Need some help, intermittent grinding?

[perlguy 0]

I'm having some problems with my prints and I've run out of ideas...

Often, the print will start just fine, then a little while into the print, the problems start.

So far, I have:

 

• Removed and completely cleaned out my nozzle (with a blowtorch).
  
• Replaced my bowden tube.
  
• Adjusted the spring tension on the feeder (tighter and looser).
  
• Blown out the knurled bolt with compressed air.
  
• Tried different filament. (Colors and manufacturers).
  
• Printed slower - as slow as 25mm/s.
  
• Tried higher temperatures. (up to 225C with PLA)
  

I've included a few photos so you can see what I am experiencing.

It looks like it will print a few good layers, then have problems feeding, then print a few more good layers, etc.

I don't know what else to try! Suggestions?

Thanks!

There should be 4 images in the gallery below.

 

 

[illuminarti 18]

What layer height and wall thickness are you printing at?

What Slicer?

Are those printed with Spiralize turned on in Cura?

Have you checked that the tension wheel in the extruder body isn't deformed, and turns freely?

Try printing without the fan, and see if that makes a difference (but set minimum layer time in your slicer to 7.5s first).

 

[perlguy 0]

Layer height was .2mm

Using the default Cura slicer.

Spiralize is NOT enabled

Tension wheel is not deformed, I actually switched to the new one I got with my dual extrusion kit, same results.

I'll try without fan and minimum layer time to 7.5s and see what I get.

I'll update when finished.

Thanks!

 

[perlguy 0]

Ok, just added more photos to my album.

The bottom few layers look almost good, then it just becomes crap.

These are with the fan off and cooling set to 7.5.

Here are the complete settings that I am using:

 

