FamiLAB

Projects => Project Journals => Topic started by: DWoodsTEC on August 07, 2013, 11:41:19 AM

Title: HAAS VF-1 Rebuild
Post by: DWoodsTEC on August 07, 2013, 11:41:19 AM
Last night Simply7 asked me to get the dimensions of a screw for the Big CNC.
It is a 1/4" 10-24 flathead with an 1/8" hex socket.  It has a standard countersink of 82 degrees.


A picture should be attached but I don't see it in the preview.  (some day I will figure all this stuff out)
Title: Re: HAAS VF-1 Rebuild
Post by: Simply7 on August 07, 2013, 12:37:28 PM
Announcing the  CNC hackathon!!!   This event will run from the 23rd through the weekend until we have a working and fully assembled HAS CNC machine.

As you can see Dave has got the dimensions for the screws we need for the tool holder. I'll order those this week so we will have the neccessary parts.

If you have worked on the machine previously and are aware of other parts that we may need please post here with any info you have and we can try to get them before the 23rd.

Pocky has a worklist of some things that need to be done and we'll work on those things as well.


This will be a Familab member event only, and I'll bring doughnuts.
Title: Re: HAAS VF-1 Rebuild
Post by: Chorca on August 07, 2013, 08:42:59 PM
I have the new screws for the ATC. The cap head ones, not the really small ones. I am trying to get the smaller ones, but they are hard to find. Fastenal has them, but they need to be ordered.

Sent from my SGH-T889 using Tapatalk 2

Title: Re: HAAS VF-1 Rebuild
Post by: willasaywhat on August 08, 2013, 06:28:42 PM
Simply7, want me to put this event on the calendar? Love the idea!
Title: Re: HAAS VF-1 Rebuild
Post by: Simply7 on August 08, 2013, 07:53:32 PM
Sure. Sounds like a good idea.
Title: Re: HAAS VF-1 Rebuild
Post by: willasaywhat on August 09, 2013, 12:44:47 AM
Done!
Title: Re: HAAS VF-1 Rebuild
Post by: Simply7 on August 13, 2013, 07:20:39 AM
Chorca, I've found the small screws through grainger, but it has to be ordered in quantities of 100. (27$) Is Fastenal any better/worse?
Title: Re: HAAS VF-1 Rebuild
Post by: Hybridsix on August 13, 2013, 08:56:16 AM
Have you tried McMaster?

Title: Re: HAAS VF-1 Rebuild
Post by: Simply7 on August 13, 2013, 12:21:23 PM
Yes, and they had some that were close (philips head, not hex). But I hate to use philips in this as there would be a chance to strip the threads and cause more problems.
Title: Re: HAAS VF-1 Rebuild
Post by: P47 on August 13, 2013, 12:39:32 PM
Simply7, try mscdirect.com as well. Sometimes if mcmaster doesn't have an item, msc does. Both suppliers are very similar, and I equally order from both.
Both have hubs out of Atlanta, and usually delivered the next day.


For instance, mcmaster did NOT have the plastic for the eyes on my last project, and msc did  ;)
Title: Re: HAAS VF-1 Rebuild
Post by: Simply7 on August 14, 2013, 06:21:45 PM
Mike found the part numbers for screws so I order them. Mike also mentioned that we need replacement windows (polycarbonate).

 Does anyone know what size they were?
Title: Re: HAAS VF-1 Rebuild
Post by: Hybridsix on August 14, 2013, 09:46:32 PM
We'll have to measure. Not sure if we ever did that to begin with. We can use the old doors in the meantime, if we have to.
Title: Re: HAAS VF-1 Rebuild
Post by: Simply7 on August 15, 2013, 08:19:31 AM
Got the measurements and have ordered the screws and polycarbonate (grainger's impact resistant poly).  These sheets will need to be cut and then heated and formed with two angles (same for both sheets).

Anyone have experience with this that wants to jump in?
Title: Re: HAAS VF-1 Rebuild
Post by: Hybridsix on August 15, 2013, 08:26:24 AM
I'm pretty sure P47 knows how to form these panels. Pat?
Title: Re: HAAS VF-1 Rebuild
Post by: P47 on August 15, 2013, 09:04:57 AM
In the past I've used nichrome wire for larger jobs, and a heatgun for smaller projects. It pays to make a bending jig (or something similar) as see in this video.
DIY: Nichrome Wire Acrylic Bending Table Tutorial (http://www.youtube.com/watch?v=wVEf7PfuKxo#ws)
To use the wire we would need, some thick nichrome wire, wood, aluminum channel and angles, and some hinges, etc. The lab has a variac.
Spare plastic sheets, or at least some to test.


