Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[Gene Heskett]

On Wednesday 05 April 2017 12:43:23 Mark wrote:

> On 04/05/2017 10:52 AM, Gene Heskett wrote:
> >> One of these days I'll learn coffee and computers are not a good
> >> mix. ;-)
> >>
> >> Mark
> >
> > Particularly if your coffee is contaminated with sugar and cream,
> > black can sometimes be tolerated. :(
> >
> > Cheers, Gene Heskett
>
> Not in my coffee.  Absolutely no additives.  Hot and black.
>
> Mark

Any temp, as long as its black. I'll go to the shop and set a steaming 
cup down someplace safe, and by the time I get back to it, its been at 
ambient for an hour.  But its still wet and still has caffeine in it, 
the 2 most important qualities.

Now to get this sorta back on an lcnc track, do we have a wireshark like 
utility for usb stuff? I am missing both keydown, and keyup events on 
this pi.

Cheers, Gene Heskett
-- 
"There are four boxes to be used in defense of liberty:
 soap, ballot, jury, and ammo. Please use in that order."
-Ed Howdershelt (Author)
Genes Web page 

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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[Gene Heskett]

On Wednesday 05 April 2017 09:20:27 John Kasunich wrote:

> On Wed, Apr 5, 2017, at 05:02 AM, andy pugh wrote:
> > On 5 April 2017 at 03:29, Ralph Stirling 
 wrote:
> > > I just wish there was an open source CAM tool of equal
> > > sophistication for CNC work...
> >
> > Unfortunately Autodesk have rather taken the wind out of the sails
> > of the open-source CAD / CAM projects.
> > Fusion 360 (Windows and Mac only) is (at the moment) zero cost to
> > hobbyists and offers very good CAD and excellent CAM.
> >
> > I can't help expecting Autodesk to wait until everyone is committed
> > to their offering then "turning evil" and starting to charge.
>
> I've been thinking the same thing...  I'm trying to decide what to do
> for my 3D CAD work.  I first got exposed to modern CAD when I was
> using Inventor at work.  Did some home projects using my work laptop
> and Inventor license, love the power of the tool.  But my work
> priorities have changed and I no longer have access to Inventor. 
> Which really drives home the problems of these tools.  The data is NOT
> portable.  I have a couple years of part-time hobby work that I simply
> can't recover.
>
> Solidworks seems to be the industry standard (something like 60%
> market share), but the pricing puts it just as far out of reach as
> Inventor or Pro-E. I actually bought a licence for Alibre a couple
> years ago for almost $1K, but I very quickly became unhappy with both
> the tool and the company (especially the company).  Not willing to
> invest further work into stuff that will be trapped in their format.
>
>  That leaves Fusion 360 and FreeCAD.  I certainly like the philosophy
> behind FreeCAD.  Unfortunately, my projects are typically machinery,
> and I absolutely need to make assemblies from a mix of standard
> (screws, bearings, etc) and custom (housings, shafts, etc) parts. 
> Assemblies seem to be a distant after- thought for FreeCAD.  There
> have been several attempts at an "assembly workbench" for FreeCAD, and
> it looks like every one has died before becoming usable.  I think part
> of the problem might be that the core of FreeCAD was designed by
> people who were thinking only of part design instead of complete
> machine design.  I haven't had time to actually set up and use
> FreeCAD, if anyone can comment on how it handles assemblies I'd like
> to hear from you.
>
> Fusion 360 seems like a very nice tool...  but like Andy, I don't
> trust Autodesk for a second.  My hobby projects move slowly - I need
> tools that are viable over a timescale of a decade or more, (or data
> format that let me extract my work and move to another tool).  I just
> don't see that in the 3D world, from anyone.

Very well said John. What freecad needs are volunteers with a bigger 
vision. And someone to bring their build tools out of the Hardy Heron 
framework. I have not been able to build the later versions for at least 
3 years now. Too many dependencies on really old libraries.
But just for S, I've dl'd the src tarballs for both version 16, and 
17-pre, which has some huge changes in the workflow, NOT recommended for 
beginners like me. :)

But now the scene is reversed, now my libraries are too old.

boost is 1.49, needs 1.55 or greater,

And even version 16, which requires cmake, refuses to do anything but 
spit out about 250k of build help per invocation regardless of what I 
pass as build options.
 
And I finally found an example build command line, which bails out quite 
early as my installed boost libraries are about 6 versions too old.

Back writing description scripts for openscad.  Sheesh...

I made some changes in the addf order in my hal file, and between that 
and hacking up a power bus for the pi directly from the 7i90 power 
input, it seems dead stable. With the maxvel slider set for a speed I  
know x can move at, its probably made a couple dozen lathe_pawns without 
a joint error in a couple hours.  Even my jog wheels can't break it.  
And they are dead accurate repeatable. I have an automation tech driver 
here that could drive x 2x faster, if I had the psu to drive it, needs 
around 5 amps at 70 volts. I can find a switcher in the pile that can do 
4 something at 60, which if it weren't so damned noisy, would help. But 
that thing puts 10 volt switching spikes all over the system.  My 
electronics box simply isn't big enough.  Sigh. 

Thanks John.

Cheers, Gene Heskett
-- 
"There are four boxes to be used in defense of liberty:
 soap, ballot, jury, and ammo. Please use in that order."
-Ed Howdershelt (Author)
Genes Web page 

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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[John Thornton]

I'm in the same boat as you and make machinery, I use SolidWorks but I 
stopped getting upgrades in 2015 due to declining business. I find that 
I can make parts and assemblies very fast in SW but I've not been able 
to do that well in Fusion 360 and I've not tried very hard as it is so 
different than SW. If you can save the files as some standard format you 
can open them in most 3D CAD programs.

JT


On 4/5/2017 8:20 AM, John Kasunich wrote:
>
> On Wed, Apr 5, 2017, at 05:02 AM, andy pugh wrote:
>> On 5 April 2017 at 03:29, Ralph Stirling  
>> wrote:
>>> I just wish there was an open source CAM tool of equal sophistication
>>> for CNC work...
>> Unfortunately Autodesk have rather taken the wind out of the sails of
>> the open-source CAD / CAM projects.
>> Fusion 360 (Windows and Mac only) is (at the moment) zero cost to
>> hobbyists and offers very good CAD and excellent CAM.
>>
>> I can't help expecting Autodesk to wait until everyone is committed to
>> their offering then "turning evil" and starting to charge.
>>
> I've been thinking the same thing...  I'm trying to decide what to do for my
> 3D CAD work.  I first got exposed to modern CAD when I was using Inventor
> at work.  Did some home projects using my work laptop and Inventor license,
> love the power of the tool.  But my work priorities have changed and I no
> longer have access to Inventor.  Which really drives home the problems of
> these tools.  The data is NOT portable.  I have a couple years of part-time
> hobby work that I simply can't recover.
>
> Solidworks seems to be the industry standard (something like 60% market
> share), but the pricing puts it just as far out of reach as Inventor or Pro-E.
> I actually bought a licence for Alibre a couple years ago for almost $1K, but
> I very quickly became unhappy with both the tool and the company (especially
> the company).  Not willing to invest further work into stuff that will be 
> trapped
> in their format.
>
>   That leaves Fusion 360 and FreeCAD.  I certainly like the philosophy behind
> FreeCAD.  Unfortunately, my projects are typically machinery, and I absolutely
> need to make assemblies from a mix of standard (screws, bearings, etc) and
> custom (housings, shafts, etc) parts.  Assemblies seem to be a distant after-
> thought for FreeCAD.  There have been several attempts at an "assembly
> workbench" for FreeCAD, and it looks like every one has died before becoming
> usable.  I think part of the problem might be that the core of FreeCAD was
> designed by people who were thinking only of part design instead of complete
> machine design.  I haven't had time to actually set up and use FreeCAD, if
> anyone can comment on how it handles assemblies I'd like to hear from you.
>
> Fusion 360 seems like a very nice tool...  but like Andy, I don't trust 
> Autodesk
> for a second.  My hobby projects move slowly - I need tools that are viable 
> over
> a timescale of a decade or more, (or data format that let me extract my work
> and move to another tool).  I just don't see that in the 3D world, from 
> anyone.
>


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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[Mark]

On 04/05/2017 10:52 AM, Gene Heskett wrote:
>> One of these days I'll learn coffee and computers are not a good mix.
>> ;-)
>>
>> Mark
>>
> Particularly if your coffee is contaminated with sugar and cream, black
> can sometimes be tolerated. :(
>
> Cheers, Gene Heskett

Not in my coffee.  Absolutely no additives.  Hot and black.

