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harriebouwens
1375 Views, 15 Replies

How to mill a moineau rotor on a 4th axis

As I wanted to make a Moineau Pump for a clay-extruder or pellet extruder, I managed to make the design.(see attachement) in Fusion360.

But I'm struggling with the CAM part.

I have a CNC Mill with 4th axis, controlled via MACH3. So in one way or another it should be possible. Walking to the different posts, and videos it seems not that simple.

 

In the attached file you can see my setup, and 2 contour trials., but I miss the indexing part, and cannot find how to add that

 

Does someone have a better idea how to machine this rotor?

 

sstephe1622
in reply to: harriebouwens

I do not have Fusion360 ultimate.  But if you go into the top level directory with all the samples and look for a folder called Ultimate, there is a file there called wrapped that you can look at and see how they set it up.  There is also a tutorial on YouTube using that exact model.

Thanks for the reply. I will try to find that file. But what I found is that the wrap option only is valid for constant thickness layer, but not for an organic form.
Steinwerks
in reply to: harriebouwens

Unfortunately wrap is not going to work for this part as it is a function only of the 2D toolpaths.

 

My closest workaround would be something like Project using a sketch and then patterning it around the body using the work axis, but that requires a separate sketch and toolpath for each pass which is very tedious.

 

Project.JPG

Neal Stein

New to Fusion 360 CAM? Click here for an introduction to 2D Milling, here for 2D Turning.

Find me on:
Instagram and YouTube
Mike.Grau
in reply to: harriebouwens

Hi @harriebouwens,

 

Thank you for sharing your design with us.

I have tried to find possible setup, I hope this can be helpful. http://a360.co/2yOiQRH

 

test.PNG

 

Thank you,

Steinwerks
in reply to: Mike.Grau

@Mike.Grau

 

And here I was hoping you'd managed to get Swarf to work in 4th-axis continuous mode! Smiley Very Happy

Neal Stein

New to Fusion 360 CAM? Click here for an introduction to 2D Milling, here for 2D Turning.

Find me on:
Instagram and YouTube
Mike.Grau
in reply to: Steinwerks

Hi @Steinwerks,

 

Yes, we could but that would be a bit more work with sketchs, planes and split face :slightly_smiling_face:

Let me try that when I have a gap later the day.


Thanks,

harriebouwens
in reply to: Mike.Grau

Mike,

 

I understand what you did, but your last 3 operations are from one side only. Shouldn't these not be copied to the other side as for the 2 adaptive operations?

And what exactly is the difference between the 2 morphed spirals ? Or should one of these be on the other side?

Mike.Grau
in reply to: Mike.Grau

Hi @Steinwerks @harriebouwens,

 

Thanks for giving me the challenge :slightly_smiling_face:

 

The previous file was just a bit playing with the features to see the result. Yes, I would have to change the WCS for every operation using 3D Adaptive.

I have chosen 3D Adaptive to to get rid of the most of the material, ideally from four sides, rotating the WCS by 90°.

 

I think I found a way to use the 4th axis here, we just needed some feature edges. http://a360.co/2yOiQRH

It is not the "Swarf" feature but includes the 4th axis in continuous movement :slightly_smiling_face: Just an idea to have a workaround 

 

 
I hope this helps. Please, keep me updated.
 
Thanks, 
harriebouwens
in reply to: Mike.Grau

Your ideas guys, gave me a solution: See the attached file.

 

In the sketch I added every 45 degrees a helpline, selectable. In the CAM section this helps to index the part in the 4th axis. Now I divided in 8, maybe I need more.  This way doesn't take to much time to program. For each new machining position you just have to change the Z-direction, according the help lines. All other parameters are the same.

 

In the simulation, apart from the resolution all looks  fine, but maybe you have an improvement??

 

This will work on my MACH3 controlled router. I'm not sure if a continuous rotation is possible. 

 

The only code I have to find out, is the way MACH3 will rotate automatically to the new position.

 

Thanks for the help sofar.

 

Mike.Grau
in reply to: harriebouwens

Hi Harrie,

 

Yes, that looks like a great idea.

Here is a setup which takes a bit longer but the result looks actually pretty good and its 4th axis continuous :winking_face: http://a360.co/2yOiQRH

 

test.PNG

 

I hope this helps.


Thank you,

Steinwerks
in reply to: Mike.Grau

@Mike.Grau

 

That toolpath doesn't work with the Fanuc Inverse Time post Smiley Wink

 

("Direction is not supported for machine configuration.")@:0

Neal Stein

New to Fusion 360 CAM? Click here for an introduction to 2D Milling, here for 2D Turning.

Find me on:
Instagram and YouTube
harriebouwens
in reply to: Mike.Grau

Mike,

 

Posting your file with "MACH3 mill with A axis" gave the attached error.(1002.log)

 

The Moineau Rotor Ok file , with the same postprocesor, gave a gcode file as attached.

 

After I finish my 4th axis I will try this.  As soon as I have results I will show them here.

 

Mike and Neil many thanks for this support, I loved it

 

 

As I was waiting for my 4th axis I found a way without a 4th axis :slightly_smiling_face:

 

The trick is using a exact square stock, and clamp that in a corner, as the picture shows. Turning the stock 4 times gives you the ability to simulate a 4th axis.

I tried this in wood as a proof of principle. Although the calmping is not perfect, the result is already nice., but not perfect.

 

The setup and pictures are attached.

harriebouwens
in reply to: Mike.Grau

As I have my 4th axis now I'm able to machine the Moineau rotor. I only need only 1 180degree rotation to machine the rotor. See MoineauRotor2Sides.f3d

 

But I was wondering if it was possible to machine the rotor in a vertical position, fixed in the vise and walk around with a rounded slotmill as in MoineuRotorVertical.f3d

It starts as if it is working but....it takes a while calculating, and he doesn't finish to the bottom. 

 

Any ideas what parameters I have to change?

michel.lebois
in reply to: sstephe1622

please i can not configure fusion for the rotary 4 axis in y you can help me not so do post processing, do you have one? thank you