Could try the heatgun and bending it over the edge of a tabletop with a clamp on the top... it might work . I helped Dan do something like this. Though the length wasn't too long and the plastic wasn't too thick it did work pretty good.


***Spare plastic sheets, or at least some to test and get dialed in***
Title: Re: HAAS VF-1 Rebuild
Post by: Simply7 on August 15, 2013, 09:28:02 AM
We will be working with 20x40 sheet of 3/16 inch thick.  I ordred 24x48 so we will have small strips for testing.

We have the old pieces which we can use to make measurements for the jigs.

Title: Re: HAAS VF-1 Rebuild
Post by: Simply7 on August 19, 2013, 09:11:26 PM
The screws and polycarbonate door panels have arrived. I will be delivering Friday... Maybe sooner.
Title: Re: HAAS VF-1 Rebuild
Post by: ki4swy on August 19, 2013, 11:03:23 PM
if you need more polycarbonate, let me know, i have a few sheets of 48x48 .
Title: Re: HAAS VF-1 Rebuild
Post by: Simply7 on August 23, 2013, 11:59:25 AM
The CNC hackaton begins!
Title: Re: HAAS VF-1 Rebuild
Post by: digitalman2112 on August 23, 2013, 12:01:53 PM
Awesome! Keep taking pics!!
Title: Re: HAAS VF-1 Rebuild
Post by: Hybridsix on August 23, 2013, 12:22:42 PM
I'll be there later for sure! Don't finish it all without me. :)

Title: Re: HAAS VF-1 Rebuild
Post by: Simply7 on August 23, 2013, 04:21:10 PM
Small emergency had to step out..... Back to hack shortly.
Title: Re: HAAS VF-1 Rebuild
Post by: Simply7 on August 23, 2013, 06:53:47 PM
Big thanks to new member Sean who helped clean (a inadequate word for this job) and assemble the auto tool changer. Our other new member, Mike, deserves a big round of thanks as well for helping figure out how the rest of the parts went together.

Few parts are missing.... The two next to the allen wrench.
Title: Re: HAAS VF-1 Rebuild
Post by: Simply7 on August 24, 2013, 10:13:25 AM
As promised....
Title: Re: HAAS VF-1 Rebuild
Post by: willasaywhat on August 24, 2013, 03:50:53 PM
Photos for hoses: http://imgur.com/a/AzBTf (http://imgur.com/a/AzBTf)
Title: Re: HAAS VF-1 Rebuild
Post by: willasaywhat on August 24, 2013, 03:54:28 PM
Photos for the blog: http://imgur.com/a/cIwgQ (http://imgur.com/a/cIwgQ)
Title: Re: HAAS VF-1 Rebuild
Post by: Simply7 on August 24, 2013, 06:58:35 PM
Tool holder is in and working. I'll try to get the video up loaded for the test run.

 Not all 16 slots are available as the corrosion was pretty bad on the base of the tool changer. Slots 1,2,3 & 16 should never be used as the doors are fixed shut to prevent metal shavings entering the tool changer.

New tube is in place and ready to be connected.  Getting close.
Title: Re: HAAS VF-1 Rebuild
Post by: willasaywhat on August 24, 2013, 08:41:51 PM
HAAS Door: http://imgur.com/a/YIxd2 (http://imgur.com/a/YIxd2)
Title: Re: HAAS VF-1 Rebuild
Post by: willasaywhat on August 24, 2013, 10:02:06 PM
HAAS Right Door: http://imgur.com/a/6PRIy (http://imgur.com/a/6PRIy)
Title: Re: HAAS VF-1 Rebuild
Post by: P47 on August 25, 2013, 08:02:04 AM
Bill, Thanks for the pics.
Title: Re: HAAS VF-1 Rebuild
Post by: digitalman2112 on August 25, 2013, 09:09:02 AM
Is there more HAAS work planned for today?
Title: Re: HAAS VF-1 Rebuild
Post by: Hybridsix on August 25, 2013, 10:43:19 AM
I believe there are some people going up there, but I do not think I am joining.

We got pretty far last night, the z way cover and the motor shroud is on.

Rick replaced the tool release switch with another, as we didn't have the electronics part to the stock switch.

We are close to putting the outside tub and doors on.

Sent from my SPH-L710 using Tapatalk 2

Title: Re: HAAS VF-1 Rebuild
Post by: Simply7 on August 25, 2013, 04:40:14 PM
Here's the current status.

Back & bottom panels are attached!!  It's starting to look 'whole' again.