Mark



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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[Ralph Stirling]

I have some assemblies in FreeCAD, which work fine, but I
don't recall if I built them in FreeCAD with the Assembly2
workbench, or if I built them in Inventor, exported as STEP
and imported into FreeCAD.  Looking at the feature tree I
think this assembly was a STEP import.

FreeCAD seems to be under heavy development at present,
so I'm hopeful that it is going to become a pretty useful tool.
It is light years ahead of where it was a couple of years ago.

If you use non-free tools like Fusion360 or Inventor, just save
to STEP or IGES often and you will most likely be able to move
your designs to other tools.

-- Ralph


From: John Kasunich [jmkasun...@fastmail.fm]
Sent: Wednesday, April 5, 2017 6:20 AM
To: emc-users@lists.sourceforge.net
Subject: Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

On Wed, Apr 5, 2017, at 05:02 AM, andy pugh wrote:
> On 5 April 2017 at 03:29, Ralph Stirling <ralph.stirl...@wallawalla.edu> 
> wrote:
> > I just wish there was an open source CAM tool of equal sophistication
> > for CNC work...
>
> Unfortunately Autodesk have rather taken the wind out of the sails of
> the open-source CAD / CAM projects.
> Fusion 360 (Windows and Mac only) is (at the moment) zero cost to
> hobbyists and offers very good CAD and excellent CAM.
>
> I can't help expecting Autodesk to wait until everyone is committed to
> their offering then "turning evil" and starting to charge.
>

I've been thinking the same thing...  I'm trying to decide what to do for my
3D CAD work.  I first got exposed to modern CAD when I was using Inventor
at work.  Did some home projects using my work laptop and Inventor license,
love the power of the tool.  But my work priorities have changed and I no
longer have access to Inventor.  Which really drives home the problems of
these tools.  The data is NOT portable.  I have a couple years of part-time
hobby work that I simply can't recover.

Solidworks seems to be the industry standard (something like 60% market
share), but the pricing puts it just as far out of reach as Inventor or Pro-E.
I actually bought a licence for Alibre a couple years ago for almost $1K, but
I very quickly became unhappy with both the tool and the company (especially
the company).  Not willing to invest further work into stuff that will be 
trapped
in their format.

 That leaves Fusion 360 and FreeCAD.  I certainly like the philosophy behind
FreeCAD.  Unfortunately, my projects are typically machinery, and I absolutely
need to make assemblies from a mix of standard (screws, bearings, etc) and
custom (housings, shafts, etc) parts.  Assemblies seem to be a distant after-
thought for FreeCAD.  There have been several attempts at an "assembly
workbench" for FreeCAD, and it looks like every one has died before becoming
usable.  I think part of the problem might be that the core of FreeCAD was
designed by people who were thinking only of part design instead of complete
machine design.  I haven't had time to actually set up and use FreeCAD, if
anyone can comment on how it handles assemblies I'd like to hear from you.

Fusion 360 seems like a very nice tool...  but like Andy, I don't trust Autodesk
for a second.  My hobby projects move slowly - I need tools that are viable over
a timescale of a decade or more, (or data format that let me extract my work
and move to another tool).  I just don't see that in the 3D world, from anyone.

--
  John Kasunich
  jmkasun...@fastmail.fm

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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[Ken Strauss]

Brass shim stock 0.009 thick is readily available.

> -Original Message-
> From: Gene Heskett [mailto:ghesk...@shentel.net]
> Sent: Wednesday, April 05, 2017 10:51 AM
> To: emc-users@lists.sourceforge.net
> Subject: Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.
>
> On Wednesday 05 April 2017 05:02:37 andy pugh wrote:
>
> > On 5 April 2017 at 03:29, Ralph Stirling
> <ralph.stirl...@wallawalla.edu> wrote:
> > > I just wish there was an open source CAM tool of equal
> > > sophistication for CNC work...
> >
> > Unfortunately Autodesk have rather taken the wind out of the sails of
> > the open-source CAD / CAM projects.
> > Fusion 360 (Windows and Mac only) is (at the moment) zero cost to
> > hobbyists and offers very good CAD and excellent CAM.
>
> And I have neither windows nor Mac's at my place.  So autodesk isn't
visible
> on my horizon.
>
> > I can't help expecting Autodesk to wait until everyone is committed to
> > their offering then "turning evil" and starting to charge.
>
> As sketchup has now done, and as M$ has always done. I presume it
currently
> phones home for auth to run?
>
> As far as librecad goes, one could build a base outline with mount tabs,
then
> the hollowing out part as a separate pattern wrapped in a depth increment,
> then turn it over and do the outside. So it could be used as 3d with
multiple
> runs.
>
> But that would be a huge waste in worn tooling without a mister and in
cubic
> alu thrown in the trash. I can't see that as a worthwhile project even if
I did
> have a block of carveable alu that big.  So the printed plastic part is
looking
> more attractive all the time.
>
> Has anyone any thin brass sheet? I need about a 3" x 4" piece about 9 thou
> thick. I can finish up sealing the crossfeed ball screw trench behind the
> crossfeed when its run inward, exposing that trench in the saddle by
putting a
> felt swarf wiper on the rear of the crossfeed slider, and slipping a sheet
of
> brass under the slider until it hits the nut carrier when its backed all
the way
> out, covering at least an inch of open trench. A .010 feeler blade just
fits
> under the rear edge of the crossfeed slider.
>
> Gotta go fix my lady something for breakfast. Pester folks again later. :)
>
> Cheers, Gene Heskett
> --
> "There are four boxes to be used in defense of liberty:
>  soap, ballot, jury, and ammo. Please use in that order."
> -Ed Howdershelt (Author)
> Genes Web page <http://geneslinuxbox.net:6309/gene>
>
>

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> tech sites, Slashdot.org! http://sdm.link/slashdot
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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[Gene Heskett]

On Wednesday 05 April 2017 06:57:39 Mark wrote:

> On 04/04/2017 11:58 PM, Gene Heskett wrote:
> > On Tuesday 04 April 2017 08:14:00 Mark wrote:
> >> On 04/03/2017 02:24 PM, andy pugh wrote:
> >>> On 3 April 2017 at 18:13, Gene Heskett  
wrote:
>  link crashes firefox.  Expected?
> >>>
> >>> On your computer? Yes.
> >>
> >> Andy,
> >>
> >>
> >> You owe me a new keyboard for that one.  ;-)
> >>
> >>
> >> Mark
> >
> > I'll have to admit I got a chuckle out of it too. ;-)
> >
> > Cheers, Gene Heskett
>
> One of these days I'll learn coffee and computers are not a good mix. 
> ;-)
>
> Mark
>
Particularly if your coffee is contaminated with sugar and cream, black 
can sometimes be tolerated. :(
>
>
> --
> Check out the vibrant tech community on one of the world's
> most engaging tech sites, Slashdot.org! http://sdm.link/slashdot
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Cheers, Gene Heskett
-- 
"There are four boxes to be used in defense of liberty:
 soap, ballot, jury, and ammo. Please use in that order."
-Ed Howdershelt (Author)
Genes Web page 

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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[Gene Heskett]

On Wednesday 05 April 2017 05:02:37 andy pugh wrote:

> On 5 April 2017 at 03:29, Ralph Stirling 
 wrote:
> > I just wish there was an open source CAM tool of equal
> > sophistication for CNC work...
>
> Unfortunately Autodesk have rather taken the wind out of the sails of
> the open-source CAD / CAM projects.
> Fusion 360 (Windows and Mac only) is (at the moment) zero cost to
> hobbyists and offers very good CAD and excellent CAM.

