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 Posted 6/1/2016 7:51:01 PM |
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Has NO LIFE!!
Last Login: 12/4/2023 11:08:55 PM
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VERTIGO’s TOOL USING PHILOSOPHY:
I buy tools to complete projects. I don’t buy tools then search for a
project. To me a plasma table is a tool with the potential to save me
time and frustration. CAD/CAM is also a tool. CAD/CAM can take
thousands of hours to truly master but there is a shortcut to get up
and cutting steel. After all we truly just want to cut the parts we
need to build on our Bat vehicles and other projects. Most of us are
not looking to be masters of Computer Aided Drafting and/or looking to
make a living doing computer aided drafting for others. I bought
TORCHMATE CAD, not in particular for the part creation by drawing
aspects but rather to manipulate imported images and drawings into cut
files for plasma cutting steel and other metals. Rarely, do I create
my part cut files by CAD drawings. Rather, I mostly use hand drawn
images and photographs that I scan into Photoshop or directly into
Torchmate. I use TORCHMATE’s Accuscan features to trace and vectorize
the imported image, then create a tool path, and finally save as a DXF
file. To cut, load the DXF file into the machine software and it is
setup in g-code. The TORCHMATE CAD learning curve for imported image
manipulation, Accuscan, cleanup, conversion to DXF file, and actual
cutting system is 100-200 hours. Depends on the individual. As an
example, the Batarang was scanned from a photograph into Photoshop,
where it was cropped, sized to 6-1/2 inches, edge sharpened, and color
adjusted. Then it was imported in TORCHMATE CAD, where the image was
scanned and vectorized with Accuscan. Then a tool path was created and
saved as a DXF file ready for exporting and use. PAINT could be used
in place of Photoshop but is much less flexible and lacks 95% of the
features found in Photoshop. I lease Photoshop for 19.oo a month. This
way it automatically upgrades the latest program changes and follows
me to whatever computer I am using at the time. TORCHMATE CAD is the
best program for the person that wants to make parts with the least
amount of effort. The part drawing section is not the best but the
image importing, manipulation, scanning, vectorization, tool path
generation, and DXF file exporting are quick and easy once learned.
Best part about TORCHMATE CAD is that you don’t need to be able to
actually do computer aided drafting to make high quality parts.
vertigo
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| Posted 6/26/2016 7:45:50 PM |
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Has NO LIFE!!
Last Login: 12/4/2023 11:08:55 PM
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Hello everyone,
Spent a few hours today completing a welding table. Always been a fan of the open grid table. Made this one from a heavy duty metal sign frame I saw at the junk yard. vertigo
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| Posted 6/26/2016 7:54:18 PM |
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Has NO LIFE!!
Last Login: 12/4/2023 11:08:55 PM
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Hello everyone,
Using my latest completed welding table as a pre-loading table for my plasma cutting table to support a stacked dozen of mixed 1/8th and 3/16th 4' X 4' metal sheets. vertigo
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| Posted 7/1/2016 6:59:44 PM |
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Has NO LIFE!!
Last Login: 12/4/2023 11:08:55 PM
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Hello everyone,
Learned a lesson about insufficient grounding of my plasma table when testing
the system didn't work exactly as expected.
If your CNC plasma table and related components are not properly
grounded, you will very likely have problems and glitches of all sorts
when you start using your system to cut parts. Here are the words of
an expert. vertigo
CNC Machine Grounding written by: Jim Colt Hypertherm Corporation
“Grounding of a CNC plasma machine is important for a few different
reasons...some are safety related and some are electrical noise
interference related. The level of need will vary from CNC machine to
CNC machine....and also varies depending on the design of the plasma
system. Also....the work lead from the plasma is not considered a
"ground", but rather it is the return path for the cutting current.
Noise issues created by high frequency start plasma systems. Older
technology air plasma systems (many of the import low cost air plasma
systems are still produced with this technology) as well as almost all
"Industrial" plasma systems use a high voltage high frequency
discharge at the beginning of every start cycle to ionize the plasma
gas....to start the torch. This 15,000 volt, 3 megahertz pulse can
shake up low voltage motor, encoder, and computer inputs and
outputs....especially of CNC machines that use a standard office
computer or laptop as the machine control. The starting effect of the
high frequency can simply affect the computer to the point that it
will not function (reboot).....or it can literally destroy circuitry
in the computer and drive electronics. Proper earth grounding,
shielded computer and drive cables...as well as electronics designed
with proper I/O input filtering are a must when using high frequency
start plasma systems.
Noise issues created by inverter based plasma systems. Newer
technology inverter based plasma power supplies also can create
electrical noise interference similar to....but not as severe as the
above high frequency noise. Inverter power supplies develop a "pulse
width modulated" output frequency that can be in the range of 16 khz
to 60 khz (depending on power supply and manufacturer design).
Typically the effect of this technology...especially on stepper driven
CNC machines will be with rough motion....or strange error messages on
the PC used as the machine control. Usually a good earth driven ground
and proper grounding of each electronic component of the machine to
the earth ground will eliminate issues when this type of plasma is
used.
Electrical grounding issues that affect height control. Poor work lead
connections to the actual plate....as well as poor cutting machine
frame and cutting bed ground connections can provide both safety as
well as inaccurate (arc voltage based) height control operation. The
height control system on most CNC plasma machines is dependent on a
good arc voltage reading between the material being cut (positive) and
the torch electrode (negative). Poor grounding and stray cutting table
voltages can and often do affect the control of torch height.
Industrial grade CNC machines all use a specifically designed
hardened, shielded, isolated CNC control that is designed to not have
issues with electrical noise from any type of plasma.