I googled around and found 3 other people that were restoring the same machine.  One of the problems noted was the front facing way cover there are cables that travel when the machine is moving on the Z? axis.  The cables are installed during the construction of the machine so they are quite hard to replace.  These cables are dragged back and for during cuts, and ours was moving through grease and metal shavings.  Fortunately the outer casing too all the damage.  The wires themselves are in excellent condition.   We need a thin wall flexible hose that is very flexible.  I've left everything exposed so take a look an give me a recommendation on what to use here. I had thought of using the extra oil hose an sealing the wires in that....


What else...
 Need some more machine screws to attache the mystery black C  shaped hunk of metal.  Turns out this fits around the table (cutting area).  This piece is mainly to catch debry.

Attach small panel under motor cover.  I didn't attach this as I suspect that there may be something that attaches to the two... lines?  Need someone to check and see if we need to do anything under here.

Need some oil resistant sealant to go around the bottom pan where it attaches to the metal base.  This keep liquid coolant from leaking.  I've already cleaned with acetone, so its just a matter of applying the goop.  Just don't know what kind to use.

Clean up and check coolant pump

Fix the doors/windows.  I've broke down and cleaned all the mechanical parts, just need someone (PAT  ;) ) to bend the polycarbonate into the correct position.

So just 5 steps to go.
1.  Cover wires & reattach way cover
2.  Seal the bottom pan
3.  Attach cutting tray
4.  Assemble shell with shiny new doors.
5. Clean and test pump.
 
Title: Re: HAAS VF-1 Rebuild
Post by: PockyBum522 on August 25, 2013, 07:44:43 PM
I think the real machine is Rick :p It looks awesome.
Title: Re: HAAS VF-1 Rebuild
Post by: Hybridsix on August 26, 2013, 10:18:20 AM
Okay, quick mind-dump before I forget.


To get stuff from your mind into the HAAS, through the use of a computer, Its a three step process.


CAD - CAM - DNC


CAD - This is whatever you perfer. Solidworks, FreeCAD, AutoCAD, anything that'll make a 3d file



CAM - This takes your 3D file and generates g-code/toolpaths. I have looked a few a CAM software packages. Some are less expensive than others, but most have a demo that we can try out to see if it'll make the machine do. Most will import a multitude of file formats, but some only work with singular files. Cost on these has ranged from Free to thousands... I'm most interested in Cut3D from Vectric(we have Cut2D for the 4x4 Router now), VisualMILL/FreeMILL from Mechsoft, GibbsCAM, Bob-CAD/CAM, and Mastercam. (EDIT: Adding CamBam) There are many others. Most importantly, we should be sure to look for one that has HAAS post-processing capability, and support for ATC's (Automatic Tool Changers). I'd like to see us get a full 3D Cam program, instead of just the 2.5D like we have for the router. Perhaps whatever we get for the HAAS can also be used with the router.


DNC - This is the communications program that "Pushes" the g-code to the HAAS. Everyone recomends NOT using hyperterminal FWIW. I found a free one for linux without much searching, DNC-X (easyDNC). Looks fairly straightforward. People have used it with HAAS Machinery.





Title: Re: HAAS VF-1 Rebuild
Post by: Simply7 on August 28, 2013, 12:47:50 PM
Got some more work done last night.  The cutting tray is in place and the bottom pan is sealed.  We are now down to the doors, the shell, and the pump.

When I left Pat was working on a jig for bending the polycarbonate for the doors and Mike was loading programs from his laptop to the HAAS.

I took a look back in Google+ and  Oct 3rd was day one of the breakdown.  OMG... I didn't see it when it first came in but this thing was covered in metal shavings, coolant residue,grease, rust, and abuse. Awesome work getting this cleaned up.


Title: Re: HAAS VF-1 Rebuild
Post by: Hybridsix on August 29, 2013, 09:12:06 AM
So. Another morning brain dump. I should really stop staying up looking at HAAS information all night...




Info!
I had serial communication working to and from the HAAS to my laptop, via a cable which is tied to the machine, and a serial-usb adapter. (9600, 7, xon/xoff, 1). I was using a basic serial terminal program on my ubuntu laptop.


Our machine has about 90kb of program space, give or take some. Hardly anything!


To overcome this, I have found a method called "Drip Feeding" which our machine should support - essentially, it loads some Gcode into its memory buffer, does those operations, and then asks for the next set. This is where a good DNC program comes in.


I have a price for some CAM software, a full retail package with two copies, plus training videos. Considering a lab kickstarter for this.


Looking into finding a good set of g-code info that I could print out poster size to stick by the HAAS. Might be good in case I decide to start programming this thing manually.




Other things:
We need to really check out the automatic oilier system I do not know if it is working, but this is vital to keeping our machine running. This should be high up on our priority list. Even if it is working, we should change the oil out. who knows the condition of that stuff.