And I have neither windows nor Mac's at my place.  So autodesk isn't 
visible on my horizon.

> I can't help expecting Autodesk to wait until everyone is committed to
> their offering then "turning evil" and starting to charge.

As sketchup has now done, and as M$ has always done. I presume it 
currently phones home for auth to run?

As far as librecad goes, one could build a base outline with mount tabs, 
then the hollowing out part as a separate pattern wrapped in a depth 
increment, then turn it over and do the outside. So it could be used as 
3d with multiple runs.

But that would be a huge waste in worn tooling without a mister and in 
cubic alu thrown in the trash. I can't see that as a worthwhile project 
even if I did have a block of carveable alu that big.  So the printed 
plastic part is looking more attractive all the time.

Has anyone any thin brass sheet? I need about a 3" x 4" piece about 9 
thou thick. I can finish up sealing the crossfeed ball screw trench 
behind the crossfeed when its run inward, exposing that trench in the 
saddle by putting a felt swarf wiper on the rear of the crossfeed 
slider, and slipping a sheet of brass under the slider until it hits the 
nut carrier when its backed all the way out, covering at least an inch 
of open trench. A .010 feeler blade just fits under the rear edge of the 
crossfeed slider.

Gotta go fix my lady something for breakfast. Pester folks again 
later. :)

Cheers, Gene Heskett
-- 
"There are four boxes to be used in defense of liberty:
 soap, ballot, jury, and ammo. Please use in that order."
-Ed Howdershelt (Author)
Genes Web page 

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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[Gene Heskett]

On Wednesday 05 April 2017 04:56:43 andy pugh wrote:

> On 5 April 2017 at 03:31, Gene Heskett  wrote:
> > Interesting, using a wooden mockup.  Nice
>
> That's the traditional way to make cast parts. A wooden pattern is
> built up by hand and is used to make sand moulds.
> If you know the right suppliers you can buy special products to form
> fillets and letters etc in your wooden pattern.
> http://www.johnburn.co.uk/product-range/leather-fillet-wax-fillet-shee
>t-wax/leather-fillet/

My experience dates from the late 1950's, and the products were in bas 
relief on 1/4" thick alu sheets, sometimes with sand molded pipes stuck 
in for sprue's etc. Corn planter seed plates, gear cases for Maytag 
Washing machines, that sort of thing.  Some of the stuff we made wasn't 
easily ID'd as to what part of a machine it may be for. And we didn't 
have time to ask any in depth questions when you are doing enough a day 
to be on piecework pay.

Cheers, Gene Heskett
-- 
"There are four boxes to be used in defense of liberty:
 soap, ballot, jury, and ammo. Please use in that order."
-Ed Howdershelt (Author)
Genes Web page 

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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[andy pugh]

On 5 April 2017 at 14:20, John Kasunich  wrote:
> But my work priorities have changed and I no
> longer have access to Inventor.  Which really drives home the problems of
> these tools.  The data is NOT portable.  I have a couple years of part-time
> hobby work that I simply can't recover.

You might as well install Fusion360 anyway (it will run in a VM) to
convert your .ipt and .iam to a more portable format.

-- 
atp
"A motorcycle is a bicycle with a pandemonium attachment and is
designed for the especial use of mechanical geniuses, daredevils and
lunatics."
— George Fitch, Atlanta Constitution Newspaper, 1916

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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[John Kasunich]

On Wed, Apr 5, 2017, at 05:02 AM, andy pugh wrote:
> On 5 April 2017 at 03:29, Ralph Stirling  
> wrote:
> > I just wish there was an open source CAM tool of equal sophistication
> > for CNC work...
> 
> Unfortunately Autodesk have rather taken the wind out of the sails of
> the open-source CAD / CAM projects.
> Fusion 360 (Windows and Mac only) is (at the moment) zero cost to
> hobbyists and offers very good CAD and excellent CAM.
> 
> I can't help expecting Autodesk to wait until everyone is committed to
> their offering then "turning evil" and starting to charge.
> 

I've been thinking the same thing...  I'm trying to decide what to do for my 
3D CAD work.  I first got exposed to modern CAD when I was using Inventor
at work.  Did some home projects using my work laptop and Inventor license,
love the power of the tool.  But my work priorities have changed and I no
longer have access to Inventor.  Which really drives home the problems of
these tools.  The data is NOT portable.  I have a couple years of part-time
hobby work that I simply can't recover.

Solidworks seems to be the industry standard (something like 60% market
share), but the pricing puts it just as far out of reach as Inventor or Pro-E.
I actually bought a licence for Alibre a couple years ago for almost $1K, but
I very quickly became unhappy with both the tool and the company (especially
the company).  Not willing to invest further work into stuff that will be 
trapped
in their format.

 That leaves Fusion 360 and FreeCAD.  I certainly like the philosophy behind
FreeCAD.  Unfortunately, my projects are typically machinery, and I absolutely
need to make assemblies from a mix of standard (screws, bearings, etc) and
custom (housings, shafts, etc) parts.  Assemblies seem to be a distant after-
thought for FreeCAD.  There have been several attempts at an "assembly
workbench" for FreeCAD, and it looks like every one has died before becoming
usable.  I think part of the problem might be that the core of FreeCAD was
designed by people who were thinking only of part design instead of complete
machine design.  I haven't had time to actually set up and use FreeCAD, if
anyone can comment on how it handles assemblies I'd like to hear from you.

Fusion 360 seems like a very nice tool...  but like Andy, I don't trust Autodesk
for a second.  My hobby projects move slowly - I need tools that are viable over
a timescale of a decade or more, (or data format that let me extract my work
and move to another tool).  I just don't see that in the 3D world, from anyone.

-- 
  John Kasunich
  jmkasun...@fastmail.fm

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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[Mark]

On 04/04/2017 11:58 PM, Gene Heskett wrote:
> On Tuesday 04 April 2017 08:14:00 Mark wrote:
>
>> On 04/03/2017 02:24 PM, andy pugh wrote:
>>> On 3 April 2017 at 18:13, Gene Heskett  wrote:
 link crashes firefox.  Expected?
>>> On your computer? Yes.
>> Andy,
>>
>>
>> You owe me a new keyboard for that one.  ;-)
>>
>>
>> Mark
>>
> I'll have to admit I got a chuckle out of it too. ;-)
>
> Cheers, Gene Heskett

One of these days I'll learn coffee and computers are not a good mix.  ;-)

Mark



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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[andy pugh]

On 5 April 2017 at 03:29, Ralph Stirling  wrote:
> I just wish there was an open source CAM tool of equal sophistication
> for CNC work...

Unfortunately Autodesk have rather taken the wind out of the sails of
the open-source CAD / CAM projects.
Fusion 360 (Windows and Mac only) is (at the moment) zero cost to
hobbyists and offers very good CAD and excellent CAM.

I can't help expecting Autodesk to wait until everyone is committed to
their offering then "turning evil" and starting to charge.

