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Prince Regent Royal Pavilion
Prince Regent Royal Pavilion
Image by Dominic’s pics
Part of a set photographs of the Prince Regent’s Royal Pavilion (also renowned as Brighton Pavilion).
Built in the Indo-Saracenic style, borrowing thoughts from Indian architecture in the days when that region was still part of the British Empire.
Unlike the originals, the building’s frame is Cast Iron – cutting edge technology at the time when the building was redeveloped by the architect en.wikipedia.org/wiki/John_Nash_(architect) are really very small scale – much too small for an adult to fit inside. Like the shrunken higher up windows and tapering outline of the Senate House of London University, the reduction in size of the minarets adds to the illusion of scale.
The viewpoint (often used in picture postcards) is also deceptive. By perching the camera on the edge of a small (four paces by ten paces) ornamental pond, the fake impression is made that the pavilion is adjacent to a huge lake.
There is an official Royal Pavilion website.
During Work War II, Adolf Hitler is famously claimed to have spared the Pavilion from bombing because he wanted to use it has his English headquarters. This is reputed to be based on statements by William Joyce, an American born German radio propaganda broadcaster (named Lord Haw-Haw by British listeners), statements most likely made to demoralise listeners into the belief that this outcome was inevitable. Brighton was bombed, but, so maybe the Luftwaffe just missed.
The image is made up from High Dynamic Range (HDR) files. A large number of (identically framed) bracketed exposures were merged into a single HDR file. This 32 bits per channel file (over 4 billion shades of red, green or blue) was converted to a more mundane 8 bits per channel jpeg file. (It is not currently technically feasible to fully show 4 billlion shades per colour on a computer monitor, or on a photograph.) In the conversion process Local Adaptation was used, a trick that enables the detail in both very bright (floodlit) areas and very dark (moonlit) areas to be viewed in the same image. The human visual system is particularly sensitive to detecting edges, and "overlooks" intervening smooth gradients. This makes Local Adaptation a viable technique / optical illusion.
The image has also been modified using transformations to remove any barrel distortion, and also adapted to ensure a classical perspective with parallel verticals.
A Canon 300D DSLR was used. The number of exposures ranged from 1/250 sec. to 30 secs. in 2 EV/stop increments. Two large, nervous, ornamental carp live in the pool. I reckon that they went about between exposures, causing the feint, weird, multiple streaks in the surface of the pond.
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Epson LQ 590 – Printer – B/W – dot-matrix – 10 in x 22 in, JIS B4 – 24 pin – up to 529 char/sec – Parallel, USB
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The Turning Page ?the Turning Revolution?
The Turning Page ?the Turning Revolution?
Broaching On A CNC Lathe
One operation seen on many turned parts today is broaching. Traditionally
broaching has been regarded as a secondary operation that was typically performed
on a broaching machine with special broaching tools. Depending on the industry,
much of this type of broaching is still life done in this manner. For instance, in the
automotive sector, nearly all broaching is done by large expensive automatic
broaching apparatus with specially designed broaching tools that can produce the
broaching at very high speed and fleeting cycles.
Of course the fact that they are doing over a million parts per year has much to do
with their method of manufacturing the parts. But today, even in the automotive
sector, the need for JIS and reduced inventory, can justify doing parts complete on a
single piece of equipment such as the multi-axis turn/mill center. With this
equipment, a new job can be easily modified and reconfigured for revision and
design changes. This is where flexibility wins out over speed.
Types Of Broaching.
There are a few different types of broaching that can be performed on the
CNC lathe.
#1. Single slot broaching on the inside or outside diameter of a part.
#2. Multiple shapes such as hexagons or squares.
#3. Timed broaching or broached slots that require an angular position to
another feature on the part.
#4. Free position broaching that does not require an angular position to
another feature n the part.
#5. Rotary Broaching
#6. Reciprocating Broaching
The type of broaching you need to do, will determine your tooling scale and
method.
ROTARY BROACHING
One of the simplest and fastest ways to produce a broached feature is Rotary
or Wobble broaching. Rotary broaching has been around for years in the screw
machine industry and is very effective, inexpensive and quick. It is used widely in the
manufacturing of plumbing parts such as valves and fittings and in the aerospace
and medical industries. When your parts require a single broached polygon that is
not related to another angular orientation or feature on the part such as a milled
flat or drilled hole, this is often a first scale.
A leading US company in the manufacture of Rotary broaching tools and
accessories is Slater Tool Company from Clinton Township, Michigan. They can be
found on the web at www.slatertools.com where they list a full complement of rotary
tool holders, tool bits, and detailed application documentation.
A simple example of this type of rotary broaching is the producing of an I.D.
hex on the end of a part. Let’s say it is a 5/8 hex in 12L14 steel. First thing is to
determine the max hole to drill, and then the size chamfer needed to make a excellent
acceptable hex. This can be determined by multiplying the hex size by 1.035 to
determine the largest pilot hole to be drilled.
Hex size .625 x 1.035 = .646 Pilot Drill = .625 to .646 diameter.
To determine an acceptable chamfering size, multiply the hex size by 1.1547
Hex size .625 x 1.1547 = .721
Next is necessary to determine the feed for the type of material and broaching tool.
For the 12L14 steel, according to Slater Tool’s web site, we should try out this at
1200 RPM with a feed of .006 i.p.r.
Here is a simple program example using the rotary try out tool programmed for a
Eurotech 735SLY.
O2007(ROTARY BROACH EX)
G0G40G80
N1G54T0101M64(.633 DRILL)
G0G99G97S3620X0Z.1M3M8
M58(LOAD MONITOR ON)
G1Z-.75F.016
M59(LOAD MONITOR OFF)
G0Z1.
