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Khalid Khattak
05-01-2008, 8:28 AM
Dear Fellows
How are you all? It is my first thread and first post on this great site. First of all i want to share somthing about myself.

1) I am not wood worker by birth....
2) I am mechanical engineer by proffession...
3) I started woodworking about 3 months ago...
4) My english is not as good as urs...
5) I love wood work...
6) I always edit first post of my first thread..

With all above info,I want to share some of my work...Note that all of my wood work created with my homemade CNC router...if u see any defect then please go through point-I & 3 above.

Regards

Khattak

Joseph B. Chritz
05-01-2008, 9:22 AM
Nice job Khalid, I would like to see some pictures and more information on your CNC router.

Khalid Khattak
05-01-2008, 2:05 PM
Nice job Khalid, I would like to see some pictures and more information on your CNC router.

Thank u Joseph:)
I built my first machine out of steel without plan (just sketched it in my mind)...and currently my second machine out of MDF is 95% completed:) The second machine is completly designed by me in AutoCAD and all the MDF parts cut with the help of my 1st machine:)

The working area of my Steel router (1st Machine) is 33" x 25" whereas my MDF machine, the second one ,has working area of 45" x 35"...

My Steel router rapid at 150IPM and cutting at 100IPM with 200 oz-in stepper motors using SLA6702 based modular card with 35V power supply. I built my steel router in 10 days and then i am contineously debottlenecking it....

John Shuk
05-01-2008, 9:49 PM
Welcome Khalid.
Very nice work on the CNC machine. It seems as though you have a talent.
Was the design of the carving created by you? It is very nice and well executed as well.
John

Joseph B. Chritz
05-02-2008, 12:11 AM
Thanks for the pictures of your machine. I like to see what others do to make their machines work. I'm sure you had a lot of fun building it and great satisfaction when it was finished.
I've recently built a fourth axis for my router. I used an old wood lathe and a servo motor and drive it with Mach3.

Khalid Khattak
05-02-2008, 10:04 AM
Welcome Khalid.
Very nice work on the CNC machine. It seems as though you have a talent.
Was the design of the carving created by you? It is very nice and well executed as well.
John
Thank u John for appreciation:)
The design was created by my Wife and i executed it on my machine...
Joseph:)
I am also incorporating 4th axis in my new MDF based machine...I got 6" 3-Jaws chuck and remaining parts will be out of MDF... I will try to learn 4th axis programming....Can i see ur machine????

Joseph B. Chritz
05-03-2008, 2:04 AM
Here's a better picture of my router.
The pedestal has holes drilled and tapped 2 inches apart with a sacrificial top. It is very rigid has been handy. 4 screws hold it down.

The fourth axis has 3 screws and the motor mount plate has 3 screws.
It just takes a few minutes to take them off if I work on big sheets.
A little longer to put them back on if I want them straight.

Khalid Khattak
05-03-2008, 5:38 AM
Here's a better picture of my router.
The pedestal has holes drilled and tapped 2 inches apart with a sacrificial top. It is very rigid has been handy. 4 screws hold it down.

The fourth axis has 3 screws and the motor mount plate has 3 screws.
It just takes a few minutes to take them off if I work on big sheets.
A little longer to put them back on if I want them straight.

Joseph B...First of all, very nice and sturdy setup:) ....Can u tell me the speed/feed u r getting out of it when working on wood....Could u please show me the thread where u have posted the details of machine...Did u designed the machine ur self?? What type of rails u r using...are u using Ball screws or ACME rods..lot of other questions.....

.

Tim Vice
05-03-2008, 7:50 AM
I am new to the world of CNC and am looking for information on where people get there designs to cut.

What software is the best, I here alot about v-carve but it is out of my price range for a hobbiest.

Any information is appriciated.

Joseph B. Chritz
05-03-2008, 9:54 AM
Hi Tim,

If you haven't already done so, do a search for Mach3.

It's the software I use to drive my CNC router.

They have a couple of forums dealing with building, debugging, programming, etc.

They have a section called "Share you Gcode" that should be pretty interesting.

When you get bored there any search with CNC in it will keep you busy for a while.

Joseph B. Chritz
05-03-2008, 10:12 AM
I didn't design or build my CNC, I bought it in 1999 and just use it for hobby.

I've had it apart several times and changed a few things, but it has been a prety good machine.

The rails are 3/4 thompson shaft (hard case) with linear guide ball bushings.

The screws are precision acme with wear compensating nuts.

My biggest complaint is the spindle is loud. That can be fixed for a price.

Keith Outten
05-03-2008, 1:23 PM
Anyone need some parts? I have four or five servo motors, a 7 foot long ball drive shaft with the ends and several pairs of precision shafts with linear bearings from 3 feet to 12 feet long. They were all salvaged from the Ultrsonic "C" Scan machine I got from NASA Langley so they are very high quality stuff.

.

Nathan Camp
05-03-2008, 1:27 PM
Anyone need some parts? I have four or five servo motors, a 7 foot long ball drive shaft with the ends and several pairs of precision shafts with linear bearings from 3 feet to 12 feet long. They were all salvaged from the Ultrsonic "C" Scan machine I got from NASA Langley so they are very high quality stuff.

.
PM Sent

nathan

Khalid Khattak
05-03-2008, 3:37 PM
Joseph:) I have two problems.. 1).LoUD SPINDLE ROUTER 2) DUST


Some Fun Work playing with my CNChttp://www.cnczone.com/forums/images/smilies/smile.gifhttp://www.cnczone.com/forums/images/smilies/smile.gif
The work i presented in this post is some of my initial experimentation with CNC...I am using VECTRIC VCARVE PRO , CUT3D....I also have Visual Mill, Artcam Insignia, Artcam Pro....My controller is MACH3...

Khalid Khattak
05-05-2008, 9:25 AM
Some more work of mantel pieces...

Khalid Khattak
05-07-2008, 1:03 AM
Following is pictures of Mirror frame i did yesterday...;)

Khalid Khattak
05-07-2008, 1:21 AM
some more stuff..:):D

Justin Leiwig
05-07-2008, 3:09 PM
Very nice work Khalid. If you haven't, you should check out cnczone.com. They have a good forum there with lots of stuff.