-- 
atp
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designed for the especial use of mechanical geniuses, daredevils and
lunatics."
— George Fitch, Atlanta Constitution Newspaper, 1916

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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[andy pugh]

On 5 April 2017 at 03:31, Gene Heskett  wrote:
> Interesting, using a wooden mockup.  Nice

That's the traditional way to make cast parts. A wooden pattern is
built up by hand and is used to make sand moulds.
If you know the right suppliers you can buy special products to form
fillets and letters etc in your wooden pattern.
http://www.johnburn.co.uk/product-range/leather-fillet-wax-fillet-sheet-wax/leather-fillet/

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"A motorcycle is a bicycle with a pandemonium attachment and is
designed for the especial use of mechanical geniuses, daredevils and
lunatics."
— George Fitch, Atlanta Constitution Newspaper, 1916

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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[Gene Heskett]

On Tuesday 04 April 2017 12:55:10 Ralph Stirling wrote:

> I believe you can use SketchUp for generating STL files
> for 3d printing.  Pretty much any 3d cad tool in existence
> can do so.  Librecad is only 2d, so not much use.  On Linux,
> you are pretty well limited to Openscad and Freecad.
>
> -- Ralph

But while freecad is in the wheezy repo's. selecting it breaks synaptic 
and aptitude, with neither bothering to explain whats broken. So I am 
intermittently poking at openscad's tires but despite looking at the 
examples of the text file input vs the relatively poor video rendition 
it offers when that text file is compiled, I have so far not even spy'd 
the light at the other end of the tunnel.  So I printed what I could get 
from wikibooks, and will see if anything can be learned from them. But 
at 75 pages, I expect its pretty sparse for a new bee like me. Tomorrows 
project unless I see about hauling my tax stuff to the local Block 
office. I'd better do that, and get done with it so I can get 
sidetracked in it for a few days to see if osmosis might help. ;-)

> 
> From: Gene Heskett [ghesk...@shentel.net]
> Sent: Tuesday, April 4, 2017 9:29 AM
> To: emc-users@lists.sourceforge.net
> Subject: Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.
>
> On Tuesday 04 April 2017 06:04:50 Erik Christiansen wrote:
> > On 04.04.17 05:00, Gene Heskett wrote:
> > > On Tuesday 04 April 2017 02:51:22 Gregg Eshelman wrote:
> > > > I wonder if they've heard about lost PLA casting? One off and
> > > > short runs without needing to make expensive, reusable patterns,
> > > > plus the ability to do casting shapes impossible with patterns
> > > > that must be removable from a sand mold, could be a money maker
> > > > for the foundry. 'Course they'd have to get and learn to use a
> > > > 3D printing setup.
> > >
> > > That looks like something I could do, if I had a big enough
> > > printer and could learn how to do the 3d model to feed the slicer
> > > software for the printer. I'm thinking of the belt guards in
> > > particular which would need at least one dimension in the 250mm by
> > > 100 by 100 range.
> >
> > Much much easier (and faster) for a relatively simple L-shaped angle
> > bracket with webs is lost polystyrene foam. For best finish, a
> > hot-wire cutter is a quite simple tool to make and use. (For the big
> > central cut-out, scribe the circle in pen, or pin on a cardboard
> > template, and cut radially to that circumference. Once around, exit
> > by the same radial cut. A little PVA glue seals that up again.) The
> > foot of the L, and webs, are similarly attached with a little PVA
> > glue.
> >
> > In extremis, lacking a hot-wire cutter, the only slicers needed are
> > a pointy breadknife to hack out the hole in the middle, and a sharp
> > box knife or similar to slice out the rectangle, triangles, and
> > external radius. Cold cutting works better (finish-wise) on that
> > fine blue "Styrofoam", sold by Dow as "Blue Ribbon Insulation
> > Boards" or "Wallmate".
> >
> > Do you have any offcuts remaining from lining the garage door, Gene?
> > You could have the pattern done in a day - for nix.
> >
> > Erik
>
> Those scraps of that blueish foam have all been binned or used years
> ago. And Lowes no longer carries that same board in 2" R22 thickness.
> The current product the last time I looked is a white, larger cell
> product and only about R20 because of that, but its the same $35 & tax
> a 4x8 foot sheet.  How it would cut with a hot wire would be TBD.
>
> The composition SW you folks use is I assume OpenScad? I started to do
> a belt cover with librecad, and had made good progress with a wire
> outline of unk dimensions but found its 2d only when I went looking
> for an extrude function.  Dropped that, installed openscad, but the
> only place I can find docs is at wikibooks. Without downloading both
> books from there, I've no clue how many pages of dead tree that would
> be.
>
> librecad apparently does not have any docs, there are none in the
> installed librecad, and clicking of the help button gets an oh fudge,
> I can't find the docs message. Theres not a separate docs package in
> the repo's for wheezy. But its pretty intuitive to draw outlines and
> such.
>
> So openscad seems to be it if I make a full 3d model, mounting tabs
> and all. Its help docs buttons go straight to wikibooks.
>
> How hot does the hot wire need to be? Seeing as how thats best
> jiggered up as a wire support frame I could stick in a vise on the
> g0704'

Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[Gene Heskett]

On Tuesday 04 April 2017 08:14:00 Mark wrote:

> On 04/03/2017 02:24 PM, andy pugh wrote:
> > On 3 April 2017 at 18:13, Gene Heskett  wrote:
> >> link crashes firefox.  Expected?
> >
> > On your computer? Yes.
>
> Andy,
>
>
> You owe me a new keyboard for that one.  ;-)
>
>
> Mark
>
I'll have to admit I got a chuckle out of it too. ;-)

Cheers, Gene Heskett
-- 
"There are four boxes to be used in defense of liberty:
 soap, ballot, jury, and ammo. Please use in that order."
-Ed Howdershelt (Author)
Genes Web page 

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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[Gene Heskett]

On Tuesday 04 April 2017 06:33:33 Gregg Eshelman wrote:

> You'd use a very low fill density, no fill if the pattern can be done
> that way. Better slicers now have a variable density fill capability
> along with variable layer height.Another benefit of 3D printing PLA
> for single use casting patterns is they can be much closer to net
> shape, which will reduce machining time a lot. An extra nifty thing
> with the process is the same 3D model can be used for plaster coated
> lost wax process, where the PLA is burned out the same way, and for
> one part sand mold casting, same as the lost foam process that buries
> molded pieces of styrofoam in the sand.
>
Well, one thing at a time, and I have 2 in the fire ATM.  The 
countershaft in the sheldon spindle drive is awaiting bearings, while I 
see if I have to cut away some of the left bearing boss to allow the 
taperlock screws room to be removed and used as jack screws. Some 
preliminary checking seems to indicate I may have to "make" some room 
for the draw and jack screws.

Project two is going to need Matsche's help. As it may be that we need to 
slow that spi driver down just to get better control over the clock 
edges. I am still haveing joint errors even after the noise from the 
dials is nearly at the vanishing point. The clock signal from the pi 
seems to be slew rate limited, and so critical that I cannot boot 
linuxcnc with a 10x scope probe looking at the spi clock, its very close 
to a sine-squared wave, no real valid logic one when active high. IMO, 
any signal so critically timed as to be destroyed by a 10x scope probes 
presence, needs help in the form of a more squareish slew rate, which 
the pi apparently cannot do.

So I may look around for a 3.3 volt Damn Fast buffer just for that gpio 
pin. And digikey doesn't seem to have anything but balanced line 
drivers.  And this is a single ended circuit.

Thanks Gregg.