M1
N2G54T0202M64(3.4 90 DEG. SPOT)
G0G99G97S635X0Z.1M3M8
G1Z-.3F.03
Z-.3605F.003
G4P100(DWELL)
G0Z3.
M1
N3G54T0303M64(5/8 ROTARY BROACH)
G0G99G97S1200X0Z.1M3M8
G1Z-.65F.006
G0Z.1
G28U0M5
M30
TOTAL PER TOOL
DRILL = 4.5 SEC. CHAMFER = 5 SEC. BROACH = 8.5 SEC.
TOTAL CYCLE TIME = 18 SEC.
NOTES AND TIPS FOR ROTARY BROACHING:
Special attention should be made to how well the tool is aligned in accordance with
the Rotary try out supplier. Miss-aligned tools will result in poor tool life and
surface end.
This application is not suited for parts where other features such as milled flats,
slots or drilled hole patterns are related to the fixed position of the polygon
bent by the Rotary try out.
Coolants or oils are required to clear chips and reduce friction for better tool life
and surface end.
SINGLE SLOT BROACHING
When single or multiple try out slots are required they can be done on the
CNC lathe using a single broaching tool either carbide or HSS. This type of
broaching requires the CNC to have C axis for spindle positioning and a spindle
brake to hold the spindle steady and firm while broaching. Multiple passes are
required and can be programmed simplest by using sub programming and/or macro
programming. Next we will examine both styles of programming to help determine
what best suits the programmer and the part.
Note that most broached slots should have a groove try out relief or go all the
way through the part. It is not recommended to use this broaching technique into a
blind hole or one without a groove relief. Another vital item is to retract the
broaching tool completely from the broached slot before feeding or rapid traversing
back to the Z start position.
EXAMPLE: .250 broached slot through .500 deep from face.
Programmed for a Eurotech 735SLY.
Sub Program.
O1444(SUB FOR .25 WIDE BROACHED SLOT)
G0X[#103](#103= .002 RADIAL DEPTH OF A PASS)
G4P100(SMALL DWELL)
G1G98Z-.5F200.(FEED BACK .5 AT 200 INCH/MIN.)
G0X.6(CLEAR THE HOLE DIAMETER)
Z.2(RETURN TO STARTING Z)
#103=[#103+#102](UPDATE #103 TO EQUAL NEXT X VALUE FOR A PASS)
M99(REWIND)
Main Program
O1234(MAIN)
XXXX
XXXX
XXXX
(SET COMMON VARIABLES FOR BROACHING)
#101=.624(BORE DIA. LESS .001 TO MAKE EVEN # OF PASSES)
#102=.004(X DEPTH OF A SINGLE PASS)
#103=#101+#102(BORE .624 + .004 = X VALUE FOR A PASS)
N5G54T0505M64M5(.250 wide try out)
M10(C AXIS ON)
G0X.624Z.2C0.M8
M70(SPINDLE BRAKE ON)
M98P331444(CALLS SUB PROGRAM 1444 TO REPEAT 33 TIMES)
M71(BRAKE OFF)
M11(C AXIS OFF)
G0X4.Z2.
M1
XXXXXXX
XXXXXXX
XXXXXXX
M30
NOTES AND TIPS FOR SINGLE BROACHING:
The 1st. pass is X.628 (.624+.004)
The 2nd pass is X.632 (.628+.004)
Etc.
Etc.
The 33rd pass is X.756 (.752+.004)
X.624 Start from X.756 End = .132
.132/.004=33 passes
Often a G4 (Stay) or a greater Z start value is used before the beginning of each
pass to minimize any taper caused by Servo Lag.
Macro Variables #100 – #199 are not held in Macro Offsets when the machine is
powered off. If you want the macro values retained in the offsets when the machine
is powered off, use #500-#999
Estimated Time to complete this single try out = 12 sec.
If you need to make more of the same try out at different angular positions, your
main program would look like this……
O1234(MAIN)
XXXX
XXXX
XXXX
(SET COMMON VARIABLES FOR BROACHING)
#101=.624(BORE DIA. LESS .001 TO MAKE EVEN # OF PASSES)
#102=.004(X DEPTH OF A SINGLE PASS)
#103=#101+#102(BORE .624 + .004 = X VALUE FOR A PASS)
N5G54T0505M64M5(.250 wide try out)
M10(C AXIS ON)
G0X.624Z.2C0.M8(INDEX TO 0 DEGREES)
M70(SPINDLE BRAKE ON)
M98P331444(CALLS SUB PROGRAM 1444 TO REPEAT 33 TIMES)
M71(BRAKE OFF)
G0C90.(INDEX T0 90 DEGREES)
M70(BRAKE ON)
M98P331444(CALLS SUB PROGRAM 1444 TO REPEAT 33 TIMES)
M71(BRAKE OFF)
G0C180.(INDEX TO 180 DEGREES)
M70(SPINDLE BRAKE ON)
M98P331444(CALLS SUB PROGRAM 1444 TO REPEAT 33 TIMES)
M71(BRAKE OFF)
G0C270.(INDEX T0 270 DEGREES)
M70(BRAKE ON)
M98P331444(CALLS SUB PROGRAM 1444 TO REPEAT 33 TIMES)
M71(BRAKE OFF)
M11(C AXIS OFF)
G0X4.Z2.
M1
XXXX
XXXX
XXXX
M30
BROACHING MACRO
Another alternative is to make a Macro program for your broaching requirements.
The advantage to making a complete Macro program is you can use the one basic format
for most of your broaching needs. Below