Install the burnishing tool in an open turret position. Use the uppermost set of mounting holes on the turret arms. The M3-4Dx8L shoulder screw should be used in the left mounting hole and the M3x14 low socket head screw should be used on the right side. Snug these screws to hold the toolhead in place temporarily. These will be torqued after tramming adjustment.
Plug the Heater and temperature sensors into the appropriate locations of the connector board on the back side of the turret.
Next, check the alignment of the burnishing tool with the Z-axis. To do this use a machinist's square or accurate fixture block against the surface of the bed. (Note: the bed must be level in order to get accurate results from this step. To level the bed, follow the instructions here: XXXXX). The burnishing tool has 2 planes of adjustment, exactly like the H-Series spindles. To make adjustments in the XZ plane, loosen slightly the two clamping screws shown in the image below, and turn the adjustment screw to tilt the unit. Check the gap between your vertical reference surface and the shank of the burnishing tool. It is helpful to hold a piece of paper behind the assembly to be able to see the gap clearly.
To align the burnishing tool in the YZ plane, loosen slightly the 2 screws that you used to mount the unit (the M3 shoulder screw and M3 Low SHCS) as shown in the image below. Then retract the thumb screw to tilt the unit in the YZ plane. (The head of the thumb screw will push on the flat surface of the turret arm to rotate the unit slightly counterclockwise.)
After acceptable alignment is obtained, torque the mounting screws to 6 in-lbs. Note, the alignment accuracy of the burnishing tool is slightly less critical than alignment of the spindles. The main goal here is to ensure some relief on all sides between the outer surface of the ball and the shank of the tool. This enables the tip of the tool to be used to clean up vertical sidewalls of a print without the shank making contact.
In the H-Series controller, the burnishing tool is configured as an extruder. So, if you are changing out a spindle for a burnishing tool, see the bottom paragraph of the "configure FDM tool" section here: https://support.diabasemachines.com/hc/en-us/articles/360005883933-Install-FDM-tool
Next, you'll need to tune the heater circuit. In order to do this, first go to your Settings>Tools tab in the controller. Here, take note of the heater number for the tool number you are using. For example, in the image below you can see that "Tool 1" is associated with "Heater 3."
Next, run the tuning cycle on your heater by typing the following code into your Gcode console (replacing the # sign with your heater number):
M303 H# P0.8 S220 ;
This code tells the machine to tune heater # using 80% PWM and a target temperature of 220C. Note: before tuning any heater, the system needs to be idle and the temperature of the particular circuit needs to be stable. If you disconnect a temperature sensor, that circuit will show a fault as below:
To clear this fault, type into your Gcode console:
Then run the tuning cycle. The machine will heat up the burnishing tool to 220 degrees, hold it at that temperature for a short period, then cool it down. The process takes 5~10 minutes.
The final setup step before the burnishing tool is ready to use is to establish the tool offsets. Measure the Z-offset first by either using the touchplate (here) or using the cigarette paper method (here). After this, to set the tool offsets for X and Y, you'll need to use the cigarette paper method on the sides of a reference block. First, attach a rectangular piece of stock to the bed. You can do this by printing the part or by screwing an artifact down to the bed as shown below.
Activate work coordinate system G59.3 and use the probing functions (below) to establish the corner of the artifact as X=0 and Y=0.
Note, by clicking the import button next to the particular work offset, you can import the current position as the work offset. So after you probe the side of the artifact, you can click the appropriate button to set that position as the new zero. Then you will need to adjust this value by the radius of the probe (1mm) in order to establish the edge of the part as zero.
After you have established the 2 surfaces of the part as X=0 and Y=0, call up the burnishing tool and jog the tool close to the edge of the part. Slide a piece of cigarette paper between the part and tool and slowly jog the tool toward the part while moving the cigarette paper until you can feel the tool in contact with the paper (preventing it from sliding). At this point, you know that the centerline of the tool is offset from the part by the radius of the tool. The standard burnishing tool is 0.250" in diameter, so the radius is 3.175mm. Adjust the tool offset until the current position reads the correct value. Repeat this process for the other direction. Note, you can change the increment of the jog buttons by right clicking on them. An increment of 0.01mm is recommended for establishing tool offsets.
The burnishing tool is now ready to go. In order to program toolpaths, treat the tool as a lollipop endmill with a 6.35mm cutting diameter, a 5mm shank and a shoulder length of 38mm. Post process the file using the Diabase post (here). Always preheat the tool using the web control before running a CAM cycle. A burnishing temperature approximately 5 to 10 degrees below your standard printing temperature is a good starting point. Note: if you experience heater faults, you may need to adjust the %pwm of your tuning cycle or your heater fault sensitivity (here).