Cheers, Gene Heskett
-- 
"There are four boxes to be used in defense of liberty:
 soap, ballot, jury, and ammo. Please use in that order."
-Ed Howdershelt (Author)
Genes Web page 

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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[Gene Heskett]

On Tuesday 04 April 2017 06:28:31 andy pugh wrote:

> On 4 April 2017 at 10:47, Andrew  wrote:
> > I exported the model to STL and feed it to a slicer.
> > It shows ~0,5kg and ~8hrs printing time with 0,45mm layer and 10%
> > infill
>
> But that is 8 hours per part (if using lost-PLA) whereas my
> conventional pattern can be re-used.
>
> This thread seems to have drifted badly. I have made a pattern, the
> pattern is at the foundry.
> My question was how many parts I should have made. It would make
> little sense for anyone to use my design file rather than one
> optimised for their requirements, there is about 45 minutes of work in
> that model, irrelevant compared to printing, machining or
> pattern-making time.
>
> If you are interested in conventional pattern-making, then I have some
> friends who restore old vehicles and so a lot of it:
> http://hmvf.co.uk/forumvb/showthread.php?13514-WW1-Thornycroft-restora
>tion=486322#post486322 For example.

Interesting, using a wooden mockup.  Nice work.  So that is a hint that 
if I print this cover, I should do 2 of them, 1 to put on the shelf for 
taking to the foundry if the best  of the 2 breaks, take the 2nd one to 
the foundry.

Thanks Andy.

Cheers, Gene Heskett
-- 
"There are four boxes to be used in defense of liberty:
 soap, ballot, jury, and ammo. Please use in that order."
-Ed Howdershelt (Author)
Genes Web page 

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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[Ralph Stirling]

STL is about all you can get out of OpenSCAD.  However, FreeCAD
has a useful feature that lets you paste OpenSCAD text files and
generate solid objects in FreeCAD.  At that point all kinds of file
formats can be generated (to transfer to other cad systems).

OpenSCAD is a "programmer's 3d cad tool".  You create a description
of your part with a text editor and then "compile" it to generate your
part.  It is great for basic combinations of primitives, but does not
have support for things like fillets and chamfers without going to a
lot of trouble.  I like to quickly make my part in OpenSCAD, then
move that to FreeCAD where it is easy to apply things like fillets and
chamfers.

I just wish there was an open source CAM tool of equal sophistication
for CNC work...

-- Ralph

From: Gene Heskett [ghesk...@shentel.net]
Sent: Tuesday, April 4, 2017 7:21 PM
To: emc-users@lists.sourceforge.net
Subject: Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

On Tuesday 04 April 2017 06:22:26 Gregg Eshelman wrote:

> 3D printing needs STL format. Any 3D modeling or CAD software that can
> output STL can be made to work as a source for this. One thing though,
> all the 3D slicer software assumes you're working in millimeters.
> That's due to the original scanning laser and vat of resin 3D printers
> only being able to do tiny things, and the guys who created the STL
> format never thought about anyone ever wanting to use such giant units
> as centimeters, let alone inches.
>
> I use Caligari trueSpace 6.6. I can work in millimeters or meters and
> the resulting print is exactly the same size. If I try any other
> units, it does not print the right size.
>
> On Monday, April 3, 2017, 9:10:07 PM MDT, Gene Heskett
<ghesk...@shentel.net> wrote:On Tuesday 04 April 2017 02:51:22 Gregg
Eshelman wrote:
> > I wonder if they've heard about lost PLA casting? One off and short
> > runs without needing to make expensive, reusable patterns, plus the
> > ability to do casting shapes impossible with patterns that must be
> > removable from a sand mold, could be a money maker for the foundry.
> > 'Course they'd have to get and learn to use a 3D printing setup.
>
> That looks like something I could do, if I had a big enough printer
> and could learn how to do the 3d model to feed the slicer software for
> the printer. I'm thinking of the belt guards in particular which would
> need at least one dimension in the 250mm by 100 by 100 range.
>
> Can we slice and print from a sketchup file, or do I had to learn
> freecad?

Looks like sketchup has gone commercial, I'd have to buy a license to
make it usefull.  Back to Openscad I guess. It can export .stl's.  Or
claims it can.

Thanks Gregg.

Cheers, Gene Heskett
--
"There are four boxes to be used in defense of liberty:
 soap, ballot, jury, and ammo. Please use in that order."
-Ed Howdershelt (Author)
Genes Web page <http://geneslinuxbox.net:6309/gene>

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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[Gene Heskett]

On Tuesday 04 April 2017 06:22:26 Gregg Eshelman wrote:

> 3D printing needs STL format. Any 3D modeling or CAD software that can
> output STL can be made to work as a source for this. One thing though,
> all the 3D slicer software assumes you're working in millimeters.
> That's due to the original scanning laser and vat of resin 3D printers
> only being able to do tiny things, and the guys who created the STL
> format never thought about anyone ever wanting to use such giant units
> as centimeters, let alone inches.
>
> I use Caligari trueSpace 6.6. I can work in millimeters or meters and
> the resulting print is exactly the same size. If I try any other
> units, it does not print the right size.
>
> On Monday, April 3, 2017, 9:10:07 PM MDT, Gene Heskett 
 wrote:On Tuesday 04 April 2017 02:51:22 Gregg 
Eshelman wrote:
> > I wonder if they've heard about lost PLA casting? One off and short
> > runs without needing to make expensive, reusable patterns, plus the
> > ability to do casting shapes impossible with patterns that must be
> > removable from a sand mold, could be a money maker for the foundry.
> > 'Course they'd have to get and learn to use a 3D printing setup.
>
> That looks like something I could do, if I had a big enough printer
> and could learn how to do the 3d model to feed the slicer software for
> the printer. I'm thinking of the belt guards in particular which would
> need at least one dimension in the 250mm by 100 by 100 range.
>
> Can we slice and print from a sketchup file, or do I had to learn
> freecad?

Looks like sketchup has gone commercial, I'd have to buy a license to 
make it usefull.  Back to Openscad I guess. It can export .stl's.  Or 
claims it can.

Thanks Gregg.

Cheers, Gene Heskett
-- 
"There are four boxes to be used in defense of liberty:
 soap, ballot, jury, and ammo. Please use in that order."
-Ed Howdershelt (Author)
Genes Web page 

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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[Gene Heskett]

On Tuesday 04 April 2017 06:21:52 andy pugh wrote:

> On 3 April 2017 at 18:13, Gene Heskett  wrote:
> > We have a foundry here, but no clue what sort of a 3d file they
> > might accept. Or what they might have as an NRE price policy
>
> This foundry appears happy to do investment casting from a solid model
> http://www.wisconsinprecision.com/file-types-accepted.php

Interesting, in a bring little red wagonloads of money way. At this time 
I don't know enough to even ask for a "quick quote".

Thanks, Andy, bookmarked FFR.

Cheers, Gene Heskett
-- 
"There are four boxes to be used in defense of liberty:
 soap, ballot, jury, and ammo. Please use in that order."
-Ed Howdershelt (Author)
Genes Web page 

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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[Gene Heskett]

On Tuesday 04 April 2017 06:19:46 andy pugh wrote:

> On 4 April 2017 at 10:46, Gene Heskett  wrote:
> >> There again, I had about 20 hours of machine time to make the solid
> >> pattern: https://goo.gl/photos/64p9cNWnEamwxUzz5
> >
> > Humm, I think you'll need a bigger vacuum than what I see sitting
> > there. :)  What sort of materiel is that?
>
> It is actually Sikablock 950. Which is sold for making prototype press
> tooling: (And, in fact, my source is a broken press tool from work).
> https://www.youtube.com/watch?v=1qc5gZE_XUg

I looked at the video, and thats one tough bit of plastic! I presume it 
has a price tag to reflect its usefullness on the production line...
Thanks Andy.

Cheers, Gene Heskett
-- 
"There are four boxes to be used in defense of liberty:
 soap, ballot, jury, and ammo. Please use in that order."
-Ed Howdershelt (Author)
Genes Web page 

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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[Ralph Stirling]

I believe you can use SketchUp for generating STL files
for 3d printing.  Pretty much any 3d cad tool in existence
can do so.  Librecad is only 2d, so not much use.  On Linux,
you are pretty well limited to Openscad and Freecad.