Khalid Khattak
05-08-2008, 9:32 AM
Very nice work Khalid. If you haven't, you should check out cnczone.com. They have a good forum there with lots of stuff.

Dear Justin Leiwig:

Thank You very much for posting in my thread and for appreciation of my work..I am an active member of CNCzone...

Following mooze seen designed by me in Artcam Pro and u will see pictures of that being machined on my mill..

Khalid Khattak
05-09-2008, 9:59 AM
I am building my second router out of MDF...Following are My second router parts...I am drafting and cutting on existing router... I made a 4-flute tapping die for threading teflon nuts...I will use 5/8" 5TPI ACME threaded rod as lead screw...

Khalid Khattak
05-13-2008, 11:29 AM
On sunday i did some work on my Z-axis. Following are the pics assembling in progresshttp://www.cnczone.com/forums/images/smilies/smile.gif

Khalid Khattak
05-14-2008, 5:55 AM
Keyboard is in my lap...with full of MDF dusthttp://www.scrollsawer.com/forum/images/smilies/smile.gif....I manage to complete most of my MDF parts for my second router...The only part left to machine is Router mount plate ... I dont know How i can secure my router(spindle)... I have the same router installed at my 1st machine... It has the metallic base but in this case(MDF machine) i dont have any idea of its mounting arrangementhttp://www.scrollsawer.com/forum/images/smilies/frown.gifhttp://www.scrollsawer.com/forum/images/smilies/confused.gif
Hmmm...i will meditate for solutionhttp://www.scrollsawer.com/forum/images/smilies/011%5B1%5D.gif .....

Khalid Khattak
05-14-2008, 2:33 PM
Few more pictures:)...

Khalid Khattak
05-15-2008, 9:35 AM
So at last i manage to make holding plate for my new Router...This router is different from previously installed in my all steel machine... So i came up with a different solution... I also manage to machine the MDF sliding blocks holding plate..You can see in picture violet colour...

In last i have posted the picture of my machine ...

Khalid Khattak
05-15-2008, 10:24 AM
How the peoples are... Why are u all saving ur words..:( Please post ur comments..

Leigh Costello
05-15-2008, 2:42 PM
Khalid,
I am very happy to see your progress as you make and use your machine. My husband and I are still in the planning stages of getting or making a CNC machine. Your detailed photos of your progress and your end results are very informative and admirable.

You are doing a great job! :D

James Stokes
05-15-2008, 6:52 PM
It looks good.

Khalid Khattak
05-16-2008, 6:27 AM
Khalid,
I am very happy to see your progress as you make and use your machine. My husband and I are still in the planning stages of getting or making a CNC machine. Your detailed photos of your progress and your end results are very informative and admirable.

You are doing a great job! :D
Thank you LEIGH for ur kind words of appreciation... Making a CNC machine is a very pleasent and unforgetable experience:)......One question, Have u any experience of CNC before?...What sort of work u r planning to get out of CNC machine...

I am very close to commission my this machine...Almost all Mechanical work completed...All the axis moving very smoothly on DIY linear rails...I am having no Racking issues... My wife painted the machine and its look pretty good...

Khalid Khattak
05-16-2008, 8:13 AM
Some information regarding my new machine:D
1- The size of my table is 60" x 44"
2- The working area is 48" x 34"
3- The travel of Z-axis is 7"
http://www.cnczone.com/forums/images/misc/progress.gif 4- i am using ACME screw (5/8"-5TPI)... The length of long axis(X-axis)is 62" and the small axis(Y-axis) is 46"... the length of the z-axis ACME screw is 17"... http://www.cnczone.com/forums/images/misc/progress.gifhttp://www.cnczone.com/forums/images/misc/progress.gifhttp://www.cnczone.com/forums/images/misc/progress.gifhttp://www.cnczone.com/forums/images/misc/progress.gifhttp://www.cnczone.com/forums/images/misc/progress.gifhttp://www.cnczone.com/forums/images/misc/progress.gifhttp://www.cnczone.com/forums/images/misc/progress.gif

Leigh Costello
05-30-2008, 12:04 AM
Khalid,
We are just beginning the research and what we would do with a CNC machine. I am very interested in custom signage, but I don't want to do large signs. So, at this point in time, we are dreaming and learning. Your machine looks very nice. I hope you do very well with it.

Khalid Khattak
07-03-2008, 12:09 PM
Khalid,
We are just beginning the research and what we would do with a CNC machine. I am very interested in custom signage, but I don't want to do large signs. So, at this point in time, we are dreaming and learning. Your machine looks very nice. I hope you do very well with it.

Okay... thanks for appreciations words...I hope you will make one and enjoy it...:D

Khalid Khattak
07-08-2008, 10:37 AM
last week i worked on scenery...So here are the pictures of it... The scenery was designed by my Wife and i carved it...The tool used is 12.5mm 60Degree V-bit with 5mm DOC/pass... It took 3.5 Hours to machine at 80IPM... The estimated time by VCARVE PRO was 3 hours and 45 minutes..that was too close

The material i used is 12mm MDF....

The scenery require finishing and colour...I called the painter today to colour it..It will take time.. I will machine a decent frame for this scenery...

http://i293.photobucket.com/albums/mm78/khalidkhattak/2-4.jpg
http://i293.photobucket.com/albums/mm78/khalidkhattak/2-3.jpg
http://i293.photobucket.com/albums/mm78/khalidkhattak/3-2.jpg
http://i293.photobucket.com/albums/mm78/khalidkhattak/4-2.jpg
http://i293.photobucket.com/albums/mm78/khalidkhattak/5-3.jpg
http://i293.photobucket.com/albums/mm78/khalidkhattak/6-4.jpg
http://i293.photobucket.com/albums/mm78/khalidkhattak/10.jpg
http://i293.photobucket.com/albums/mm78/khalidkhattak/9.jpg
http://i293.photobucket.com/albums/mm78/khalidkhattak/6-3.jpg
http://i293.photobucket.com/albums/mm78/khalidkhattak/7-4.jpg

Khalid Khattak
07-25-2008, 7:55 AM
A couple of days ago i designed and carved a table. The material of the table is MDF. I used 12.7 mm 60Degree tool with 80IPM..Total time of carving and cutting took 2.5Hr's..
MDF is 12.5mm thick. It looks beautiful, but i still have to stain it and give the colour of woodhttp://www.cnczone.com/forums/images/smilies/smile.gif

Vector art designing and adjustment done by my wife and the rest of the table and its dimensions and style of legs were created by me... VCarve Pro 4.6 used for carving toolpath generation and Mach3 Quantum used as a controller softwarehttp://www.cnczone.com/forums/images/smilies/smile.gif

Khalid Khattak
07-29-2008, 8:51 AM
Hmmm..I got the painting job done on the scenery....and I am pretty happy with overall outlook...Now I have to make a decent frame for it....:D:D:D

Jack Coats
07-29-2008, 12:32 PM
Kahalid,
I am very impressed with the work you and your wife have done!
Thank you for sharing the pictures.

