HSMAdvisor/FSWizard got featured on DIY Engineering!

It seems like HSMAdvisor's machine profile settings and power compensation work just fine even for as small of a CNC machines as  Nomad  Carbide 3D:

Just found a very good video of testing a table-top gantry router cutting mild steel.

YouTuber named "Breaking Taps" used speeds and feeds generated by HSMAdvisor to get a starting point.

To see where exactly he was in the calculations I decided to reproduce all of cuts in HSMAdvisor.

A couple of assumptions i made:

1. Tool Type: Solid End Mill. It is not recommended to use the HP/Roughing tool type on such light machines, so i assumed this is the tool BT used.
2. Tool Stick-out looked like about 3/4" so I used that number.
3. Material was set to A36 Hot rolled steel.

Test 1) Minute 4:52

Good, slow and very safe starting point.

Test 2) Minute 6:20

Twice as aggressive as before, but we can still push it further.

Test 3) Minute 7:10

Here we can see the lack of machine rigidity starting to show. But at 65% feed rate it is still alive.

Test 4) Minute 8:30

This last test did not go well at all.

The machine has finally hit its limit and the endmill broke at all S&F overrides at about 100%

Was this fault of the software? Not really!

If that were a heavier machine, the last cut would not even be considered that difficult.

Here is a full slotting cut on a Matsuura VMC:

And here is the calculation that was done using HP/Roughing End Mill tool type:

If i were using the "Solid End Mill" tool definition, i would have to dial the feed override to 176% to match the 45ipm feed rate!

So what can users of light machines do in order to not break taps end mills?

First of all make sure the spindle torque curve is built and enabled in your machine profile settings.

The easiest solution is to de-rate the spindle. There is "Warning at" level in machine profile settings. Set that to 50% for starters and it should save you from exceeding the machine's capabilities.

Overall this was a great test of this little machine's capabilities and of the great help that software like HSMAdviasor can lend in discovering them.

Please head over to Breaking Taps YouTube account and subscribe.

Previously when someone asked me whether HSMAdvisor works on linux or Mac I would steer them towards using VirtualBox or Parallels or some other virtual machine to run HSMAdvisor in the virtual Windows box.

As it turns out it is not always necessary.

Our customer has just managed to successfully run HSMA on Linux using package called Wine.

All he had to do was to use wine in 32 bit mode.

I, personally, did not think it was possible to run an app as complex as HSMAdvisor on linux without any modifications on my side. But i was wrong!

Here is a helpful link if you are running 64 bit version of linux and your Wine refuses to launch HSMAdvisor in 32 bit mode:

https://askubuntu.com/questions/136714/how-to-force-wine-into-acting-like-32-bit-windows-on-64-bit-ubuntu

Reportedly Reference and Geometry tabs do not work. But this is not surprising, since they use Internet Explorer to show the information.

Also pressing ENTER key causes the app to crash.

I am going to install a test Linux system on my workstation in the near future and figure out how to fix those issues and make Non-Windows support more readily available.

On another news.

Having made a new FSWizard App design and right before publishing. I decided to rewrite the whole core almost from scratch.

This was needed to make room for new modules like User Tool Libraries and Machine Profiles.

The work is going ahead at full speed and in due time i will roll our the brand new spanking FSWizard!

Hello everybody!

I have not made many blog posts here lately because i have been working a lot on new features and simply did not have much time for anything.
So I decided i'd make a little report on how we are doing and where the project is.

First things first.

I just released an update to HSMAdvisor v1.503

• Drilling tools now consider Shank Diameter when calculating maximum allowed torque on the tool.
  This will lead to more safety when using, say 1" tool with a 0.5" shank.
• Thread Milling tools have been immensely improved.
  Shank diameter is now included into the calculations.
  Default Length is now 2.5 diameters
  Improved suggested cutting speeds and feeds

Our Multiple Language Translation Program is chugging along nicely

Several people messaged me about intentions to build translations so far.

At this point we have people working on translations for the following languages:

• Croatian
• Serbian
• Portuguese
• Perhaps Polish (I see someone uploading translations, but the person have not contacted me about it)

Mobile FSWizard app is due for major improvements

Major visual re-design is under way and we are working on making FSWizard Mobile accessible on more devices in more ways.
It is going to be a fully fledged WEB app, that can be run on any internet-connected device. Even on a desktop.

Integration with HSMAdvisor Machine Profiles and Tool Libraries is also planned.

Perhaps we are going to drop native support for Google Play and iOS stores. I am sick of them charging us 30% for their services.

This is 21st century and we all live in the age of the Internet.

While some software developers claim to use it for the benefit of the customers they in fact only care about license protection benefits it can provide.

