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CNC'd Loco Wheel & Earning Brownie Points
philf:
Having finished my CNC miller I wanted to try to cut a wheel for the model "Lion" loco I'm building.
I modelled the wheel in ViaCad:
and today I had a go at cutting one:
The code was generated for me in Vectric Aspire. I used a 3.5mm ball ended cutter for profiling, 3d roughing and 3d finishing. There were about 18,000 lines of code and it took only 19 minutes to cut.
I was really mystified by the order the wheel was cut - it seemed totally random and I was somewhat disappointed that the finished item didn't look like the model. Chamfers on the model weren't completed on the part (only the chamfers adjacent to the spokes were cut!) and the spokes weren't radiused like on the model - it made some attempt at rads but they weren't complete. The rim certainly isn't good enough to run on a rail.
I'm wondering if using a much smaller cutter might improve matters (I can't think why it should) - I'll try get the code redone for me using a 2mm b/e cutter for the 3d finishing to see how it ends up.
The 19 minute cutting time was so quick because it's cut in MDF (painted gold afterwards to make it look like brass) at 1,000mm/min feed rate with a 6mm depth of cut. If cut in mild steel or cast iron I'd probably be using about 100mm/min and max 4mm depth of cut so the cutting time would be more than 3 hours (and with a 2mm cutter probably more than 8 hours!) It will be an interesting exercise but in the end I think I'll have to shell out for the castings.
I've just finished painting the front door and thought I'd finish it off with an engraved number courtesy of the CNC. I've earned a few more Brownie points (which equates to more time in the workshop!) :thumbup: :
Cheers.
Phil
raynerd:
Hi Phil, your door plate looks great, nice one!
I think your wheel looks amazing too but I`m taking from your message that your not that impressed. Your finish is good for MDF - I know you gave use the feed but what spindle speed did you use?
Chris
philf:
--- Quote from: craynerd on April 03, 2012, 02:40:17 AM ---Hi Phil, your door plate looks great, nice one!
I think your wheel looks amazing too but I`m taking from your message that your not that impressed. Your finish is good for MDF - I know you gave use the feed but what spindle speed did you use?
Chris
--- End quote ---
Hi Chris,
I was quite happy with the door plate and , more importantly, so was my wife. To earn some more points I need to get some plastering done on the hall, stairs and landing - she can't see the character in bare brick walls!
The wheel shows some promise and that the miller works OK. Another friend, who used to work for Cosworth, has offered to produce the code for me on a high-end CAM package and so I might take him up on the offer. I think it will still take too long to machine out of a useable material. I used my maximum spindle speed of 10,000rpm and stood holding my vacuum cleaner over it for the 19 minutes - MDF dust isn't very healthy.
I suppose if I were to get into casting I'd at least be able to make the patterns ................
Cheers.
Phil.
75Plus:
What's wrong with this picture?
With such a beautifully finished door plate the attaching screws cry out to have their slots in perfect alignment!!!! :med:
Joe
philf:
--- Quote from: 75Plus on April 03, 2012, 10:15:00 AM ---
What's wrong with this picture?
With such a beautifully finished door plate the attaching screws cry out to have their slots in perfect alignment!!!! :med:
Joe
--- End quote ---
Thanks Joe - I'll go out and line them up now!
(They're now all vertical - is that OK - or do you think they'd be better horizontal?)
:beer:
Phil.
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