Khalid Khattak
08-05-2008, 4:45 AM
Currently I am involved in making some box type sitting arrangement (5' x 2' x 1.5') for one of my drawing room corner....Attached picture shows one of the many pieces under carving operation...

Designing and toolpath generation carried out in VCarve Pro 4.6...I will show the details as i am proceed in this new venture...This part is 300 x 250mm and carving time was about 56Minutes...

I love wood burning effects in the mango woodhttp://www.scrollsawer.com/forum/images/smilies/smile.gif

Dennis Parrott
08-06-2008, 11:18 AM
Khalid,

That is some very nice work you are doing. Could you describe your painting/finishing process on the MDF? How do you get the wood grain effects on the material? Thanks.

Dennis

Khalid Khattak
08-07-2008, 2:17 AM
Thanks Dennis:) basically the first two coats were undercoat especially for MDF...This retard the absorption of paint and protect it fron weather..

Then two coats of oil based paint for surface preparation..Staining the carved letter and Finally the texturing carried out with little darkish colour.... Laquer was applied after drying of paint....

Attached are some more work on panels for my sitting arrangement and the Wood is MANGO wood abundantly found here...:D

Khalid Khattak
08-07-2008, 2:21 AM
Few more pictures:):D:D ohh..the total time for painting of scenery is approx. a week:):eek:

Khalid Khattak
08-20-2008, 10:44 AM
A couple of days ago, I recieved one of my Chest bench in assembled form... At that time i have no camera so couldn't post picshttp://www.cnczone.com/forums/images/smilies/frown.gif...Todayi got oppurtunity and took some snaps....Still no sanding no polishing with no cushions.. The second one will be recieved tomorrowhttp://www.cnczone.com/forums/images/smilies/wink.gif Hope to see ur comments...

Khalid Khattak
08-20-2008, 10:55 AM
I love to post photos...so my first post allowed me to post only 05 out of 10;)..so i made it to post in the next one;) Although the details are not visible and the quality of pictures are bad...but i love to post...:D:D

James Jaragosky
08-20-2008, 5:45 PM
I have one question and one suggestion
question - what are the dimensions?
Suggestion - you should start a new thread with each new project unless they are related, otherwise the threads get rather long, also it will make it easier to search through them later. just my opinion
please post a completed photo when you finish, it I would like very much to see it.
Jim J.

james mcgrew
08-21-2008, 8:45 AM
that is beautiful, kahlid i met tony mac and james booth yesterday, we are using thier work here at iwf and they are comming to uor booth on friday to give a demo of thier programs, i will video it if you want to see it

jim mcgrew

Khalid Khattak
08-21-2008, 10:10 AM
that is beautiful, kahlid i met tony mac and james booth yesterday, we are using thier work here at iwf and they are comming to uor booth on friday to give a demo of thier programs, i will video it if you want to see it

jim mcgrew

Jim:)...Pay my compliments to Tony Mac:)... I will be very happy to see the video...As far as VCARVE PRO is concerned, it is very easy and user friendly...
It took me only one hour to completly grasp CUT3D and Vcarve Pro..

I saw ur work..it is very interesting..I hope u will keep posting...

Khalid Khattak
09-04-2008, 7:05 AM
I have one question and one suggestion
question - what are the dimensions?
Suggestion - you should start a new thread with each new project unless they are related, otherwise the threads get rather long, also it will make it easier to search through them later. just my opinion
please post a completed photo when you finish, it I would like very much to see it.
Jim J.

Thanks JIM for appreciation:)..
The dimensions of chests are 5' x 2' x 1.7 ' and 4' x 2' x 1.7'. I recieved the second one a couple of days ago. Still equire sanding and polishing... Have no time to do:(

Khalid Khattak
09-04-2008, 7:13 AM
Quite busy on my 4th Axis..now it is almost complete..Here are the updates on my 4th Axishttp://www.cnczone.com/forums/images/smilies/smile.gif...http://www.cnczone.com/forums/images/smilies/RAINFRO.gif

Khalid Khattak
09-04-2008, 7:16 AM
Few more pics of my 4th Axis.:D:D:D:D

Khalid Khattak
10-15-2008, 3:54 AM
I have completed my 4th axis and now experimenting with it.:D

Some progress yesterday...Here is the rough operation of Egg-grapes part. The job is incomplete...I have just checked wether my small 4th axis motor can hold the cutting forces/Torque on the wood!!! or not ... Need some more optimization... However so far, results are good... I think so....http://www.cnczone.com/forums/images/smilies/RAINFRO.gif

james mcgrew
10-15-2008, 7:58 AM
kahlid, that is pretty innovative!!!

jim

Khalid Khattak
10-15-2008, 9:09 AM
kahlid, that is pretty innovative!!!

jim

Thanks Jim.. Here is the close pictures of My A-axis and Controller box after wiring.:D

Clara Koss
10-15-2008, 2:47 PM
beautiful carvings!!!!! your english is very nice.... i hope you keep sharing your work with us.... hasta la vista!!!!:p

Khalid Khattak
10-16-2008, 12:15 AM
beautiful carvings!!!!! your english is very nice.... i hope you keep sharing your work with us.... hasta la vista!!!!:p

Thank you Clara:).. Who says my English is Nice;).. You will always laugh by reading my posts;).. I just break the legs of english and u will always find fractured sentences;):D

Khalid Khattak
10-20-2008, 11:17 AM
I removed the rough machined rotary part from the machine... cut it off the extra material from the ends... and wowlaaaa, it seems to be a good showpiece stand... Tomorrow I will polish it and see How it comes out...:D

Mike Null
10-23-2008, 11:05 AM
Khalid

Remarkable work. Thanks for the posts.