We need to scrounge around the lab, and see what kind of things we have for clamps and tools. I know we have some good hold downs and some paralells  - not sure if we've got a HAAS worthy clamp or not.

Title: Re: HAAS VF-1 Rebuild
Post by: Chorca on August 30, 2013, 01:55:24 PM
Which software were you looking at? CamBam?
Title: Re: HAAS VF-1 Rebuild
Post by: Hybridsix on August 30, 2013, 02:18:10 PM
I currently have been working with Bob-CAD/CAM to get us a good deal on a few seats of the software, plus training videos. We'll see what happens though.
Title: Re: HAAS VF-1 Rebuild
Post by: Hybridsix on August 31, 2013, 07:24:44 PM
Micha and I took the automatic oiler off the HAAS, cleaned, and refilled. It appears that its works. Should be noted that I pumped oil through the machine manually while it was running the warm up program, and squirted lots of oil. (there's a little extra in the tub, oops!)


Its a cyclic oiler. so, the system runs VERY slowly, primes it, then releases it, pushing about 20psi of oil pulse into the system. I'm confident that this all works now.


I also changed a setting in the menu that allows us to send it MDI data on a stream from a computer, overcoming the 90kb limit.
Title: Re: HAAS VF-1 Rebuild
Post by: Simply7 on August 31, 2013, 11:51:04 PM
Is the oiler system what keeps the linear rails lubricated?

Awesome job  on the continous feed option for gcode.
Title: Re: HAAS VF-1 Rebuild
Post by: Hybridsix on September 01, 2013, 12:45:25 AM
Yes, the automatic oiler keeps the linear slides and ball screws lubricated. It can, and does now use the same oil that we had for the transmission. I filed it up about 3/4 of the way.


Sent from my SPH-L710 using Tapatalk 2

Title: Re: HAAS VF-1 Rebuild
Post by: digitalman2112 on September 01, 2013, 09:48:31 AM
Really impressed by this rebuild, thanks for all the hard work!
Title: Re: HAAS VF-1 Rebuild
Post by: Simply7 on September 03, 2013, 08:42:22 AM
I'll be coming in today to work on the HAAS  some more (before open house). Is there anything that needs to be done before I put the lid on? I think the doors and compressor hose can be done after, but would like confirmation if anyone can provide.
Title: Re: HAAS VF-1 Rebuild
Post by: Hybridsix on September 03, 2013, 09:45:27 AM
I think we're good to go. I did spill some oil inside the lower housing, from me over-pumping the oiler that could be cleaned up, but i'm not sure how necessary that is.


Pocky wired the door switch closed so that we don't have to do the door hold override setting - at least, until we put the doors back on.


I bought a long heating element, that we might be able to use to bend the door plastic, its sitting by the old doors on the table.


I have some G-Code that I wrote last night that i'm going to put into the machine tonight, hopefully, to draw a FamiLAB logo.



Title: Re: HAAS VF-1 Rebuild
Post by: Simply7 on September 03, 2013, 10:24:43 AM
That will be one heavy duty plotter!

I'll dig around and see if I can find the drill that p47 needed for the doors.
Title: Re: HAAS VF-1 Rebuild
Post by: PockyBum522 on September 08, 2013, 08:54:49 PM
Is gift.


http://imgur.com/myjqe0l (http://imgur.com/myjqe0l)


You can has gift. Is gift.
Title: Re: HAAS VF-1 Rebuild
Post by: P47 on September 08, 2013, 09:16:55 PM
Awesome Pocky  :)
Title: Re: HAAS VF-1 Rebuild
Post by: PockyBum522 on September 08, 2013, 09:22:14 PM
For those of you that can't make it down, that's a milling vice, some plastic and aluminum stock, 4 roughers of various diameters and alloys, 5 1/4" endmills of Carbide, 5 3/8 HSS endmills and 4 Carbide 1/2" endmills
Title: Re: HAAS VF-1 Rebuild
Post by: Simply7 on September 09, 2013, 09:02:34 AM
Christmas came early!
Title: Re: HAAS VF-1 Rebuild
Post by: Simply7 on September 10, 2013, 09:39:46 PM
The panels are all attached. Doors are next...and we should probably check out the pump/fluid.
Title: Re: HAAS VF-1 Rebuild
Post by: P47 on September 10, 2013, 09:49:21 PM
She looks BEAUTIFUL!
Title: Re: HAAS VF-1 Rebuild
Post by: AtomicProf on October 23, 2013, 06:30:43 PM
Can someone give an update as to what remains to be done please?
Title: Re: HAAS VF-1 Rebuild
Post by: Hybridsix on October 23, 2013, 06:38:09 PM
Doors need to be fabricated, bent, etc. Coolant purchased, and some basic test programs created.

