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> r/c Fuchs wheel project progress thread, in production on a real machining center. :)
RJMII
post Jul 21 2010, 07:44 PM
Post #41


Jim McIntosh
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Yes, my CNC is setup to do 3d.

I'm still working on the fourth axis; I'd like to program it so I can get perfect circles and the correct contours.


More progress pictures:

My VW donor car showed up the other day. Xac and I put it together, and I showed him how much fun it is to assemble stuff.
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I've also been working on the polishing. See the sides of the Fuchs in the picture? that's from hanging out in the walnut shells for 24 hours.

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RJMII
post Jul 22 2010, 04:16 PM
Post #42


Jim McIntosh
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I now have two cars here, and I've got the measurements! I am ready to start cutting out the wheels. It will be easiest to do them if I do a larger run.

The process for cutting out the wheels requires me to set up my CNC mill in multiple configurations.

The process, for those that are curious:

Step one, chop up the stick of 2inch aluminum into inch and a half long chunks. - 2 hours.

(Dial in vice on rotary table to be centered with spindle) - half an hour, 45 minutes. Requires dial indicator.

Step two: Face the chunks/machine one face square and mark it. - 10 minutes per wheel.

Step three: Face other side of chunks/machine down to size. (1.125 for narrow wheels, 1.25 for wide wheels. - 10 to 15 minutes per wheel

Step four: Rough out the fronts of each wheel. (I'll put a spacer between the bottom of the vice and the wheel so that the same code can be used for narrow and wide wheels and run all of them through at once) - 35 to 45 minutes per wheel

Step five: Rough out the backs of the wide wheels - 35 to 45 minutes per wheel

Step six: Rough out the backs of the narrow wheels - 30 to 35 minutes per wheel

step seven: Run the finishing script for the backs of the Wide wheels - 15 minutes per wheel

step eight: run the finishing script for the backs of the narrow wheels. (finishes the 'hex' for the drive nut) 15 minutes per wheel

Step nine: Run the script for the 3d portion of the fronts of the wheels. (the part that makes them have 'the look') - hour and a half per wheel (working on making this take less time)

(now I set the machine up with the rotary table being vertical, with out the vice. I'll have a fixture to bolt the wheels to, and it will be dialed in centered on the rotary table)

Step ten: Run the script for each wheel for the area that the tire mounts. 10 to 15 minutes per wheel.

Step eleven: Put a couple of sets of wheels in the polisher for over night. The polisher has walnut shells and rouge. - one to two nights.
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RJMII
post Jul 22 2010, 04:53 PM
Post #43


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Here is a top view of the car.

Back left tire is the wide one.

Back right tire is a narrow one.

Front right tire is a narrow one.

Front left tire is a stock bug tire and wheel. (much smaller diameter, takes different tires)


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rick 918-S
post Jul 22 2010, 05:59 PM
Post #44


Hey nice rack! -Celette
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Somehow I missed the pre-order info on the first post. I just sent the better half an email and asked her to send money via PP.

Get your orders in boys!
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RJMII
post Jul 22 2010, 06:08 PM
Post #45


Jim McIntosh
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Rick, I just added it. I wanted to get the measurements and code sorted out first. Quality is high priority here and I wanted to make sure I can do it and do it right. I am confident enough in the project now to go forward.
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rick 918-S
post Jul 22 2010, 06:23 PM
Post #46


Hey nice rack! -Celette
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Great! I'm looking forward to seeing the finished produce. Specially on MY (IMG:style_emoticons/default/biggrin.gif) car.
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RJMII
post Jul 23 2010, 03:35 PM
Post #47


Jim McIntosh
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anyone else?
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rick 918-S
post Jul 23 2010, 04:18 PM
Post #48


Hey nice rack! -Celette
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Sent the pay pal I think. (IMG:style_emoticons/default/icon_bump.gif)
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RJMII
post Jul 27 2010, 12:28 PM
Post #49


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I ordered the metal today. Should be in my posession early next week; and I'm still taking pre-orders. (IMG:style_emoticons/default/smile.gif)

the pre-orders will close when I post pics of Rick's car with a full set of them cut in 3d. Yes, the contours of the leaf will be rounded.
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RJMII
post Aug 3 2010, 10:45 AM
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I've been working on the 3d tool paths to get the very fine details in the wheels. (IMG:style_emoticons/default/smile.gif)

another teaser pic. the green lines show the tool path.


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RJMII
post Aug 3 2010, 10:46 AM
Post #51


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zoomed in


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rick 918-S
post Aug 3 2010, 05:50 PM
Post #52


Hey nice rack! -Celette
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That's cool! Build em and they will sell! (IMG:style_emoticons/default/assimilate.gif)
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VaccaRabite
post Aug 3 2010, 06:21 PM
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I am looking forward to seeing the initial maps for the cookie cutters!


zach
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RJMII
post Aug 9 2010, 12:57 PM
Post #54


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beginnings of COOKIES!



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underthetire
post Aug 9 2010, 01:56 PM
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Man, I just read some of your times for cutting. We need to find you a CNC lathe bad !
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rick 918-S
post Aug 10 2010, 07:41 AM
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Hey nice rack! -Celette
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The cookies look diffecult... (IMG:style_emoticons/default/wacko.gif)
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RJMII
post Aug 10 2010, 08:18 AM
Post #57


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QUOTE
Man, I just read some of your times for cutting. We need to find you a CNC lathe bad !

I keep looking for used mini lathes that I can convert. PM or email if you find something?


QUOTE
The cookies look diffecult...


They are proving to be a challenge. (IMG:style_emoticons/default/smile.gif)



Now to get back to finishing my last run of emblems. I've about got my machine modified with the new controller, drivers, and more voltage. Hopefully this helps drop my machining times.
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RJMII
post Sep 21 2010, 07:41 PM
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Jim McIntosh
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as promised;

picture of prototype FOUR! starting to go 3d. (IMG:style_emoticons/default/smile.gif) It looks cooler in person, IMHO.


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RJMII
post Sep 21 2010, 07:46 PM
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Jim McIntosh
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QUOTE(underthetire @ Aug 9 2010, 01:56 PM) *

Man, I just read some of your times for cutting. We need to find you a CNC lathe bad !



The new 42ipm rapids are helping a ton, along with adjusting my cutting styles. I learned a lot playing with the new setup, trying different things. I'm able to hit 23ipm for a feed rate if I use just the right amount of bit; before I was going full bit width. :S I could hit faster rapids if I were to go full stepping instead of half, but I like it where it is at and probably won't gain much with the smaller movements that primarily rely on the acceleration capabilities of the steppers.
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rick 918-S
post Sep 21 2010, 11:05 PM
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Hey nice rack! -Celette
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QUOTE(RJMII @ Sep 21 2010, 08:41 PM) *

as promised;

picture of prototype FOUR! starting to go 3d. (IMG:style_emoticons/default/smile.gif) It looks cooler in person, IMHO.


That's really starting to look good!
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