chiere
01-12-2009, 02:38 PM
Greetings All!
Our shop opperates a PRSalpha96 with the Porter Cable router. We've had it now for about 3 years, and it's used every day, all day. We have 2 routers, so when the brushes go in one, it can be in the repair shop and we can continue production. We get about 6 months out of a set of brushes, =-)
We cut 1 lb EPS foam and 15 lb Precision Board with it. (it's like cutting butter.) We mainly use a 1/8" ballnose bit or a 1/4" ballnose bit. A bit will last us a year. I design using ArtCam software, and 99% of the files I design are bas reliefs.
Here's the problem; pieces used to come off the table very smooth, with few tool marks. But reciently, when using the 1/4" ballnose bit, the tool marks are extreme, and encompass the entire piece.
At the same time, I replaced ArtCam Pro with ArtCam 2008. (I know I am behind everyone else; I work from home and only just got the software from my boss)
I like the new software, so I am hoping it's not that, but I get the distinct feeling my boss believes the extreme tool marks are because of how I am designing stuff now. (Even tho it's no different that how I did it before with ArtCam Pro)
When we cut with the 1/8" ballnose bit, I am told stuff comes out smoothe (I even had him find an old file that cut great before and run a test) But when we cut with the 1/4" ballnose bit, it comes out looking very groovy, and not the good groovy. I even went back and redid the files in Pro and it still looked like poop. Then I redid the file in Pro using a 1/8" ballnose, and so far, he says it is looking better.
Before the Christmas holidays, I went to the shop and went over the machine. The waster board has deep grooves even though the operator uses the proper thickness of material for the job, and properly sets the z-home, the tracks were a bit crusty from ground and melted foam, the wheels on the z-rails didn't all touch any more (about half did,) I could jiggle the router by holding the bit and applying force to the tune of about 1/16th of an inch, and I think the thing still had the original collet. Also, when running the router at a diagonal across the table, it made a loud chatter/grinding noise in places, and when running the router up and down the z rails, it also made a nasty grindy thunk sort of noise.
So, we cleaned it, oiled it, and scraped off the crusty bits. I ordered new bits, suggested the wasterboard be replaced, suggested a new collet (the 1/8th inch bits and the 1/4" bits all use the same 3 year old collet) and suggested tightening up the z carriage. I don't believe the last three things have been done.
Is it the software? (I am trying to keep a straight face here, work with me,...) My boss is sure I am doing something wrong. I don't think so, but I want to double check just in case I am. I keep suggesting a new collet, cuz I think the heavier 1/4" bit is slipping, and a tightening up of the z carriage (which I am afeared to do, what if I screw it up! Oh, wait, it can't get much WORSE,)
Also, it sorta broke my heart to see my baby all grody and neglected, =-(
Anyway, here's a picture of the current end results. On the left is the old file using a 1/8" ballnose bit. On the right is the new file, created in the old program, with a 1/4" bit. Advice would be much appreciated!
8131
Our shop opperates a PRSalpha96 with the Porter Cable router. We've had it now for about 3 years, and it's used every day, all day. We have 2 routers, so when the brushes go in one, it can be in the repair shop and we can continue production. We get about 6 months out of a set of brushes, =-)
We cut 1 lb EPS foam and 15 lb Precision Board with it. (it's like cutting butter.) We mainly use a 1/8" ballnose bit or a 1/4" ballnose bit. A bit will last us a year. I design using ArtCam software, and 99% of the files I design are bas reliefs.
Here's the problem; pieces used to come off the table very smooth, with few tool marks. But reciently, when using the 1/4" ballnose bit, the tool marks are extreme, and encompass the entire piece.
At the same time, I replaced ArtCam Pro with ArtCam 2008. (I know I am behind everyone else; I work from home and only just got the software from my boss)
I like the new software, so I am hoping it's not that, but I get the distinct feeling my boss believes the extreme tool marks are because of how I am designing stuff now. (Even tho it's no different that how I did it before with ArtCam Pro)
When we cut with the 1/8" ballnose bit, I am told stuff comes out smoothe (I even had him find an old file that cut great before and run a test) But when we cut with the 1/4" ballnose bit, it comes out looking very groovy, and not the good groovy. I even went back and redid the files in Pro and it still looked like poop. Then I redid the file in Pro using a 1/8" ballnose, and so far, he says it is looking better.
Before the Christmas holidays, I went to the shop and went over the machine. The waster board has deep grooves even though the operator uses the proper thickness of material for the job, and properly sets the z-home, the tracks were a bit crusty from ground and melted foam, the wheels on the z-rails didn't all touch any more (about half did,) I could jiggle the router by holding the bit and applying force to the tune of about 1/16th of an inch, and I think the thing still had the original collet. Also, when running the router at a diagonal across the table, it made a loud chatter/grinding noise in places, and when running the router up and down the z rails, it also made a nasty grindy thunk sort of noise.
So, we cleaned it, oiled it, and scraped off the crusty bits. I ordered new bits, suggested the wasterboard be replaced, suggested a new collet (the 1/8th inch bits and the 1/4" bits all use the same 3 year old collet) and suggested tightening up the z carriage. I don't believe the last three things have been done.
Is it the software? (I am trying to keep a straight face here, work with me,...) My boss is sure I am doing something wrong. I don't think so, but I want to double check just in case I am. I keep suggesting a new collet, cuz I think the heavier 1/4" bit is slipping, and a tightening up of the z carriage (which I am afeared to do, what if I screw it up! Oh, wait, it can't get much WORSE,)
Also, it sorta broke my heart to see my baby all grody and neglected, =-(
Anyway, here's a picture of the current end results. On the left is the old file using a 1/8" ballnose bit. On the right is the new file, created in the old program, with a 1/4" bit. Advice would be much appreciated!
8131