Now that I've developed a ballscrew attachment for the JD TB3 tube bender, I need to prepare to get the new compts machined. This requires:
- Find suitable material for the 2 blocks., This should really be steel, as loominum isn't going to work so well, either in terms of strength or as a bearing material where it bears against the bender's arms. I seem to have a piece of 1" x 3" hot rolled steel of 190mm length. That's a bit shorter than I'd planned but I have little choice of material to start from. I can cut it into a 100mm length for the bearing bock and a 90mm length for the ballnut. I will modify the blocks in Fusion to suit the new reality.
- Cut the stock ready for machining.
- Flash up some lathe tools in Fusion. Currently, most of the tools in my library are for the Tree ie LH tools, whereas I need RH tools. So to start with I will create a 25.5mm drill, a CCMT060204 tipped boring bar and a fairly conventional RH turning tool with DCMT11T304 insert, while I'm at it.
- Create the toolpaths in Fusion using the new tools.
- Export the tools from Fusion as a JSON file and import them into the PBL as the tool library.
- Import the g code for the boring operations into PBL.
I don't intend to do the predrilling as a CNC operation, as I will be using a tailstock mounted drill for that. Similarly I'm not sure I can be arsed to face off the front of the stock afterwards. So this will simply comprise the rough boring and finish boring operations.
Here's the modified bearing block. It's a fair bit thinner than before and instead of having pillars sticking out on top and bottom, I will insert short collared spacers or shouldered screws.
Here's the boring bar setup:
And the turning tool:
For the CCMT060304, I will use 80m/min surface speed, 0.1mm per rev feedrate and 1mm depth of cut. This is a slender boring bar, albeit carbide, so I've erred on the cautious side.
For the DCMT11T304, I will use 150m/min surface speed, 0.1mm per rev feedrate and 2mm depth of cut. Or I would if I planned to use it here.
Note that there's no actual (internal) boring operation as such. Instead, you select Profile Roughing and Profile Finishing and by selecting the appropriate features you define a boring operation.
The (not used facing operation):
The g code for the boring operations:
%(3001)(BRG BLOCK)N10 G7N11 G18N12 G90N13 G21N14 G28 X0.N15 G28 Z0.(PROFILE ROUGHING2)N16 T12 M6N18 G54N19 G97 S3500 M3N20 G95........N127 G1 Z-16.9 F0.1N128 X59.9N129 X57.9 Z-15.9N130 G0 X0.N131 Z5.N132 G97 S3500 M3(PROFILE FINISHING2)N133 M5N134 M1N135 G97 S2000 M3N136 G95N137 G0 X0. Z5.N138 G96 D2000 S80 M3N139 G0 Z1.014N140 X58.922N141 G1 X59.172 F0.1N142 X62. Z-0.4N143 Z-17.N144 X50.N145 X47.172 Z-15.586N146 G0 X0.N147 Z5.N148 G97 S2000 M3(PROFILE FINISHING3)N149 M5N150 M1N151 G97 S2000 M3N152 G95N153 G0 X0. Z5.N154 G96 D2000 S80 M3N155 G0 Z-15.986N156 X46.922N157 G1 X47.172 F0.1N158 X50. Z-17.4N159 Z-25.4N160 X46.N161 G0 X0.N162 Z5.N163 G97 S2000 M3N164 M5N165 G28 X0.N166 G28 Z0.N167 M30%
Let's get the stock set up in the 4 jaw and import the g code into PBL.
Ooof, those jaws are in the way of the boring toolpath. That's what happens when you allow The Stupid Fat Bloke to get ahead of himself and set stuff up before thinking things through. And it was all dialled in at this stage of course.
That's better. With a 4-jaw chuck you can remove 2 of the jaws and swap them round without removing the work, then do the same with the other 2 jaws. So it remains true and now has a helpful gap between the rear of the stock and the chuck and jaws. This method costs less in terms of inserts, carbide boring bars and chuck jaws.