Sent from my SPH-L710 using Tapatalk 2

Title: Re: HAAS VF-1 Rebuild
Post by: Simply7 on October 23, 2013, 07:22:49 PM
After I finish my halloween project I plan to do a little more work.  We also need to fix the air line. I think we just need a quick disconect adapter.
Title: Re: HAAS VF-1 Rebuild
Post by: Hybridsix on October 23, 2013, 09:02:26 PM
You mean the airgun line on the front of the machine? yeah. Would also not be a terrible idea to replace the air filters/driers, but that's a secondary issue.
Title: Re: HAAS VF-1 Rebuild
Post by: willasaywhat on October 25, 2013, 11:20:07 AM
After everything calms down, let's figure out what it'll take to get this thing up and running once and for all. I want a working HAAS for 2014. :)
Title: Re: HAAS VF-1 Rebuild
Post by: ki4swy on October 25, 2013, 11:49:36 AM
Brian has the 36" plexi/acylic bender he was willing to donate to the lab... Maybe i will poke him if i see him over the next week to make get to Ian to bring to the lab.


He was the gentleman who hung out with me @ the maker faire, and also at the after party.



Title: Re: HAAS VF-1 Rebuild
Post by: Simply7 on October 25, 2013, 01:21:36 PM
Poke Brian +1
Title: Re: HAAS VF-1 Rebuild
Post by: Simply7 on November 06, 2013, 09:10:06 AM
I spoke with Ian last night and he said we could pick it up ourselves if we were so inclinde.

I want to finish those doors and Doug is willing to help. So if its possible can I go and pick it up?  PM me for contact info and we can try to arrange something.
Title: Re: HAAS VF-1 Rebuild
Post by: Hybridsix on November 06, 2013, 09:34:39 AM
we're so close guys. I also told Doug that he could take the vice home to clean it. In case anyone wonders where that has gone.

Title: Re: HAAS VF-1 Rebuild
Post by: Simply7 on November 06, 2013, 09:41:09 AM
Willa,
Can you post the pics that you took of the doors to the drop box. I will not even pretend I remeber all the details for reassembly.

Thx
Title: Re: HAAS VF-1 Rebuild
Post by: willasaywhat on November 06, 2013, 09:43:04 AM
I think they are on page 2 of this thread, if you need more I can check my archives. :)
Title: Re: HAAS VF-1 Rebuild
Post by: ki4swy on November 06, 2013, 10:55:43 AM
I will see him at SPF.. i will try to get him to throw it in his truck, he is very timid, and doesn't get out much :(


When he is in the village chat, i will ask him again.

Title: Re: HAAS VF-1 Rebuild
Post by: Simply7 on November 06, 2013, 12:29:46 PM
Thanks Willa i found them.
Title: Re: HAAS VF-1 Rebuild
Post by: PockyBum522 on November 07, 2013, 12:06:44 PM
I'll pick it up. Where's it at? Give me an address. john@davidsik.es
Title: Re: HAAS VF-1 Rebuild
Post by: Simply7 on November 07, 2013, 12:51:00 PM
I can help with the pickup as well. We should also see about making a standard form for donations so people can get a tax write off.
Title: Re: HAAS VF-1 Rebuild
Post by: Simply7 on November 08, 2013, 05:21:26 PM
What is the SPF event?  I was planning on fixing the doors this coming Tuesday. Any chance the spf is before then?
Title: Re: HAAS VF-1 Rebuild
Post by: digitalman2112 on November 08, 2013, 05:26:32 PM
SPF = Southern Pinball Festival - http://www.southernpinballfestival.net/SPF/index.php (http://www.southernpinballfestival.net/SPF/index.php)

Nov 22-24
Title: Re: HAAS VF-1 Rebuild
Post by: P47 on November 08, 2013, 05:26:45 PM
Did Bill poke Brian?