-- Ralph

From: Gene Heskett [ghesk...@shentel.net]
Sent: Tuesday, April 4, 2017 9:29 AM
To: emc-users@lists.sourceforge.net
Subject: Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

On Tuesday 04 April 2017 06:04:50 Erik Christiansen wrote:

> On 04.04.17 05:00, Gene Heskett wrote:
> > On Tuesday 04 April 2017 02:51:22 Gregg Eshelman wrote:
> > > I wonder if they've heard about lost PLA casting? One off and
> > > short runs without needing to make expensive, reusable patterns,
> > > plus the ability to do casting shapes impossible with patterns
> > > that must be removable from a sand mold, could be a money maker
> > > for the foundry. 'Course they'd have to get and learn to use a 3D
> > > printing setup.
> >
> > That looks like something I could do, if I had a big enough printer
> > and could learn how to do the 3d model to feed the slicer software
> > for the printer. I'm thinking of the belt guards in particular which
> > would need at least one dimension in the 250mm by 100 by 100 range.
>
> Much much easier (and faster) for a relatively simple L-shaped angle
> bracket with webs is lost polystyrene foam. For best finish, a
> hot-wire cutter is a quite simple tool to make and use. (For the big
> central cut-out, scribe the circle in pen, or pin on a cardboard
> template, and cut radially to that circumference. Once around, exit by
> the same radial cut. A little PVA glue seals that up again.) The foot
> of the L, and webs, are similarly attached with a little PVA glue.
>
> In extremis, lacking a hot-wire cutter, the only slicers needed are a
> pointy breadknife to hack out the hole in the middle, and a sharp box
> knife or similar to slice out the rectangle, triangles, and external
> radius. Cold cutting works better (finish-wise) on that fine blue
> "Styrofoam", sold by Dow as "Blue Ribbon Insulation Boards" or
> "Wallmate".
>
> Do you have any offcuts remaining from lining the garage door, Gene?
> You could have the pattern done in a day - for nix.
>
> Erik
>
Those scraps of that blueish foam have all been binned or used years ago.
And Lowes no longer carries that same board in 2" R22 thickness. The
current product the last time I looked is a white, larger cell product
and only about R20 because of that, but its the same $35 & tax a 4x8
foot sheet.  How it would cut with a hot wire would be TBD.

The composition SW you folks use is I assume OpenScad? I started to do a
belt cover with librecad, and had made good progress with a wire outline
of unk dimensions but found its 2d only when I went looking for an
extrude function.  Dropped that, installed openscad, but the only place
I can find docs is at wikibooks. Without downloading both books from
there, I've no clue how many pages of dead tree that would be.

librecad apparently does not have any docs, there are none in the
installed librecad, and clicking of the help button gets an oh fudge, I
can't find the docs message. Theres not a separate docs package in the
repo's for wheezy. But its pretty intuitive to draw outlines and such.

So openscad seems to be it if I make a full 3d model, mounting tabs and
all. Its help docs buttons go straight to wikibooks.

How hot does the hot wire need to be? Seeing as how thats best jiggered
up as a wire support frame I could stick in a vise on the g0704's table
and rig some sort of a sheet gripper leaving a cutaway, for the hot wire
to move within, attached to the chip pan, if I get it rigid enough to
keep its place as the wire moves, I could probably just write gcode to
drive the cutters path. Where it needs a lid like the outside face of a
belt cover, just cut the outline out and glue it on.

But, I think buying the printer would get me a nicer looking belt cover.

Have any of you bought an open frame big enough to use, then built an
insulating box to make it run smoother and faster? Best deal for the
dollar but with a pellet fed head, that and working envelope big enough
for a 10x5x4 length.width,height, or 250x125x100 in mm's.

Throw some brand names I can google for at me please.
>
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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[Gene Heskett]

On Tuesday 04 April 2017 06:04:50 Erik Christiansen wrote:

> On 04.04.17 05:00, Gene Heskett wrote:
> > On Tuesday 04 April 2017 02:51:22 Gregg Eshelman wrote:
> > > I wonder if they've heard about lost PLA casting? One off and
> > > short runs without needing to make expensive, reusable patterns,
> > > plus the ability to do casting shapes impossible with patterns
> > > that must be removable from a sand mold, could be a money maker
> > > for the foundry. 'Course they'd have to get and learn to use a 3D
> > > printing setup.
> >
> > That looks like something I could do, if I had a big enough printer
> > and could learn how to do the 3d model to feed the slicer software
> > for the printer. I'm thinking of the belt guards in particular which
> > would need at least one dimension in the 250mm by 100 by 100 range.
>
> Much much easier (and faster) for a relatively simple L-shaped angle
> bracket with webs is lost polystyrene foam. For best finish, a
> hot-wire cutter is a quite simple tool to make and use. (For the big
> central cut-out, scribe the circle in pen, or pin on a cardboard
> template, and cut radially to that circumference. Once around, exit by
> the same radial cut. A little PVA glue seals that up again.) The foot
> of the L, and webs, are similarly attached with a little PVA glue.
>
> In extremis, lacking a hot-wire cutter, the only slicers needed are a
> pointy breadknife to hack out the hole in the middle, and a sharp box
> knife or similar to slice out the rectangle, triangles, and external
> radius. Cold cutting works better (finish-wise) on that fine blue
> "Styrofoam", sold by Dow as "Blue Ribbon Insulation Boards" or
> "Wallmate".
>
> Do you have any offcuts remaining from lining the garage door, Gene?
> You could have the pattern done in a day - for nix.
>
> Erik
>
Those scraps of that blueish foam have all been binned or used years ago. 
And Lowes no longer carries that same board in 2" R22 thickness. The 
current product the last time I looked is a white, larger cell product 
and only about R20 because of that, but its the same $35 & tax a 4x8 
foot sheet.  How it would cut with a hot wire would be TBD.

The composition SW you folks use is I assume OpenScad? I started to do a 
belt cover with librecad, and had made good progress with a wire outline 
of unk dimensions but found its 2d only when I went looking for an 
extrude function.  Dropped that, installed openscad, but the only place 
I can find docs is at wikibooks. Without downloading both books from 
there, I've no clue how many pages of dead tree that would be.

librecad apparently does not have any docs, there are none in the 
installed librecad, and clicking of the help button gets an oh fudge, I 
can't find the docs message. Theres not a separate docs package in the 
repo's for wheezy. But its pretty intuitive to draw outlines and such.

So openscad seems to be it if I make a full 3d model, mounting tabs and 
all. Its help docs buttons go straight to wikibooks.

How hot does the hot wire need to be? Seeing as how thats best jiggered 
up as a wire support frame I could stick in a vise on the g0704's table 
and rig some sort of a sheet gripper leaving a cutaway, for the hot wire 
to move within, attached to the chip pan, if I get it rigid enough to 
keep its place as the wire moves, I could probably just write gcode to 
drive the cutters path. Where it needs a lid like the outside face of a 
belt cover, just cut the outline out and glue it on.

But, I think buying the printer would get me a nicer looking belt cover.

Have any of you bought an open frame big enough to use, then built an 
insulating box to make it run smoother and faster? Best deal for the 
dollar but with a pellet fed head, that and working envelope big enough 
for a 10x5x4 length.width,height, or 250x125x100 in mm's.

Throw some brand names I can google for at me please. 
>
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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[Mark]

On 04/03/2017 02:24 PM, andy pugh wrote:
> On 3 April 2017 at 18:13, Gene Heskett  wrote:
>> link crashes firefox.  Expected?
> On your computer? Yes.
>
Andy,


You owe me a new keyboard for that one.  ;-)


Mark


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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[Erik Christiansen]

On 04.04.17 10:21, andy pugh wrote:
> On 4 April 2017 at 07:51, Gregg Eshelman  wrote:
> > I wonder if they've heard about lost PLA casting?
> 
> This is a 13kg casting in iron, that would be 2kg of PLA, about £40.
> Though i guess you would use a low fill density, so it wouldn't be
> quite that much.