Khalid Khattak
10-24-2008, 1:52 AM
Thanks Mike Null;)
Scenery frame completed.. I have to install it on a suitable placehttp://www.cnczone.com/forums/images/smilies/wink.gif

Khalid Khattak
11-10-2008, 1:39 AM
You can find more than 100 designs i created with Aspire:)
http://www.vectric.com/forum/viewtopic.php?f=29&t=3997&start=0

Khalid Khattak
11-19-2008, 12:34 PM
Profile Cut the mantle piece, i am planning to install under the scenery i made earlier... Basically this mantle will have some 3D work and carving...behind the mantle i will make few boxes to keep some flower pots...:D

Khalid Khattak
11-19-2008, 3:55 PM
Today I did one of my relief design..The relief design was first converted into recess stylehttp://www.cnczone.com/forums/images/smilies/wink.gif
Initially rough machining was carried out with my home made 6mm ball nose bit http://www.cnczone.com/forums/images/smilies/wink.gif u can see the rough machining of that tool in picture.. Finally I did it with 3mm ball nose with 10% step over.. Total machining time 50 minutes...

Skip Weiser
11-19-2008, 5:10 PM
Khalid, you amaze me with your nice work, and it is done on a homemade machine. Now you have made a homemade 6mm ball nose bit too? You are a very talented guy!

All of your work is great but I especially love how you have routed designs in that entrance door. That looks awesome.

Happy routing!
Skip

James Jaragosky
11-19-2008, 9:58 PM
Khalid, you amaze me with your nice work, and it is done on a homemade machine. Now you have made a homemade 6mm ball nose bit too? You are a very talented guy!

All of your work is great but I especially love how you have routed designs in that entrance door. That looks awesome.

Happy routing!
Skip

You do very nice work. You have some amazing talents.

Khalid Khattak
11-19-2008, 11:30 PM
Skip.. thats your eyes that make my work beautiful..thanks for motivation:).. Jim, I like your work tooo..no flattery at all...:)

Attached are some of the relief i designed for my future woodworking projects...

Khalid Khattak
11-19-2008, 11:32 PM
Few more.. I have 100+ of those all i created myself....:cool:

Khalid Khattak
11-19-2008, 11:36 PM
Following are the router bit having ball nose.... machined using inhouse facilities...

U can see the bit is straight from top to bottom, just like straight end mill... at the top the ball nose was made...

Khalid Khattak
11-20-2008, 11:39 AM
Few more pics..this time my mantle piece is completed... Now see the difference.. the left side corner relief in Fig7, i carved today is very neat as compare to right side one...

The reason is left side one is completly machined with a single tool i.e. 3mm ball nose... http://www.cnczone.com/forums/images/smilies/wink.gif

In the center, i am thankful to James Booth, who provided free flower relief at www.vectorart3d.com (http://www.vectorart3d.com/)..Thanks James

The center flower took 45 minutes...

Khalid Khattak
11-26-2008, 5:11 AM
Did made following reliefs for my upcoming project:)

Khalid Khattak
11-26-2008, 4:12 PM
My second border design in progress:)

Khalid Khattak
11-27-2008, 3:18 AM
Today i completed the border design:) How it look???
Can't it look better when carved on vertical fireplace mantle...;)

Khalid Khattak
11-27-2008, 9:34 AM
Now i just have it hanged on the wall;)

Khalid Khattak
12-20-2008, 3:04 PM
My 3rd Machine 5' x 5' x 8" (X Y Z)...Target completion date 30th Dec-2008...

1- Cutting area 4.5' x 4.2' x 8"
2- Will use Nema 23 motors 200oz-in
3-Estimated minimum rapid 800IPM (can be more)
4- Cutting IPM - 400+
5- Possibly chain/belt driven

sorry for pictures quality...it was night and just snap it through mobile...

James Jaragosky
12-20-2008, 4:20 PM
My 3rd Machine 5' x 5' x 8" (X Y Z)...Target completion date 30th Dec-2008...

1- Cutting area 4.5' x 4.2' x 8"
2- Will use Nema 23 motors 200oz-in
3-Estimated minimum rapid 800IPM (can be more)
4- Cutting IPM - 400+
5- Possibly chain/belt driven

sorry for pictures quality...it was night and just snap it through mobile...
looks like a good start. keep us informed.

Khalid Khattak
12-21-2008, 1:59 AM
It is a silence build so far... we have best aligned the rails with resin...almost all the parts are available and currently assembling in progress... The white material u see in above picture is Marble... so we are going to build the base(table top) of that router with marble...

In marble we have provision of drilled holes for vacuum clamping.. For slides we are using V-rollers... Our calculations shows the accuracy 0.01mm...

The first test part we will cut is the slab of marble on the bed...

Khalid Khattak
12-25-2008, 8:25 AM
Recently i am/been busy to produce some wood work for an upcoming yearly event at my community... This event is Funfair and we have every type of stall and fungames for the full day here... All the money (profit) goes to local community charity...

Last year i had a Stall of woodworking and we ( Me and my wife) really enjoyed it... Many peoples amazed to see our wood work bcas we are not wood worker by profession....You can see my Stall pictures at following link

http://www.cnczone.com/forums/showthrea ... 588&page=8 (http://www.cnczone.com/forums/showthread.php?t=39588&page=8)

Next month we have it again so trying to make few interesting things... Mostly ladies like some stuff related to Kitchen and there interests...so i designed a simple Salad platter...This is the first rain drop and i have lot to go... time is very short here:)
In the bottom i will place 04Ea ,1/2" round wooden plugs for placing it on table..also i will round the bottom periphery for 3D look

Any suggestions from u are welcome...

Information:
Tool used
A- Profile cut= 3mm end mill
B- V-carving = 12mm 90 degree V-bit
C-Pocketting = 8mm straight endmill

Softwares:
1- Vectric Vcarve Pro 4.6 for all above toolpath generation
2- Mach3 Quantum (latest version)

Wood:
Type = Mango wood
Thickness= 5/8" (~15.8mm)
Dimension = 300mm x 245mm

Khalid Khattak
12-25-2008, 8:29 AM
some more pictures:)

Khalid Khattak
12-27-2008, 10:42 AM
Another Funfair project, Deer relief Mantle, carving on back board carried out as u can see in my Today's work...http://www.cnczone.com/forums/images/smilies/smile.gif

In the center I pretend to do some texture mapping...:)

Khalid Khattak
12-27-2008, 10:43 AM
few more pics..

