MDF Rose Engine Lathe 2.0

Control System for Multiple Stepper Motors

Continuous Flutes using a Profiled Cutter

The idea behind this approach is you are cutting one flute down the entire length of the Z axis. A shaped cutter which is moved along the Z axis to cut one flute, the spindle is indexed, and the whole process is repeated until all the flutes are cut.

Rosette	No rosette is used for this approach. The shape comes from the cutter's profile. The headstock is held fixed (the centering block is inserted in the back, and the fading wedge dropped down).
Spindle	The spindle is not rotated whilst the cutter is moving in the Z direction. The spindle is indexed after each flute has been cut to the desired depth. (This may be multiple passes.)
Cutting Frame	The cutting frame selected and the angle of cutting can have great effects on the results achieved. Typically, a horizontal cutting frame is used. The cutting frame is moved slowly down the Z axis. Movement of the cutter along the Z axis can be achieved at least two ways. The most efficient way is to use a slide rest which has automated movement using a lead screw (e.g., a curvilinear slide). This also has the most likelihood of achieving a smooth, even finish. If you don't have a slide rest which can automate the movement using a lead screw, then you will have to move it manually a small increment after each revolution. Something like 0.005" at a time is not uncommon. Note: a Drill Spindle could be used with this, but the cuts would probably not be as nicely made.
Cutter	Use a cutter with a profiled shape which will yield the desired cut. Hold it in a cutting frame, and move it down the whole length.
Rubber	The shape of the rubber has no effect as no rosette is used for this.

Screen

Actions

Ind

On the Indexing page,

The radio button selections are set as:

Div			Deg
Fixed			File

Set the variables on the screen as:

Divisions = number of desired flutes around the piece.

Main

On the Main page,

The radio button selections are set as:

Engage the cutter to the desired depth.

Touch either

		to cut towards the headstock
		to cut away from the headstock

If additional depth is needed for the flute, use the opposite movement as in previous step.

At this point, you can:

recut the same flute in the opposite direction, or

cut the next flute in the opposite direction.

Ind

On the Indexing page,

To index to the next flute, touch either

		to rotate the spindle counter-clockwise (recommended) or
		to rotate the spindle clockwise

Repeat steps 4 thru 8 for each flute.

Cutting Downhill

Cutting to the Left

Cutting to the Right

When cutting with a spinning cutter, just as on a router, it is a good practice to always cut downhill. This is not always possible, but it typically leaves the smoothest surface.

The choices for the direction to move the cutter (the red arrow) and the cutter's rotation (blue arrow) should be made to ensure downhill cutting happens.

This is an advantage for using a fly cutter over a carbide bit. With a fly cutter, the direction of the cut can be reversed. (For more information about fly cutters vs. carbide bits, see also Cutters on the Cutting Frames page at the Ornamental Turning Book of Knowledge.)

Click on any of the pictures on this page to see bigger images.