With the right tool we could have these bent in minutes  :)
Title: Re: HAAS VF-1 Rebuild
Post by: P47 on November 08, 2013, 05:34:54 PM
OR

Maybe I could grab the plexi and goto Brians... he lives right by me   
Title: Re: HAAS VF-1 Rebuild
Post by: ki4swy on November 08, 2013, 06:23:31 PM
Pat, Maybe you can reach out to him, He was kinda turned off after the membership rules change..
Title: Re: HAAS VF-1 Rebuild
Post by: Claybuster on November 10, 2013, 08:30:51 PM
I took the vise apart, cleaned it, and reassembled it with grease and way oil.  I still need to replace its missing jaw bolt, make guide blocks, and make a handle.  I'll bring the vise Tuesday evening.  The handle and guide blocks will follow.
Title: Re: HAAS VF-1 Rebuild
Post by: Simply7 on November 11, 2013, 05:54:46 PM
Awesome. Another step closer.
Title: Re: HAAS VF-1 Rebuild
Post by: Simply7 on November 20, 2013, 07:40:15 AM
Does it look like the acrylic bender is still going to happen?  Let me know cause we are close to cutting and need doors. If not I'll set up a jig and get them finished.
Title: Re: HAAS VF-1 Rebuild
Post by: ki4swy on November 20, 2013, 07:42:31 AM
i asked him to throw in the truck for southern pinball festival this weekend.
Title: Re: HAAS VF-1 Rebuild
Post by: PockyBum522 on November 20, 2013, 11:19:32 PM
Thanks :D That's awesome.
Title: Re: HAAS VF-1 Rebuild
Post by: Simply7 on November 21, 2013, 09:58:37 AM
Very cool. Claybuster and I put some time on the haas and the hydraulics and air lines are now connected.

Lights are next on the list with doors.
Title: Re: HAAS VF-1 Rebuild
Post by: Ben2 on November 23, 2013, 10:23:26 AM
I saw the heating strip for the plastic sheet bender.  Do we need to fab up a hinge-like folding platform, or were we thinking of trying to just lift the edge up by hand evenly and hold it still while it cools, or hang it partially off the edge of a table or something, etc?
-Ben2
Title: Re: HAAS VF-1 Rebuild
Post by: ki4swy on November 23, 2013, 10:34:26 AM
you should be able to heat it, and then bend by hand without issue..
Title: Re: HAAS VF-1 Rebuild
Post by: P47 on November 23, 2013, 10:54:11 AM
If it helps, there's some wood that I cut that has the angle of the bend.


~P47
Title: Re: HAAS VF-1 Rebuild
Post by: Simply7 on November 26, 2013, 10:31:07 AM
Did the acrylic bender make it to the lab?  I thought I saw a post but can't find it. I plan to do more work on the Haas Wednesday. If we dont have the bender I will take a shot at bending wit the heating element on some of the scrap pieces. See whats possible.
Title: Re: HAAS VF-1 Rebuild
Post by: Claybuster on November 26, 2013, 11:26:09 AM
I'll join you Wednesday, what time?  This time I will not be late due to buying a Knee Mill.


Sent from my iPad using Tapatalk (http://tapatalk.com/m?id=1)
Title: Re: HAAS VF-1 Rebuild
Post by: Simply7 on November 26, 2013, 01:10:31 PM
I plan to be there around 5:00
Title: Re: HAAS VF-1 Rebuild
Post by: ki4swy on November 26, 2013, 06:04:06 PM
yes, rhe bender was left there last friday.. (http://img.tapatalk.com/d/13/11/27/yvutary8.jpg)
Title: Re: HAAS VF-1 Rebuild
Post by: Simply7 on November 26, 2013, 08:07:44 PM
Shiny!  Any special instructions or just heat & bend?
Title: Re: HAAS VF-1 Rebuild
Post by: ki4swy on November 26, 2013, 08:10:42 PM
heat, and bend
Title: Re: HAAS VF-1 Rebuild
Post by: Claybuster on November 27, 2013, 09:36:58 PM
Simply7, I realized what the springs are for and I hung the completed door.  The rollers need a little tweaking and grease but it is working pretty good.  It looks so good it outshines the mill.


Sent from my iPad using Tapatalk (http://tapatalk.com/m?id=1)
Title: Re: HAAS VF-1 Rebuild
Post by: Simply7 on November 27, 2013, 09:40:29 PM
Doug (claybuster) and I started working on the doors.

We made some jigs one was 45? the other 30ish.

After boiling some scrap polycarbonate we went for it.

Then had to hold in place as our jig didn't have a pressure fit.

Then we drilled some holes and moved the fittings over

Final pictures compare the old and new.