[profile]layer_height = 0.2
wall_thickness = 0.8
retraction_enable = True
solid_layer_thickness = 0.8
fill_density = 25
nozzle_size = 0.4
print_speed = 50
print_temperature = 210
print_temperature2 = 0
print_temperature3 = 0
print_temperature4 = 0
print_bed_temperature = 0
support = None
platform_adhesion = Brim
support_dual_extrusion = Both
wipe_tower = False
wipe_tower_volume = 15
ooze_shield = False
filament_diameter = 2.89
filament_diameter2 = 2.89
filament_diameter3 = 0
filament_diameter4 = 0
filament_flow = 100
retraction_speed = 25
retraction_amount = 4.5
retraction_dual_amount = 16.5
retraction_min_travel = 1.5
retraction_combing = True
retraction_minimal_extrusion = 0.5
bottom_thickness = 0
object_sink = 0
overlap_dual = 0.4
travel_speed = 150
bottom_layer_speed = 20
infill_speed = 0.0
cool_min_layer_time = 7.5
fan_enabled = False
skirt_line_count = 1
skirt_gap = 3.0
skirt_minimal_length = 150.0
fan_full_height = 0.5
fan_speed = 100
fan_speed_max = 100
cool_min_feedrate = 10
cool_head_lift = False
solid_top = True
solid_bottom = True
fill_overlap = 50
support_fill_rate = 25
support_xy_distance = 0.35
support_z_distance = 0.07
spiralize = False
brim_line_count = 15
raft_margin = 10
raft_line_spacing = 2
raft_base_thickness = 0.3
raft_base_linewidth = 1.5
raft_interface_thickness = 0.3
raft_interface_linewidth = 0.3
fix_horrible_union_all_type_a = False
fix_horrible_union_all_type_b = False
fix_horrible_use_open_bits = False
fix_horrible_extensive_stitching = False
plugin_config = (lp1
.
object_center_x = -1
object_center_y = -1
[alterations]
start.gcode = ;Sliced at: {day} {date} {time}
;Basic settings: Layer height: {layer_height} Walls: {wall_thickness} Fill: {fill_density}
;Print time: {print_time}
;Filament used: {filament_amount}m {filament_weight}g
;Filament cost: {filament_cost}
G21        ;metric values
G90        ;absolute positioning
M107       ;start with the fan off
G28 X0 Y0  ;move X/Y to min endstops
G28 Z0     ;move Z to min endstops
G1 Z15.0 F{travel_speed} ;move the platform down 15mm
G92 E0                  ;zero the extruded length
G1 F200 E3              ;extrude 3mm of feed stock
G92 E0                  ;zero the extruded length again
G1 F{travel_speed}
M117 Printing...
end.gcode = ;End GCode
M104 S0                     ;extruder heater off
M140 S0                     ;heated bed heater off (if you have it)
G91                                    ;relative positioning
G1 E-1 F300                            ;retract the filament a bit before lifting the nozzle, to release some of the pressure
G1 Z+0.5 E-5 X-20 Y-20 F{travel_speed} ;move Z up a bit and retract filament even more
G28 X0 Y0                              ;move X/Y to min endstops, so the head is out of the way
M84                         ;steppers off
G90                         ;absolute positioning
start2.gcode = ;Sliced at: {day} {date} {time}
;Basic settings: Layer height: {layer_height} Walls: {wall_thickness} Fill: {fill_density}
;Print time: {print_time}
;Filament used: {filament_amount}m {filament_weight}g
;Filament cost: {filament_cost}
G21        ;metric values
G90        ;absolute positioning
M107       ;start with the fan off
G28 X0 Y0  ;move X/Y to min endstops
G28 Z0     ;move Z to min endstops
G1 Z15.0 F{travel_speed} ;move the platform down 15mm
T1
G92 E0                  ;zero the extruded length
G1 F200 E10             ;extrude 10mm of feed stock
G92 E0                  ;zero the extruded length again
G1 F200 E-{retraction_dual_amount}
T0
G92 E0                  ;zero the extruded length
G1 F200 E10              ;extrude 10mm of feed stock
G92 E0                  ;zero the extruded length again
G1 F{travel_speed}
M117 Printing...
end2.gcode = ;End GCode
M104 T0 S0                     ;extruder heater off
M104 T1 S0                     ;extruder heater off
M140 S0                     ;heated bed heater off (if you have it)
G91                                    ;relative positioning
G1 E-1 F300                            ;retract the filament a bit before lifting the nozzle, to release some of the pressure
G1 Z+0.5 E-5 X-20 Y-20 F{travel_speed} ;move Z up a bit and retract filament even more
G28 X0 Y0                              ;move X/Y to min endstops, so the head is out of the way
M84                         ;steppers off
G90                         ;absolute positioning
support_start.gcode = 
support_end.gcode = 
cool_start.gcode = 
cool_end.gcode = 
replace.csv = 
switchextruder.gcode = ;Switch between the current extruder and the next extruder, when printing with multiple extruders.
G92 E0
G1 E-36 F5000
G92 E0
T{extruder}
G1 X{new_x} Y{new_y} Z{new_z} F{travel_speed}
G1 E36 F5000
G92 E0

[illuminarti 18]

Those test pieces look nasty. But they're also tiny, so with the minimum layer time set, I imagine they're printing very slowly, so the head is probably staying over the piece and keeping the plastic molten.

Do they print better if you print two or more at once? (set gantry height to zero to force simultaneous rather than sequential printing in Cura).

 

[gr5 2,167]

A couple of things to check (grasping here on 1-3):

1) Maybe your temp is lower than you think - do the calibration where you set the temp to 105C and touch a drop of water to it and make sure it boils.

2) Could the fan be blowing onto the tip of your nozzle? That can cause problems. If it might be close try turning off the fan just for a test (although parts come out much better with fan - especailly small parts like this)

3) Does the delrin (delrin is that black plastic) wheel pushing against the filament turn okay? Could it be stuck?

4) Consider spending (really very little) money to buy a new nozzle. It may just be full of some kind of gunk stuck to the sides (think paint on the inner walls). I suspect Illuminarti will sell you one (or maybe two different sizes to boot!?) if you click on his name and send him a personal message. The nozzle is pretty easy to change - just unscrew it when temp is 180C. Although it sounds like you took it off already.

 

[perlguy 0]

I have a total jam in that print head now. I am going to tear it all apart again and make sure it is completely cleaned out.

Thanks for the help. I'll post more if I am still having problems.