Khalid Khattak
12-28-2008, 9:54 AM
Today I did some texture mapping in the center of the blank portion...

Khalid Khattak
01-03-2009, 7:39 AM
I must have to share my 3rd machine pictures... tomorrow it will be test run on Mach3...http://www.cnczone.com/forums/images/smilies/smile.gifhttp://www.cnczone.com/forums/images/smilies/smile.gif Still i want to keep this machine some NAME...

Khalid Khattak
01-07-2009, 7:58 AM
Did some work on the Ducks Pond... Machining photos as per following attachment... Need help if u have any ideas to look it better or adding some more work on the pond..http://www.cnczone.com/forums/images/smilies/smile.gif I will round the edges of the pond...http://www.cnczone.com/forums/images/smilies/smile.gif

Khalid Khattak
01-07-2009, 9:08 AM
Leaf Platter is polished and its handle corner were rounded...http://www.cnczone.com/forums/images/smilies/smile.gif

Khalid Khattak
01-17-2009, 9:52 AM
Today I did some machining for the Mirror Top..I will install it above the wall hanging... Tomorrow I will complete the side pieces..http://www.cnczone.com/forums/images/smilies/smile.gif

Khalid Khattak
01-18-2009, 8:19 AM
Today i did Side panel of the Mirror Project. :D

Darren Salyer
01-18-2009, 12:02 PM
very nice work!!

Angus Hines
01-18-2009, 1:44 PM
You always amaze me with your skillz.

So whats the weather like there. Is your avatar the way it looks out your window.....LOL?

Khalid Khattak
01-18-2009, 2:02 PM
Thank You Darren Salyer (http://sawmillcreek.org/member.php?u=15689) http://sawmillcreek.org/images/statusicon/user_offline.gif and Angus Hines:)

Angus.. We have a cold weather here and experiencing snow falls in our country Northern areas...:) I wish to live the place shown in my Avatar... I like Pine trees and snow falls, also i like snow carved peaks...:)

In the attach picture you will see the machine carving the wood...:) I have experimented CAM side to reduce the machining time..and this time i cut half of the time for machining the same 3D relief:)

james mcgrew
01-18-2009, 2:04 PM
kahlid is that a router i see on the new table?

jim

Khalid Khattak
01-18-2009, 2:28 PM
kahlid is that a router i see on the new table?

jim

Jim.. In the above picture, behind the MDF Router, you can see my First Router that was made completely with structural steel.. I used ball screws in it i purchased from Junk Yard... I made my MDF machine by the help of my First steel router...and when i cut the last part of MDF machine, the ball screw rotating nut plastic component got damage.. From that time the my First Router is in break down condition...

My New router 5ft x 5ft is under testing and it is not with me... So far we achieved very goood results, currently we are doing some marble cutting work on it for experimentation purposes....

As soon it comes in my hand i will use strictly for wood working...

Khalid Khattak
01-19-2009, 12:38 PM
Repeatable Border Relief

Length:400
Width:150
Relief Max. Height:12mm

Khalid Khattak
01-20-2009, 8:26 AM
Border design and bunch of flowers:)

James Jaragosky
01-20-2009, 10:29 AM
Border design and bunch of flowers:)
I like it!

Ken Higginbotham
01-20-2009, 11:09 AM
Those are some cool gizmos. I built something similar several years ago and hooked an airbrush up to it. Got the logic chips, powersupply and all that stuff and put it together from scratch. I think I used a pc of free ware called danplot to drive the actual stepper motors...

Again, cool stuff - I'm jealous :)

ken

Khalid Khattak
01-23-2009, 10:39 AM
Those are some cool gizmos. I built something similar several years ago and hooked an airbrush up to it. Got the logic chips, powersupply and all that stuff and put it together from scratch. I think I used a pc of free ware called danplot to drive the actual stepper motors...

Again, cool stuff - I'm jealous :)

ken

Ken:)
Come on man.. we want to see your work:):D:D

Today I made another design... ;)
Height: 120 mm
Width: 480 mm
Relief Height from Flat : 7 mm

Khalid Khattak
01-27-2009, 1:40 AM
Another Border:)

Length:100
Width:120
Relief Max. Height:12mm

James Jaragosky
01-27-2009, 2:57 AM
Another Border:)

Length:100
Width:120
Relief Max. Height:12mm

looks like you got the hang of aspire.
Nice work.

Khalid Khattak
01-27-2009, 3:00 AM
looks like you got the hang of aspire.
Nice work.

Thanks James.. But this work is created in Artcam:)

Ken Higginbotham
01-27-2009, 7:30 AM
Ken:)
Come on man.. we want to see your work:):D:D
...

I don't think I have any pics :o

Khalid Khattak
01-29-2009, 10:15 AM
After a Long Looooong timeeeeeeeee....Today I worked on my 4th axis... Did some flutes and Vcarving on scrap wood http://www.cnczone.com/forums/images/smilies/smile.gif...

Ken Higginbotham
01-29-2009, 10:38 AM
So 1 is horizontal, 2 rotates the pc, 3 moves the cutting head in and out, what does 4 do?

Khalid Khattak
01-29-2009, 10:49 AM
1- Along X-axis
2- Along Y-axis
3- Along Z-axis
4- Rotary Axis

At a time I use only 3-axis ;) i.e. 1 +3+ 4:)

Ken Higginbotham
01-29-2009, 10:55 AM
Can you post some better pictures of the machine? I'm having a hard time picturing what’s going on...

Khalid Khattak
01-29-2009, 12:21 PM
Can you post some better pictures of the machine? I'm having a hard time picturing what’s going on...
Hmmm... Ken if you go through my thread you will see the complete machine along with my DIY rotary Indexer...

However you can see the machine with indexer in following:D
http://sawmillcreek.org/showthread.php?t=83325&page=4

Ken Higginbotham
01-29-2009, 12:26 PM
Oh... Sorry.