Still....industrial tables (when properly installed) all have a
dedicated ground rod for safety and operational issues.
Entry level machines that use an office PC or Laptop are far more
susceptible to electrical noise and safety issues....and should always
be installed with a dedicated, properly designed grounding system as
well.
I have both a PlasmaCam (with Hypertherm Powermax85) and a Torchmate
(with Powermax45) entry level machines in my home shop.....both have
had issues with electrical noise interference. Both sets of issues
were solved with proper machine grounding, a ground rod, as well as
with input line conditioning (for the computers and the drive
electronics) through a common UPS (uninterruptible power supply)
available at office supply stores.”
Jim Colt, Hypertherm Corporation
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| Posted 7/1/2016 7:21:53 PM |
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Has NO LIFE!!
Last Login: 12/4/2023 11:08:55 PM
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Hello everyone,
Here is an old trick taught to me by a professional welder friend of mine.
Spring operated grounding clamps in reality have very little contact with the metal they are clamped onto.
Not much of a problem, usually, for general purpose welding but frequently a problem when grounding a plasma table, as I experienced, and even much more so when completing the circuit between the metal cutting stock and the plasma cutting torch.
Fray the end of the grounding or circuit completion wire, bunch it up into a roll, place a 2 inch automotive freeze plug on top, and clamp it down tight with a C-clamp. This grounding and circuit completion method is very effective because the bunched up wire make hundreds of contacts with the metal that it is clamped onto.
vertigo
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| Posted 7/2/2016 8:03:48 PM |
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Has NO LIFE!!
Last Login: 12/4/2023 11:08:55 PM
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Visits: 5,166
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Hello everyone,
Finally, got my militarized Tough Book setup for my CNC plasma table and CNC milling machine programs.
Have a number of DXF files imported and G-coded into Torch Mate that I plan to cut tomorrow.
Attached a photo showing a G-code file set up in Torch Mate to cut part of the Tumbler roof panel assembly with openings for the stack exhausts.
vertigo
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| Posted 7/15/2016 4:16:38 PM |
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Has NO LIFE!!
Last Login: 12/4/2023 11:08:55 PM
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Visits: 5,166
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HOW MUCH DOES IT COST TO HAVE YOUR CAD FILES CUT OUT OF STEEL?
Some welding and/or metal shops have plasma CNC metal cutting tables.
Rates are calculated in various ways.
Hourly: 100-150.00 per hour + material
Linear inch at .25 to .50 + .25-.35 per pierce + .75 to 1.00 per minute table rate + material.
To get the best deals, do your own CAD, create your own DXF files, know you linear inches, buy your own metal, and try to find a guy that bought his CNC plasma table and cuts for a hobby, usually as a metal work artist. vertigo
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| Posted 7/17/2016 7:03:46 PM |
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Has NO LIFE!!
Last Login: 12/4/2023 11:08:55 PM
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Visits: 5,166
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Hello everyone,
Finally got the bugs worked out in my CNC plasma cutting table. It was only fitting that the first parts I cut were Batarangs. vertigo
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| Posted 7/17/2016 7:20:48 PM |
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Has NO LIFE!!
Last Login: 12/4/2023 11:08:55 PM
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Hey I forgot something,
I have attached the DXF cut file for anyone that might want to have some cut for themselves.
Just take the file to anyone with a CNC plasma table and get them cut from steel, stainless steel, or aluminum.
You can find CNC plasma cutting services at most welding, fabrication and sign making shops. Tried to upload the DXF file but this forum doesn't allow the upload of DXF files. You can take the files from the main forum on Vertigo's Batarang build to these same shop and they can convert them to DXF files and then cut them for you. Some of the people I know have told me they were charged 3-5.00 each. vertigo
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| Posted 7/26/2016 6:07:16 PM |
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Has NO LIFE!!
Last Login: 12/4/2023 11:08:55 PM
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PLASTIC MODEL REVERSE ENGINEERING
UP-SCALING and 3D VIRTUAL MODELING
From existing physical parts and other models
The available plastic and die cast models available world-wide number
over a million catalog numbered model kit types available with some
kits still available from 1951 when Revell introduced the first all
plastic kit. The first plastic models were injection molded in
cellulose acetate but currently most plastic models are
injection-molded in polystyrene, which was discovered in 1839. Eighty
percent of the plastic model cars sold are scaled between 1/20 -1/32
with 1/24 -1/25 being the most popular.
Virtually every life-sized replica vehicle and even the Batmobiles,
Tumbler, Bat Pod, and other Bat Vehicles, most likely owe their
creation to a plastic model somewhere. With such modeling resources
available, what builder could resist such a tempting reservoir of
information, and why should he? So, how can we extract the very
useable information from a plastic model?
Reverse engineering, also called back engineering, is the processes of
extracting knowledge or design information from anything man-made and
re-producing it or re-producing anything based on the extracted
information. The process often involves disassembling something such
as a plastic model and analyzing its components and workings in detail
and measurement.
As computer-aided design (CAD) has become more popular, reverse
engineering has become a viable method to create a 3D virtual model of
an existing physical part for use in 3D CAD, CAM, CAE or other
software. The reverse-engineering process involves measuring an object
and then reconstructing it as a 3D model. The physical object can be
measured using 3D scanning technologies like CMMs, laser scanners,
structured light digitizers, or Industrial CT Scanning (computed
tomography). The measured data alone, usually represented as a point
cloud, lacks topological information and is therefore often processed
and modeled into a more usable format such as a triangular-faced mesh,
a set of NURBS surfaces, or a CAD model.
Reverse engineering is also used by businesses to bring existing
physical geometry into digital product development environments, to
make a digital 3D record of their own products, or to assess
competitors' products.
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