think it is shipping at this moment because they are having some troubles with the board. However, I believe that it does have a logic out for short detection. 


I am really hoping I can get something together. I would really love to hear everyones thoughts. I can provide more detail if needed. 

Here are some links to some of the parts I am considering:

www.aliexpress.us/item/3256806213357626....yOTE0OTY1MC4xMy4wLjA. 
 
<!--td {border: 1px solid #cccccc;}br {mso-data-placement:same-cell;}--> www.aliexpress.us/item/3256803997349850....ller%7Cquery_from%3A

<!--td {border: 1px solid #cccccc;}br {mso-data-placement:same-cell;}--> www.amazon.com/gp/product/B01CFOFZ08

<!--td {border: 1px solid #cccccc;}br {mso-data-placement:same-cell;}--> www.amazon.com/gp/product/B004Z2090U?th=1

Best,
-Dylan 

Всем здравствуйте, пр обрёл токарный станок с linux cnc ,очень понравилось но захотелось мне кнопку внешнюю поставить для запуска программы и вот тут я сдаюсь,нужна помощь в этом вопросе ,я подключил кнопку но вот как привязать пин и какой я не умею пока ,спасите памагите пожалуйста  _222115_023.jpg[/attachment]

Since I am new to the topic of Ethercat, here is another question. I have now installed a servo( As715N) in my test series, but what is it written as in the ethercat-conf.xml 

   <master idx="0" appTimePeriod="1000000" refClockSyncCycles="-1">
    <slave idx="1" type="EK1100"/>
    <slave idx="2" type="EL1008"/>
    <slave idx="3" type="EL2008"/>
     <slave idx="4" type="AS715N"/>

is that right?

 

Danke für die Rückmeldung,

1) Welcher Button? Der 'Manual Log' button kann eigentlich nicht verschwinden.
2) Was meinst du mit ' keine Dateiänderung angegeben'

Perfect, I'm going to try.

Hi Grotius

I try to upload on my github .... honestly first time for me. when done I advice you. real thanks
Yesterday I try to load your old repo .... maybe I forgot somethings ... but nothings ... seems equal or quite equal ..... I read again and again my old ssd without find anythigs .... but I'm tired in these period ...so maybe somethings is looses .... or for sure is looses .... if not all works.

regards

Good advice on the SSR's and the diagram, I'll do that. Also on the note of switching from steppers to servos.... I only have 2 of my motors so far, do you think I'll regret not just starting with servos? its not too late to return at least 1 of them.

The machine already had a bunch of glentek stuff on it, but it was all oldschool analog and I wanted to modernize and I just impulse bought the biggest steppers I could find.

I m stuck - can you give me an sample of config for real time.
i have mesa 7i92TF - Gecko540

Das kleine Programm ist echt nett und hat mir viel Arbeit erspart. habe gestern ca. 5h damit gearbeitet, ohne dein Programm hätte ich viel länger gebraucht, jetzt muss ich noch die Daten aufbereiten und neu testen. DANKE für so ein cooles Programm.

Was mir aber beim Arbeiten aufgefallen ist.
1) Es werden nicht alle Einstellungen gespeichert.
Beim Neustart musste ich viele Ansichten neu holen, der Button für die Logen war nicht mehr da.
2) Beim Speichern habe ich keine Dateiänderung angegeben, das war für mich anfangs verwirrend, da das Programm dann einfach nichts macht.
3) Ich persönlich finde die Option "Move Type" an dieser Stelle unpassend und würde es lieber über oder unter dem LOG sehen.
Aber das ist Geschmackssache.
4) Da ich kein Englisch kann und alles über den Übersetzer mache, wäre eine Sprachdatei gut, dann könnte man alles in die jeweilige Sprache übersetzen.

Aber das ist nur meine Meinung, ich finde das Programm wirklich gut, es hat mir viel Arbeit erspart, DANEK !!!!!


Gruß Mücke
 

Hi All, 
I've started to build a retrofit system for a Cincinnati Sabre 500 milling machine, however now I've come across a more urgent job where I'd need to reasonably quickly convert one of my Mazak QT10 lathes, Both are known to have faults, I planned to repair them using the original Mazatrol T1 controllers, however the original parameter information and documents are missing from the machines. I have contacted the previous owner, despite his best efforts, he had decided to scrap the machines a week before I contacted him, and put the old manuals in the fire pit as he couldn't sell the machines. 
one machine has a tail stock, one doesn't. Both run ATC turrets 
unlucky for me! (I have an electronics engineer who would have helped repair the machines hardware faults) 
I'm now in the position, of what's going to be the quickest way to get them running,  
options -
1. Fit resolvers to the axis motors and run a Mesa board type setup - lots of custom config and wiring. (I see someone on here has done this on a Mazak before, a micro15, seemed very in depth to get it working) Seems controlling the original spindle wasn't to hard.
2. Fit 2 x new step/direction type servo motors and control it with a Pico systems step/direction controller. Jon has been very helpful with the setup on the milling machine to date.
3. Open to ideas! - the easier the better, I'm very electrically inclined but I'm a mechanic not an engineer

I have built a retrofit cnc controller previously for a stepper motor CNC router using UCCNC, I'm looking to have closed loop feedback on this machine if possible.
I appreciate any help anyone can give towards this subject! 

Check and make sure the directories are correct os the only thing i can think, loke i said i tested it here and it worked as expected. So im not sure why it wouldn't on your install.

AFAIK Sim is non-realtime by definition

Ok cool thanks... it is a HP4600 Workstation and it has a parallel port so it's I guess pretty old now... I might just do and image backup of this HHD and crack on using what I have.

do you have a good configuration for realtime sim config ?

I clicked on file and save or I hit ctrl+s on the keyboard. If I use "Save As..." it shows that the name it is saving to is probe_basic.ui is this the correct name?