Turkey Box Call

[IslaWW]

Guys...
I made a demo video for a guy interested in seeing what a 4th axis can do for a call maker. I was going to put this in the rotary section, but it is not a rotary wrapped file, but has been toolpathed completely with VCPro with a few added rotary positions added.


Turn the sound down, my webcam mike doesn't like cutting noises.

[scottp55]

Nice Gary, Thank you for posting that. What wood was it?

[IslaWW]

Scott...
I think that blank was Philippine Mahogany, aka Luan, didn't pay much attention tho.

[scottp55]

Thanks, Kept me guessing in the middle of the night(for me) trying to figure out species from feeds/speeds/noise/chips best guess before I finally drifted off at 3 was Western Red like my cedar flute. Sweet set-up!

[IslaWW]

Scott....
We were given a pallet of these blanks by one of the students at our CAMaster Rotary School. Even now I am not sure of the species, but they do look and smell like Luan. Much denser than any of the cedars. I think that plying the teachers with turning blanks is much nicer than a plain ol apple!!!

[glenninvb]

Maybe you should save the sound chamber for last
or was that just the mike?

Nice job!

[IslaWW]

Glenn...
There is a combination of things going on there. The compression bit is hungry, as its rated for 400+ipm and screams under 100. But it was the only bit I had that would cut deep enough for this project. The sound chamber made it louder. The worst offender is the mic on the webcam, it will make classical music sound bad!

[IslaWW]

As a side note, and answer to a couple emails, The hand coded rotary codes were hand placed where needed and are very simple. They were added to the appropriate lines. IF you see rotary movement, there has been a rotary call added.

There are 2 types of additions made. 1) was added to the end of an existing line that had an exiting Y move. Since the side angle of the piece was 7* those calls were: (for my B (rotary) axis) B7 , B-7 and B0 (zero). This only applied to the finish (angular) clearance of the center pocket.

2) a standalone positioning move. These were all preceded with a G53Z0 (lift z to max) and were: B97 for the 1st side pocketing, B-97 for the second side pockets and carving and B180 for surfacing and text carving on the bottom.

[IslaWW]

One additional note. Other than the hand entered rotary positioning moves listed in the post above, 100% of this code was generated with VCarvePro. Shows how versatile it can be.

In this video using the backnife, 100% of this code was generated with VCarvePro. It does use a postP that has no output to the Z axis.

[IslaWW]

An update to callmakers considering machining this type of product on a rotary axis:

Using techniques shown at Jim McGrew's Aspire gathering this past May, the need to use hand coding for rotation of the blank has been eliminated. Both VCPro and Aspire are capable of cutting these angled side box calls using 2D design and toolpath tools. Of course the rotary axis must have the torque to rotate for aggressive cutting. Hopefully this will answer your questions.

[sluggo]

That's an awesome video - it always impresses me to see what the forum experts are working on as it inspires me to learn new things and expand my own capabilities. I wish I had a rotary axis!

Charlie

[IslaWW]

Guys...
An update to this thread. Due to the length and bad sound, I have made a faster speed version of this Box Call video and removed the cutting sound. These box calls are sound chambers that amplify any bit noise during cutting.

You might get to the end of this version:

GC

[Fleming]

Gary,

Thanks for the update on the video.

Quick question: It looked as if the main box hollowing was created using sloped sides with the rotary acting in concert with the XY movements. Your description said all toolpaths were done in Vcarve. Could you elaborate on how this was done without directly modifying the G-code?

Thanks,

Paul

[IslaWW]

Paul...
The rotational movements use a bit of post processor trickery using the "Tool Notes"

[llwood]

Thanks for the video. My only disappointment was that you didn't demonstrate its use. I'd love to hear what it sounds like!! Could you include in your video a clip of you using it so we can hear the sound it makes?

Andy