Hum...

So the x axis is simple enough - back and forth.

For the y axis, or vertical axis movement, does the rotary indexer increment to rotate the work pc to mimick vertical movement?

james mcgrew
01-29-2009, 12:47 PM
kahlid, what software are you using to a) generate the file and b) software to convert to 4rth axis wrap

thanks again

jim

Khalid Khattak
01-29-2009, 12:52 PM
Oh... Sorry.

Hum...

So the x axis is simple enough - back and forth.

For the y axis, or vertical axis movement, does the rotary indexer increment to rotate the work pc to mimick vertical movement?

yes X-axis back and forth and Z-axis up and down and rotary indeser rotate in degrees:)

Khalid Khattak
01-29-2009, 12:56 PM
kahlid, what software are you using to a) generate the file and b) software to convert to 4rth axis wrap

thanks again

jim

Jim I am using Artcam for both a) and b) :) I have independent rotary axis so no swapping of Y-axis to A-axis...

Khalid Khattak
01-29-2009, 1:08 PM
NEVILLE STEWART:)

The above indexing work i posted will remember you some special you did for me:)... "A gift from a woodworker to a woodworker":);)

With compliments and thanks:)

Ken Higginbotham
01-29-2009, 1:16 PM
Sorry to be dense but that's three, where does the forth axis come in...?

Also, does it use one line/one pulse to move one step and a second line with a high/low for direction per axis? And is this all going through a parallel port?

The best I can remember one of my issues wase getting solid state relays with enough power to drive the steppers. The second was the drill head motor (when I attempted to get one to run) would cause noise back through the system and cause the low voltage logic circuits to bomb... Looks like you fixed all of that... :)

Khalid Khattak
01-29-2009, 10:39 PM
Sorry Ken..My machine is not a true 4th axis machine..For any type of work, I can always use 3 of the axis on my machine...

I think nowadays controller as will as softwares become very robust as compare to those times when you were working on CNC machine...:)

I welcome you to start this hobby again..:D

Khalid Khattak
02-01-2009, 6:51 AM
Okay:).. Here are some Indexing work I did today.. Its a candle stand..:)

Khalid Khattak
02-01-2009, 6:53 AM
Pictures continued:)

Khalid Khattak
02-01-2009, 3:15 PM
Some more stuff i did...

Khalid Khattak
02-07-2009, 9:50 AM
My version of Barley Twist tool.. I will soon post the results of this tool.. currently the radius is very steep....

Khalid Khattak
02-11-2009, 12:07 PM
Here is the completed mirror frame :)

James Jaragosky
02-11-2009, 4:08 PM
Here is the completed mirror frame :)
Beautiful work. I bet your wife is very happy.

Khalid Khattak
02-12-2009, 3:21 AM
Thanks James:)

My wife designed the complete Mirror frame and Flower Box.. She even generated the Gcode for it.... I just put the wood on machine Bed and did some Magic ;)

Khalid Khattak
02-13-2009, 6:33 AM
Here is the cheap modification to my Indexer to turn it into TURNING Tool ;) Today I will travel in search of small 1HP Motor for my Lathe.. However, I have substitute arrangement (Drill Machine) if i not find the Motor...

james mcgrew
02-13-2009, 8:08 AM
all woodworking tools are just a motor and a shaft!! the motor you need is a router with variable speed like the ome in your photo!!

jim

Khalid Khattak
02-13-2009, 4:24 PM
Jim, you are absolutly right....However, by installing router motor i would have two problems, the noise and very high RPM... I don't have variable speed router... its 26000 RPM straight chinese Plunge router...
The Motor with 2800 RPM will be very quite solution to the lathe... At least, the less noise will make me happy while working with lathe ;)

Khalid Khattak
02-20-2009, 8:50 AM
Okay man..here is the 15 minutes work out of my machine testing the new home made barley twist tool...

Khalid Khattak
02-21-2009, 5:58 AM
Here the twist was machined by the Lathe attachment at my CNC router... It was a great experience and confidense...

Khalid Khattak
02-21-2009, 12:59 PM
Okay ..The time is come to show you the results of my Lathe attachment work on my Milling machine... I didn't found 1HP motor in Junk Yard so I powered the chuck with the existing Drill Machine, the work you see is for FunFair Bazar, i start creating from yesterday.. The CAD part took much time as compared to CAM and machining...

You can also see the home made Lathe tools and inserts...

Khalid Khattak
02-22-2009, 1:13 PM
Following is the carving done on one of the candle holder..More to Come..Stay tunedhttp://www.cnczone.com/forums/images/smilies/wink.gif

James Jaragosky
02-22-2009, 6:56 PM
Following is the carving done on one of the candle holder..More to Come..Stay tunedhttp://www.cnczone.com/forums/images/smilies/wink.gif
I like what you do with what you have. I have so much more; and am able to do so much less:confused:
Jim J.

james mcgrew
02-22-2009, 7:08 PM
kahlid can we send you some bits?

jim

Khalid Khattak
02-22-2009, 11:41 PM
I like what you do with what you have. I have some much more; and am able to do so much less:confused:
Jim J.

Jim, i am really amazed you have a big stable machine... but you are only doing cabinets with it... I don't know why you not do carving!!!! I think you can improve your business by doing such carving work on the cabinets...

I am not that good as you think... i don't know much about the wood as you know... I have nil experience as compared to you... You are the real woodworker, i am just an apprentice...

The 28th Feb, Funfair shocked me to do more and more work... Peoples come to my home and want to see what i have produce... I didn't produce much as committed.:(

Pray for me, its very hard to please all the people all the time...

Khalid Khattak
02-23-2009, 12:57 AM
kahlid can we send you some bits?

jim

James... Thanks for the offer, but i need no tools.... Necessity is the Mother of Invention... A couple of months ago,I got some high Quality Tools from one of the friend among you...and i think those are enough for me...

I stucked in the new tooling like Barley Twist Tools and its Family, that are new to me... If you have dimensional drawings or skecth of that tool then please send me... that will be great help from your side..

Again thanks for offer...