The acrylic bender is good basic model. If someone knows how add a thermostat that would be a nice add. Doug and i talked about adding some hinges to one side with a device to measuee the degree of the bend.
Works good but test with scrap so you know how long to leave it heating.
Title: Re: HAAS VF-1 Rebuild
Post by: Hybridsix on November 27, 2013, 09:42:06 PM
Could you hook the strip up to a variac? We have one in the lab somewhere

Sent from my SPH-L710 using Tapatalk

Title: Re: HAAS VF-1 Rebuild
Post by: Hybridsix on November 27, 2013, 09:42:17 PM
Also, excellent job! :-)

Sent from my SPH-L710 using Tapatalk

Title: Re: HAAS VF-1 Rebuild
Post by: digitalman2112 on November 27, 2013, 09:42:30 PM
Wow - that looks amazing!!
Title: Re: HAAS VF-1 Rebuild
Post by: Hybridsix on November 28, 2013, 12:01:37 AM
Simply7 - Found at least one source for those D018 keys, if they cannot be copied.


http://www.pac-supply.com/Allen-Bradley--D018-replacement-keys_p_1595.html (http://www.pac-supply.com/Allen-Bradley--D018-replacement-keys_p_1595.html)


I'm sure there are others, but that came up with them in stock, at a relatively reasonable price. 6 keys for $21.
Title: Re: HAAS VF-1 Rebuild
Post by: PockyBum522 on November 28, 2013, 11:26:40 AM
You all are amazing. Great work :D
Title: Re: HAAS VF-1 Rebuild
Post by: Claybuster on December 03, 2013, 07:35:04 PM
The doors are on.


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Title: Re: HAAS VF-1 Rebuild
Post by: willasaywhat on December 03, 2013, 07:53:22 PM
Thank you, they look awesome! :D
Title: Re: HAAS VF-1 Rebuild
Post by: Simply7 on December 03, 2013, 10:43:24 PM
Shiny!
Title: Re: HAAS VF-1 Rebuild
Post by: ki4swy on December 03, 2013, 10:46:38 PM
now lets see it work :)
Title: Re: HAAS VF-1 Rebuild
Post by: Chorca on December 03, 2013, 10:48:09 PM
Freaking superb job on the doors guys. Sorry I haven't been here as much but its awesome to see it coming back together!

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Title: Re: HAAS VF-1 Rebuild
Post by: Claybuster on December 12, 2013, 01:24:44 PM
I haven't been to the lab for a week because I've been out of town or swamped.  I did order and have received a CAT40 Jacobs chuck.  I' ll be out of town again tomorrow through Sunday, I expect to be at the lab cutting aluminum next Tue or Wed using the MDI interface.



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Title: Re: HAAS VF-1 Rebuild
Post by: Hybridsix on December 12, 2013, 01:26:42 PM
Awesome! I'll be there tuesday for sure. :) Look forward to seeing what you have going on. :)
Title: Re: HAAS VF-1 Rebuild
Post by: Simply7 on December 12, 2013, 01:59:19 PM
Very cool. PM when you nail down a day, I would love to see first cut.
Title: Re: HAAS VF-1 Rebuild
Post by: Claybuster on December 17, 2013, 02:14:18 PM
I hope to cut some AL this evening.


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Title: Re: HAAS VF-1 Rebuild
Post by: Hybridsix on December 17, 2013, 02:16:05 PM
I'll be there! We can get it going after the meeting. What do you intend to cut out of the aluminum?    Do we need to find coolant?

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Title: Re: HAAS VF-1 Rebuild
Post by: Claybuster on December 17, 2013, 03:13:43 PM
We'll be OK without coolant this evening.


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Title: Re: HAAS VF-1 Rebuild
Post by: Simply7 on December 18, 2013, 08:19:36 AM
Claybuster was successful in cutting and drilling. The cut failed at one point but that was a clamp issue.

Pocky, can you post the video?
Title: Re: HAAS VF-1 Rebuild
Post by: Hybridsix on December 18, 2013, 09:32:39 AM
It was awesome watching the machine run, even for just the drilling cycles. Great Job Claybuster!


for the record, this is what it involved in the drilling cycles:


Claybuster typed in his G-Code manually into the machine (~12 lines maybe?) into the MDI program interface


He set the part zero point to where he programmed from in x and y using the wobbly edge finder device(technical name?) mounted in a jacobs chuck. He then subtracted radius of the tool from the resulting "zero" position, to get the true center position for each axis.


Then, a standard/jobber type drill bit was placed into the jacobs chuck, and tightened down. The spindle and tool were then moved closer, and closer to the "top" of the part, with a sheet of paper in between to set the Z axis part zero, moving that back and forth until it no longer moved.


Once the work was set in it's zero point (on the G54 part) he went to the tool offsets for the #4 tool (the one that was in the spindle) and set the tool offsets for this tool. If I recall correctly, this was zero, or near to it, as the machine takes the tool zero/offset off of the work zero, not machine zero.


The machine was run at very low feed/sped rates, to ensure that the e-stop button could be hit in time if needed. The six holes that were drilled were using a standard (non peck) drilling cycle.


Unfortunately, when the machine was set up to cut the pocket out of his plate, one of the clamps gave way and the part was no longer in a condition to be used.