+1

The reason that lost foam works well is the large amount of air and
small amount of plastic. The gush of flame from the riser(s) is limited,
at least on smaller castings, resistance to metal flow is negligible,
and heat loss to plastic fusion is minimal.

To replicate that, I figure that 3D printing would have to print a thin
solid skin to exclude the mould sand, and a very open internal weave,
sufficient to support the external walls, but minimising the height of
the flames at the vents, as well as the obstruction to metal flow.
(The last is doubtless a bit less critical with CI than Al, so long as
the risers and vents can vent the gas pressure, to avoid molten metal
erupting back out while pouring.)

A mould cavity filled with 2 kg of solid plastic fuel does not bear
contemplation. If the printed volume were as much as 10% plastic, I'd
experiment with a quite small one first - for the purpose of surviving
the experience.

Erik

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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[Gregg Eshelman]

You'd use a very low fill density, no fill if the pattern can be done that way. 
Better slicers now have a variable density fill capability along with variable 
layer height.Another benefit of 3D printing PLA for single use casting patterns 
is they can be much closer to net shape, which will reduce machining time a lot.
An extra nifty thing with the process is the same 3D model can be used for 
plaster coated lost wax process, where the PLA is burned out the same way, and 
for one part sand mold casting, same as the lost foam process that buries 
molded pieces of styrofoam in the sand.

On Monday, April 3, 2017, 9:28:43 PM MDT, andy pugh  
wrote:On 4 April 2017 at 07:51, Gregg Eshelman  wrote:
> I wonder if they've heard about lost PLA casting?

This is a 13kg casting in iron, that would be 2kg of PLA, about £40.
Though i guess you would use a low fill density, so it wouldn't be
quite that much.
But it would be many hours of extrusion time.

There again, I had about 20 hours of machine time to make the solid pattern:
https://goo.gl/photos/64p9cNWnEamwxUzz5
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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[andy pugh]

On 4 April 2017 at 10:47, Andrew  wrote:
> I exported the model to STL and feed it to a slicer.
> It shows ~0,5kg and ~8hrs printing time with 0,45mm layer and 10% infill


But that is 8 hours per part (if using lost-PLA) whereas my
conventional pattern can be re-used.

This thread seems to have drifted badly. I have made a pattern, the
pattern is at the foundry.
My question was how many parts I should have made. It would make
little sense for anyone to use my design file rather than one
optimised for their requirements, there is about 45 minutes of work in
that model, irrelevant compared to printing, machining or
pattern-making time.

If you are interested in conventional pattern-making, then I have some
friends who restore old vehicles and so a lot of it:
http://hmvf.co.uk/forumvb/showthread.php?13514-WW1-Thornycroft-restoration=486322#post486322
For example.

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lunatics."
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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[andy pugh]

On 4 April 2017 at 10:46, Gene Heskett  wrote:
>> There again, I had about 20 hours of machine time to make the solid
>> pattern: https://goo.gl/photos/64p9cNWnEamwxUzz5
>
> Humm, I think you'll need a bigger vacuum than what I see sitting
> there. :)  What sort of materiel is that?

It is actually Sikablock 950. Which is sold for making prototype press tooling:
(And, in fact, my source is a broken press tool from work).
https://www.youtube.com/watch?v=1qc5gZE_XUg

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designed for the especial use of mechanical geniuses, daredevils and
lunatics."
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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[Gregg Eshelman]

3D printing needs STL format. Any 3D modeling or CAD software that can output 
STL can be made to work as a source for this. One thing though, all the 3D 
slicer software assumes you're working in millimeters.
That's due to the original scanning laser and vat of resin 3D printers only 
being able to do tiny things, and the guys who created the STL format never 
thought about anyone ever wanting to use such giant units as centimeters, let 
alone inches.

I use Caligari trueSpace 6.6. I can work in millimeters or meters and the 
resulting print is exactly the same size. If I try any other units, it does not 
print the right size.

On Monday, April 3, 2017, 9:10:07 PM MDT, Gene Heskett  
wrote:On Tuesday 04 April 2017 02:51:22 Gregg Eshelman wrote:

> I wonder if they've heard about lost PLA casting? One off and short
> runs without needing to make expensive, reusable patterns, plus the
> ability to do casting shapes impossible with patterns that must be
> removable from a sand mold, could be a money maker for the foundry.
> 'Course they'd have to get and learn to use a 3D printing setup.

That looks like something I could do, if I had a big enough printer and 
could learn how to do the 3d model to feed the slicer software for the 
printer. I'm thinking of the belt guards in particular which would need 
at least one dimension in the 250mm by 100 by 100 range.

Can we slice and print from a sketchup file, or do I had to learn 
freecad?
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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[andy pugh]

On 3 April 2017 at 18:13, Gene Heskett  wrote:
> We have a foundry here, but no clue what sort of a 3d file they might
> accept. Or what they might have as an NRE price policy

This foundry appears happy to do investment casting from a solid model
http://www.wisconsinprecision.com/file-types-accepted.php

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designed for the especial use of mechanical geniuses, daredevils and
lunatics."
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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[Erik Christiansen]

On 04.04.17 05:00, Gene Heskett wrote:
> On Tuesday 04 April 2017 02:51:22 Gregg Eshelman wrote:
> 
> > I wonder if they've heard about lost PLA casting? One off and short
> > runs without needing to make expensive, reusable patterns, plus the
> > ability to do casting shapes impossible with patterns that must be
> > removable from a sand mold, could be a money maker for the foundry.
> > 'Course they'd have to get and learn to use a 3D printing setup.
> 
> That looks like something I could do, if I had a big enough printer and 
> could learn how to do the 3d model to feed the slicer software for the 
> printer. I'm thinking of the belt guards in particular which would need 
> at least one dimension in the 250mm by 100 by 100 range.

Much much easier (and faster) for a relatively simple L-shaped angle
bracket with webs is lost polystyrene foam. For best finish, a hot-wire
cutter is a quite simple tool to make and use. (For the big central
cut-out, scribe the circle in pen, or pin on a cardboard template, and
cut radially to that circumference. Once around, exit by the same radial
cut. A little PVA glue seals that up again.) The foot of the L, and
webs, are similarly attached with a little PVA glue.

In extremis, lacking a hot-wire cutter, the only slicers needed are a
pointy breadknife to hack out the hole in the middle, and a sharp box
knife or similar to slice out the rectangle, triangles, and external
radius. Cold cutting works better (finish-wise) on that fine blue
"Styrofoam", sold by Dow as "Blue Ribbon Insulation Boards" or
"Wallmate".

Do you have any offcuts remaining from lining the garage door, Gene?
You could have the pattern done in a day - for nix.

Erik


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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[Andrew]

2017-04-04 12:21 GMT+03:00 andy pugh :

> This is a 13kg casting in iron, that would be 2kg of PLA, about £40.
> Though i guess you would use a low fill density, so it wouldn't be
> quite that much.
> But it would be many hours of extrusion time.
>

I exported the model to STL and feed it to a slicer.
It shows ~0,5kg and ~8hrs printing time with 0,45mm layer and 10% infill
density (with a Volcano hotend, which performs twice faster than usual).
And that's not a completely hollow part http://i63.tinypic.com/4t8z5u.png
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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[Gene Heskett]

On Tuesday 04 April 2017 05:21:10 andy pugh wrote:

> On 4 April 2017 at 07:51, Gregg Eshelman  wrote:
> > I wonder if they've heard about lost PLA casting?
>
> This is a 13kg casting in iron, that would be 2kg of PLA, about £40.
> Though i guess you would use a low fill density, so it wouldn't be
> quite that much.
> But it would be many hours of extrusion time.
>
> There again, I had about 20 hours of machine time to make the solid
> pattern: https://goo.gl/photos/64p9cNWnEamwxUzz5

Humm, I think you'll need a bigger vacuum than what I see sitting 
there. :)  What sort of materiel is that?