Regards

Khalid Khattak
02-23-2009, 8:51 AM
Here is the 2nd version of Deer mantel i will put on Auction:)

Khalid Khattak
02-25-2009, 9:17 AM
Here is the Deer Plaque i will keep in Auction:)

Khalid Khattak
02-25-2009, 11:25 AM
and the Finished Candle Stand;)

Khalid Khattak
02-26-2009, 11:39 AM
Here is some work i did today:)

Khalid Khattak
02-26-2009, 11:57 AM
Here is the Finished Mirror Frame ;)

Khalid Khattak
02-27-2009, 6:33 AM
Here is the floral box wall hanging ;)

Khalid Khattak
02-27-2009, 3:14 PM
Some modificvation to the Duck Pond...

James Jaragosky
02-28-2009, 1:16 AM
Some modificvation to the Duck Pond...
I like it!
Did you design the texture pattern yourself?
How many operation files did it take to complete the project?

Khalid Khattak
03-01-2009, 12:26 AM
I like it!
Did you design the texture pattern yourself?
How many operation files did it take to complete the project?

I designed all the toolpaths in Vcarvepro including the textures too... it has 03 operations in a single File..
1- Pocketing
2- Texture carving and then
3- Finally Cut out
Thanks

James Jaragosky
03-01-2009, 2:30 AM
I designed all the toolpaths in Vcarvepro including the textures too... it has 03 operations in a single File..
1- Pocketing
2- Texture carving and then
3- Finally Cut out
Thanks
How did you cut the profile?

Khalid Khattak
03-01-2009, 11:33 AM
How did you cut the profile?
I cut the profile with CNC router using End mill..Then afterward, I rounded the corners manulaly with the Plunge Router with a design bit :)

Khalid Khattak
03-03-2009, 11:06 AM
We have a very good crowd at our stall and in the Mid-day we sold 60% of our artifacts... Total revenue generated was about $410 US dollars... All goes to charity...

I will here acknowlege the efforts of Mr. Neville Stewart for gifting me the high quality bits at the time when i needed those , that made me more courage to machine some quality stuff that generated a good amount of money for the the local community.. Thanks Neville..


P.S:
The entrance and the Canons were shop-made...

Khalid Khattak
03-03-2009, 11:07 AM
and see my stall full of crowd:) :D

james mcgrew
03-03-2009, 12:26 PM
excellent!!!!

jim

James Jaragosky
03-03-2009, 5:22 PM
excellent!!!!

jimYou look very serious, standing there behind your spice kabobs:D
Nice stand and nice to see you have a crowed.

Khalid Khattak
03-06-2009, 11:04 AM
You look very serious, standing there behind your spice kabobs:D
Nice stand and nice to see you have a crowed.

Two JAMES rulz the Sawmillcreek Forum :D:D

I am very bad cook ;).... thanks for appreciation :)

P.S: I took all the pics so u can't find me in those :)

Khalid Khattak
03-10-2009, 6:19 AM
I am using Teflon Nuts on 5/8" 5TPI Leadscrews...I didn't install any backlash prevention mechanism everbefore on both of my machine, but after Funfair i felt to install anti-backlash nuts...

I planned to Overhaul my Machine (after 1 years of service) to check any abnormality in the machine components, I found nothing but Backlash in the Nuts.. so I just installed the Homemade Backlash nuts to both of X and Y-axes...

Today I cut the Fish bowl and the machine work great http://www.talkshopbot.com/forum/clipart/happy.gif

For 12mm deep Pocket operation I used 1" Barley Twist Tool, for Profile cut i used 6.5mm endmill and V-carving was done by 12.5mm 90 degree V-bit...

The Platter Length is 610mm and width 250mm and the thickness 16mm.... TOTAL TIME 45Minutes with toolchange...

James Jaragosky
03-10-2009, 11:49 AM
I am using Teflon Nuts on 5/8" 5TPI Leadscrews...I didn't install any backlash prevention mechanism everbefore on both of my machine, but after Funfair i felt to install anti-backlash nuts...

I planned to Overhaul my Machine (after 1 years of service) to check any abnormality in the machine components, I found nothing but Backlash in the Nuts.. so I just installed the Homemade Backlash nuts to both of X and Y-axes...

Today I cut the Fish bowl and the machine work great http://www.talkshopbot.com/forum/clipart/happy.gif

For 12mm deep Pocket operation I used 1" Barley Twist Tool, for Profile cut i used 6.5mm endmill and V-carving was done by 12.5mm 90 degree V-bit...

The Platter Length is 610mm and width 250mm and the thickness 16mm.... TOTAL TIME 45Minutes with toolchange...

How did you hold the fish in place for the profile cut?
did you use tabs?

Khalid Khattak
03-10-2009, 1:08 PM
How did you hold the fish in place for the profile cut?
did you use tabs?

James thanks for posting in this thread :)

Answer to your question is No I didn't use Tab.. actually i forget to place them:rolleyes:.. However, as soon as the cut reach to the end i stopped the machine :) and saved my workpiece:)..

Here is the 3D Bear I did today.. No sanding yet..

1- used 6.5mm Endmill for rough passess ( tHe relief height was 14mm)
2- Used 3mm ball nose cutter for finish pass
3- Used 3mm ball nose for profile cut..

total time 1Hr and 10minutes:)

tim harris
03-11-2009, 7:24 AM
Hi, everyone, I just stumbled into this thread this morning and was amazed at the details and pictures. I really enjoyed making machines (when I did, and that was a few years ago). I always thought that the concept of making a tool with another tool was the mark of intelligence, ( this I lack). At any rate, I like making jigs, mostly for routers and wanted to make a router mounted to a lathe to create hollow spiral spindles. Any one doing this? Any Pics? Thanks again , Great Work Khalid!!

Khalid Khattak
03-11-2009, 12:17 PM
Hi, .... wanted to make a router mounted to a lathe to create hollow spiral spindles. Any one doing this? Any Pics? Thanks again , Great Work Khalid!!

Hi Tim.. The hollow spiral can be made with the help of CNC easily... You can see in my previos post i made some spirals with the help of barley twist tool.. i can easily use endmill to hollow the spaces between spirals..
Jack Jervis at Talkshopbot forum has a good expereince of doing such spirals..thanks for appreciating my workk

Here is some more parts i cut for the jewelery box today, some more to go by tomorrow.. and you can see how the parts going to match with each other...;) The Pen is kept to give you an idea of the size of Box...