Here is how HSMAdvisor Speed and Feed Calculator uses the big WWW for the benefit of its users:

1. Tool Database and Cutting Data Sharing
   Not many users realise that simply placing the Tool Data Base file on a shared network drive or service like DropBox or Google Drive will keep their Tool DB in sync on all of their computers running HSMAdvisor.
   Oh, regarding the "running on multiple computers" thing.....
2. Floating License allows users to run a single seat of HSMAdvisor on multiple computers non concurrently.
   All you need is internet connection! Permanent Licenses do not even need internet connection at all.
3. Cloud-Hosted Machine Profiles.
   Machine Profiles are important part of out calculator tool. Among other things they allow to prevent machine stalls and resulting machine damage and tool breakage.
   You can upload your Machine Profiles to HSMAdvisor Cloud for Public or Private access.
   Or you can request a machine profile to be added and I will upload it for you to easily download.
   All within the HSMAdvisor Machine Definition dialog!
4. Cut Cloud. The place to get other Machinist's experience at your fingertips.
   Another great feature that we are actively developing right now is the Cut Cloud.
   It allows Machinists to share their cutting experience with other HSMAdvisor users.
   It is still in development but shortly we are going to populate out public online library (Cut Cloud) with cutting data from popular tool manufacturers.
   Anyone running HSMAdvisor will be able to just dial in their cutting tool, connect to the Cloud and see how others run their tools in similar cutting conditions on similar machines.
5. Immediate and Accurate Licensing.
   A few times I got emails from disappointed machinists who were not aware of HSMAdvisor and thus chose a competing software product.
   They all were complaining about misleading Licensing schemes some software developers were using that hindered their work. Things ranged from not being able to register their seats for hours after completing the purchase to having to keep their computers online almost uninterruptedly (despite claims it could run offline for weeks) to keep their software running.
   HSMAdvisor uses transparent Permanent and Floating Licensing scheme that will not leave you hanging.
   All purchases are handled automatically and our new customers do not need to wait for a next business day to get their purchase functioning.
   We constantly work on making your experience as flawless as possible and do not linger on past achievements.

There is a lot more work planned and already in progress.

In the age when everyone is talking about how internet is turning the world around we are doing our small part in making it happen!

Thank you, everybody for your support and feedback!

There is more than one way to skin a cat! Previously i have showed how to machine multiple pieces out of a flat plate holding only on to 0.010" thick material on the outside of the part. (here) But there is more than one way to do it. Sometimes your part is so hard to hold, that using tabs or skin is the best, or even the only way of machining something. Very often, working in prototyping, I have to make only one single part and designing and producing special fixturing is also not feasible.

Here is how you can easily machine a difficult-to-hold part from both sides without using a separate fixture:

Setup: Put or part in vise. Make sure to square off at least two sides contacting the jaws for accurate positioning and minimum distortion.

Program part normally. Perform as many operations on the first side as possible.

When machining outside profile, machine to the exact depth of your part.

Here is how your part might look after completing the first OP:Read More 

This weekend was very productive

I have finished work on floating license scheme and volunteers have begun testing it.

Licensing like that requires a lot of work on both the web side AND the client side. So a lot of things can go wrong and hopefully testing exposes all of the possible problems before a paying customer has the opportunity to face any.

Aside from cleanup here and there i have added the material search feature.

"Material" panel is now expandable and it is hiding a search field.
When you type anything into that field, material list right above will filter out items that contain the text being searched.
To clear search results user can just click the red x button to the right of the search field.

Here is how it looks:

You don't really need to click on the magnifying glass button as searing and selecting of material is done in real time as you type text.

In fact in many cases simply typing things like "D2" will select the material you need.

What's New:

• Material Search Feature
• Added several new machine profiles to the default machine list
  (When you install over existing installation, use machine import function to add them to your current machine list)
• Finished floating license module (pending testing)

What's improved:

• Added Aluminum 6061-T4 to materials list
• Fixed missing Aluminum 6061-T6
• Added floating pop-up box to pretty much all fields on the FSWizard screen
• Cleaned up various things.

In this tutorial we are going to explore different options and techniques when programming cutter movement.

Lets begin with a simple part shown in a drawing below.

Basically it is a rectangular piece 4.00x2.00
For the purpose of simplicity lets make the depth of our profile (z- dimention) 0.75"

We are going to use a 0.5" dia endmill, again because it is a very common size and is easy to do basic math with.

I took a liberty of puting locations for our part/toolpath, so it is easy to extract numbers from the drawing just by looking at it.

Notice the green rectangle. This rectangle represents the path that the center of the tool will have to take to produce the part with required dimentions.
The thing is: because endmills have certain diameter, the center of the tool must be always offset by its radius.

There are two ways of doing that.Read More 

This release is a major step forward.
We are starting to wander away from just Speeds and Feeds calculator part of the project.

Version 0.022 was a little buggy.

All reported and known bugs have been fixed.

New update version is 0.023

New features:

• Threads page: You can now get thread cutting and tapping data for most popular threads in north America (UNC/UNF/ISO).
  The list of supported threads and features will grow according to necessity and user feedback.
• Machine Profiles now have 2 new buttons: Clone and Import.
  Clone button simply copies selected machine definition with a different name.
  Import button is needed to be able to update/add machine definitions from default machine list. As users modify and customize their Machine List, thay are now able to add machine definitions hassle-free from default_machines.xml file that is supplied with every update.

Bugs Fixed:

• Sticky Ball nose check box

• Max HP improperly rounded

Additions:

• Thanks to Greg Jackson and Matt Doeppers from Tormach i was able to create Horse Power/RPM curves for Tormach PCNC770 and PCNC1100 models (if you install over previous version, you can use import function to add those machines to the list)

Threading Machine Definition Import