Thanks Andy.

Cheers, Gene Heskett
-- 
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 soap, ballot, jury, and ammo. Please use in that order."
-Ed Howdershelt (Author)
Genes Web page 

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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[andy pugh]

On 4 April 2017 at 07:51, Gregg Eshelman  wrote:
> I wonder if they've heard about lost PLA casting?

This is a 13kg casting in iron, that would be 2kg of PLA, about £40.
Though i guess you would use a low fill density, so it wouldn't be
quite that much.
But it would be many hours of extrusion time.

There again, I had about 20 hours of machine time to make the solid pattern:
https://goo.gl/photos/64p9cNWnEamwxUzz5

-- 
atp
"A motorcycle is a bicycle with a pandemonium attachment and is
designed for the especial use of mechanical geniuses, daredevils and
lunatics."
— George Fitch, Atlanta Constitution Newspaper, 1916

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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[Gene Heskett]

On Tuesday 04 April 2017 02:51:22 Gregg Eshelman wrote:

> I wonder if they've heard about lost PLA casting? One off and short
> runs without needing to make expensive, reusable patterns, plus the
> ability to do casting shapes impossible with patterns that must be
> removable from a sand mold, could be a money maker for the foundry.
> 'Course they'd have to get and learn to use a 3D printing setup.

That looks like something I could do, if I had a big enough printer and 
could learn how to do the 3d model to feed the slicer software for the 
printer. I'm thinking of the belt guards in particular which would need 
at least one dimension in the 250mm by 100 by 100 range.

Can we slice and print from a sketchup file, or do I had to learn 
freecad?

Looking at the relative cost of the string vs the pellet fed printing 
head, pellet is 5% of the string on a cost per pound basis.  One belt 
guard out of pellets would pay for the diff in print heads, and I can 
think of several things hacked up out of 1/2" alu plate now that would 
look better if cast, but would probably be plenty functional in one of 
the higher temp plastics, like timeing belt guards. Z is fairly well out 
of the way, and I'll have a keyboard/mouse  house/shelf above it, but x 
is right in the flying swarf path.  Don't like the plastics color?  
Paint it.

And I am fairly familiar with iron casting, having spent much of a summer 
setting and pouring the molds I set at the end of my shift in an iron 
foundry in Perry Iowa. But then I was in my mid 20's, ten foot tall and 
bulletproof enough to handle an 80 lb bucket of iron on the far end of a 
6 foot handle.  Today I'd be hurting whats left of my back with 5 lbs of 
iron in a clay lined and lipped small bucket. That summer hurt my back 
and its never fully recovered.

> On Monday, April 3, 2017, 5:17:33 AM MDT, Gene Heskett
>  wrote: We have a foundry here, but no clue what
> sort of a 3d file they might accept. Or what they might have as an NRE
> price policy. Currently their main contract is for wheel hubs for 20"
> and 24" White Truck wheels. White being one of our smaller truck
> makers in terms of the overall market for "large cars" here in the US.
> So I'd expect the NRE stuff may be farmed out, and the finished form
> shipped back for pouring and final machining.
>
> Cheers, Gene Heskett
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Cheers, Gene Heskett
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 soap, ballot, jury, and ammo. Please use in that order."
-Ed Howdershelt (Author)
Genes Web page 

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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[Gregg Eshelman]

I wonder if they've heard about lost PLA casting? One off and short runs 
without needing to make expensive, reusable patterns, plus the ability to do 
casting shapes impossible with patterns that must be removable from a sand 
mold, could be a money maker for the foundry.
'Course they'd have to get and learn to use a 3D printing setup.

On Monday, April 3, 2017, 5:17:33 AM MDT, Gene Heskett  
wrote:
We have a foundry here, but no clue what sort of a 3d file they might 
accept. Or what they might have as an NRE price policy. Currently their 
main contract is for wheel hubs for 20" and 24" White Truck wheels.  
White being one of our smaller truck makers in terms of the overall 
market for "large cars" here in the US. So I'd expect the NRE stuff may 
be farmed out, and the finished form shipped back for pouring and final 
machining.

Cheers, Gene Heskett
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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[sam sokolik]

Hehehe...

works great here - even tool paths.

http://electronicsam.com/images/KandT/testing/Screenshot-60.png

sam

On 04/03/2017 01:24 PM, andy pugh wrote:
> On 3 April 2017 at 18:13, Gene Heskett  wrote:
>> link crashes firefox.  Expected?
> On your computer? Yes.
>


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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[andy pugh]

On 3 April 2017 at 18:13, Gene Heskett  wrote:
> link crashes firefox.  Expected?

On your computer? Yes.

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designed for the especial use of mechanical geniuses, daredevils and
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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[Gene Heskett]

On Monday 03 April 2017 11:37:54 andy pugh wrote:

> I am making a 4th-axis out of an FHA Harmonic drive. This is an
> integrated system of harmonic drive, crossed-roller bearing and servo
> motor.
>
> Specs here. I am working with the 25-sized part:
> http://www.harmonicdrive.net/products/rotary-actuators/hollow-shaft-ac
>tuators/fha-c (Note that the -C variant is much harder to interface
> than the -B variant to LinuxCNC-supported hardware)
>
> I have just handed over the pattern to the foundry for a right-angle
> housing. http://a360.co/2oQX7Ct

link crashes firefox.  Expected?

> is the 3D model of the pattern. The inner bore will need to be
> machined to suit the harmonic drive.
>
> I have just checked, and the casting can just about be used with the
> FHA-17 sized actuators (the mounting flange cleans-up to give a land
> around the mounting screws, but with a rather generous chamfer) and
> you _could_ use it with the FHA-32 size if you were prepared to
> break-through the top semicircle and dress back what is left.
>
> I don't yet know how much each casting will cost, but I would guess
> approximately £75. I should have an estimate later in the week.
> So far I have 3 spoken-for. One for me and one each for two other
> folk. Does anyone else want one, bearing in mind that they are likely
> to be 13kg and postage to (for example) the US would be £50 and
> Germany £11.

We have a foundry here, but no clue what sort of a 3d file they might 
accept. Or what they might have as an NRE price policy. Currently their 
main contract is for wheel hubs for 20" and 24" White Truck wheels.  
White being one of our smaller truck makers in terms of the overall 
market for "large cars" here in the US. So I'd expect the NRE stuff may 
be farmed out, and the finished form shipped back for pouring and final 
machining.

Cheers, Gene Heskett
-- 
"There are four boxes to be used in defense of liberty:
 soap, ballot, jury, and ammo. Please use in that order."
-Ed Howdershelt (Author)
Genes Web page 

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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[andy pugh]

On 3 April 2017 at 17:30, Peter Blodow  wrote:
> Sorry, I just get a white screen after a lot of downloading. Must be an
> autocad-specific file format!?

It should be an online 3D viewer.

-- 
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designed for the especial use of mechanical geniuses, daredevils and
lunatics."
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Re: [Emc-users] Cast Bracket for FHA-25 Harmonic Actuator.

[Peter Blodow]

Sorry, I just get a white screen after a lot of downloading. Must be an 
autocad-specific file format!?
Peter

Am 03.04.2017 17:37, schrieb andy pugh:
> I have just handed over the pattern to the foundry for a right-angle housing.
> http://a360.co/2oQX7Ct
> is the 3D model of the pattern. The inner bore will need to be
> machined to suit the harmonic drive.
>


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