Khalid Khattak
03-22-2009, 2:57 AM
Yesterday Me and my Wife went market to get some Beads for her cloth projects ... When I saw the Bead stuff , all of sudden, got an idea to introduce the beads to Mirror frame.. I picked few very low-cost plastic beads and they are very good fit in the grooves.. http://www.cnczone.com/forums/images/smilies/smile.gif

Khalid Khattak
03-23-2009, 3:55 PM
Today I partially did 3D Dolphin Model on my Indexer.. I created toolpath and did rough machining only... You can see something bad happened at the end of rough machining toolpath.. Basically the tail of the dolphin was very thin and i modeled the end anchors in a very bad way.. The Tail of dolphin snapped off due to bad supports...Also The tool was a little short and collet strikes with the stock, this collision is also detected by the software simulation...

Although My Dolphin was ruined:rolleyes: but It was my first experience with the software.. Next time i will do complete A-axis machining and post here..:)

Khalid Khattak
03-23-2009, 3:57 PM
Here is the second batch of actual machining :)

Khalid Khattak
03-26-2009, 11:38 AM
Here is the updates on Bear Jewelery Box....:)

Khalid Khattak
03-28-2009, 11:28 AM
Here is the small setup i made to generate 3D models from simple pictures..Following are the results of pictures i snapped at various angles.... it is than converted into 3D object..its marvelous.. No laser setup, no point cloud, no stitching of surfaces.. its give you complete 3D model within few minutes..

Once i made a wind mill for electricity generation.. I removed the blades from PM generator hub.. and pasted the grid patterns on it....

Rotated by hand and taking pictures (No camera stand required) ..almost 16 pictures in 360 degree angle...

Khalid Khattak
03-28-2009, 11:35 AM
and the remaining pictures...

Khalid Khattak
03-28-2009, 12:29 PM
some more experimentation:)

Khalid Khattak
04-03-2009, 3:46 AM
Tomorrow i plan to machine my Virtual Head, but in some artistic way... If you have any comments or you point any modification i will be gratful.. :D

Brian Robison
04-03-2009, 12:30 PM
Khalid,
Any tips on making the 3D drawings? Maybe you can start a new thread to show what it take to do the drawings and the software you used.

Khalid Khattak
04-04-2009, 4:58 AM
Brian.. For 3D you need some basic knowledge and then Practice Practice Practice... I will write a brief tutorial may be a video..but currently i have no time...

At last I have 100% success... and this was the first time i succeeded in understanding the toolpath creation within Artcam..

The above toolpath was created in visualMill.. and the picture i am posting now is Complete work within Artcam..The complete time for Roughing 13 Minutes and Finishing pass took 1 Hr and 13Minutes...

The stepover and tolerance were kept high so the quality was not come out great.. but this is in my hand.. The main was i know how to create efficient 4th axis toolpath..

Khalid Khattak
04-04-2009, 5:00 AM
and the process continue...

Khalid Khattak
04-05-2009, 10:23 AM
A short video...

http://www.youtube.com/watch?v=E9fijZhr1PA

http://www.youtube.com/watch?v=5ezG0ELmerk

Khalid Khattak
07-28-2009, 10:51 AM
After long time i touched my CNC Machine... I purchased oil painting from Paris and that was without frame... I made a relief 14mm height carved on 1.5" thick 150mm wide wood for it but lately my wife suggested to make window pelmet from it...

Brian Robison
09-30-2009, 4:39 PM
Can you tell me more about the software you used for the 3D pictures. I'm looking at making a 3D scanner.

Khalid Khattak
10-01-2009, 2:31 AM
Can you tell me more about the software you used for the 3D pictures. I'm looking at making a 3D scanner.
Brian..I made all the above relief with software..However I made a very low cost 3D Scanner known as "David Laser Scanner".. Its perfect for my type of work...

The guys at the following link scan Flys and minute object with full details.

www.david-laserscanner.com (http://www.david-laserscanner.com)

Regards

Khalid Khattak
10-04-2009, 2:24 AM
I am designing 3set table for my home.. Some 6Hrs work from scratches still in complete.. table top 5feet x 2.4 feet and relief height 9mm..

i did the center piece in 03 steps.. The right and Left done on yesterday and it took 12 Hours straight... I use ear-plugs when i am near to machine..When the room door is closed i just hear a Buzz sound that remind me that router is running ... Yesterday due to malfunction in the power-cable socket the router ( Spindle) stopped and bit stucked in the workpiece with steppers running.. Thanks its a slow speed machine ;)..

Brian Robison
10-05-2009, 8:47 AM
Do you use a web cam for scanning? 1.3 mega pixel?

Khalid Khattak
10-06-2009, 12:30 PM
Do you use a web cam for scanning? 1.3 mega pixel?

I am using Logitech Pro 9000 camera... I recently improved my laser scanning setup... I have a stepper motor attached to 1:60 gear box..the output from the gear box further reduced to 1:7 with timing belt..Now i can scan with very high resolution..Attached is the low resolution scan from free version of David Laser scanner..Its smoothness and interpolation kept to one..You can see how small the object with details...
The green laser pointer was gifted by my friend..i made a teflon attachment with a lens to make it Line laser...

Nathan Chennault
10-11-2011, 3:01 PM
wow! (at least 10 characters now)

Mike Heidrick
10-16-2011, 12:56 AM
Yes WOW!! +1000

Thanks for digging this up and posting it. Anyone else make a Laser scanner like this??

Khalid Khattak
10-26-2011, 7:34 AM
Dear All,
Thank You all for posting:).. Recently i have finished improved laser scanner hardware with incredible results :) Here is the latest machining video of diaphragm valve seat mold , that i have scanned..

I don't know why the opening of this forum is very tedious and slow..My internet speed is very good but this forum opening page time interval is very high more than 3 minutes it takes to open one page...
Raster Toolpath strategy:)

http://www.youtube.com/watch?v=EVwwP5tg16o&feature=feedu

Spiral 3D Toolpath:)

http://www.youtube.com/watch?v=GwoiosTJ2RM&feature=related

Khalid Khattak
10-26-2011, 10:20 AM
Wow..now the forum is opening very quick:)..

james mcgrew
10-26-2011, 10:22 AM
good looking work!!