Claybuster - did I forget anything? You were the one working the machine, I was just observing. :)
Title: Re: HAAS VF-1 Rebuild
Post by: Hybridsix on December 18, 2013, 09:33:19 AM
I should also ask - Have we ensured that the machine clamp is itself zeroed to the bed?
Title: Re: HAAS VF-1 Rebuild
Post by: Ben2 on February 19, 2014, 10:02:19 AM
Last night I fiddled with the HAAS.  I got rather familiar with it.  Everything from writing a short program at the controller and running it "in the air", to simple stuff to realizing the machine needs compressed air hooked up first, Lol.
 
I successfully fumbled through about 5 alarm messages I stumbled upon over the course of the evening, but the last one stumped me.  118 Spindle Low Gear Fault.  Basically it's behaving like it's having an issue shifting into low gear for the lower speed that I'd like to use for larger bits/ tools.
 
I did some reading on the alarm, but I was wondering if anyone has already figured this one out... the 118 Spindle Low Gear Fault?
 
BTW, do we have/ need some cutting coolant?
 
-Ben2
Title: Re: HAAS VF-1 Rebuild
Post by: Hybridsix on February 19, 2014, 10:35:47 AM
We don't have any cutting coolant, but Doug and I talked about it. If we use flood coolant, we just need to take some precautions when we're done with the machine (i.e. machine wiped down of all coolant to prevent rust) and we'll probably have to change out the coolant when it gets bacteria and such growing it it (apparently it starts to smell).


118 - spindle low gear fault -


Not sure if I've encountered that error, but most anything I've had to do with the spindle/gears has been air pressure. The HAAS I think runs on about 90-100psi of air, and will complain sometimes if its less. Although, this could be the mystery error that the company that donated it to us was having, although seems unrelated to their complaint - they were saying that when the spindle had a lot of torque on it, (cutting through metals/etc) it would throw a fault, but when cutting through soft materials (plastics, wood) , it would run just fine. What RPM were you trying to run it at? Did you runt  the machine through a warm up cycle first?
Title: Re: HAAS VF-1 Rebuild
Post by: Ben2 on February 19, 2014, 01:41:19 PM
I didn't run a warm up cycle.  I'll look into what it is.
 
I noticed that the pressure regulator on the back of the HAAS was only set at 35 psi according to the gague.  I turned the regulator thinking, this can't possibly run on only 35 psi, but the needle on the gague never moved.  (Bad gague, bad regulator, does the regulator have a lock-out ring to prevent movement?)  So I wonder if that is what could be it?  The blue vertical compressor (digital) was indicating over 100 psi output, so that end seems to be ok.  If the machine is only getting/ indicating 30-ish psi, that could be the problem if it needs more pressure to shift gears.
 
Coolant will smell after a while, and ways-lubricating oil will eventually accumulate in the coolant too.  But coolant ususally has rust-preventative additives in it, so wiping down/ removing the coolant from the machine surfaces is unnecessary (in my experience).  But blowing coolant off the machine surfaces with compressed air when finished machining is common practice also.
Title: Re: HAAS VF-1 Rebuild
Post by: Claybuster on March 11, 2014, 02:22:30 PM
The HAAS has three needs to call it fully operational; in priority they are:

1) Dedicated PC.  Preferably with Serial port, for sending GCODE files less than 64K and drip feeding files > 64K.  It would be best if this were a laptop that we could mount right on the existing control panel.  I've found a DNC program for $60 that has very specific and complete instructions for the communicating to HAAS machines.  Once we get a PC I'll free-trial it to confirm.  (only three wires of the serial cable are used, one is not straight through)

2) Coolant.  I think flood coolant is more expense and trouble than it is worth.  We can make/buy a mist coolant setup for cheap.  This is not a show-stopper.  We can cool/lubricate by hand in the interim.

3) Compressor.  The current compressor runs all the time and is so loud you can't hear yourself think.  This is not a show-stopper, just a matter of keeping your sanity.  Being distracted is not good.  I can move it 20-30 feet away and fashion a makeshift sound-deadening box for it until something better comes along.
Title: Re: HAAS VF-1 Rebuild
Post by: Simply7 on March 19, 2014, 08:26:43 PM
Someone dropped of a pc yesterday that has a serial port. Its an XP machine. So not sure if can handle win7... Or if we could use a light linux distro on it.

Title: Re: HAAS VF-1 Rebuild
Post by: Hybridsix on March 19, 2014, 10:33:26 PM
FWIW, that serial port to USB adapter that is hooked up to the machine works perfectly. I've successfully transferred code to the machine in both linux and windows with it.