Wanhao 4s printing incorect

HI people. I am pretty new in printing and learned a lot about it and purchased wanhao duplicator 4s
Ok, first after leveling the bed, i started printing and first print was good. Then i started new print of some taller objects. One thing, dimensions of objects are around 20 mm diameter.I am using abs on 230 celsius and heated plate 100. Speed of extrusion is 60 mms and travel 90 mms. Then i measured object and it is failimg 0.6 mm . So it is missimg 0.6 mm.
Whatt shoud i do next. Thanks

It is normal for cylindrical shapes comes short of actual measurements, but not by that much usually it's 0.2. You need to check that the extruded plastic is of the right width. Also, you are trying to print faster that what your printer can trully handle with small prints.

If you haven't, download saifish and update your firmware and adjust setting to get better prints.

Edited 1 time(s). Last edit at 06/03/2015 01:10PM by ggherbaz.

Ok that is good to know about speed. Tried it and really is better
But still scale is way off desired one
Im trying to connect it to replicator g to calibrate scale but still did not connect. Im having a problem with com port. As i want to connect it it says an error message lik: com port already in use. Try to quit any programe that use it ????
How. I tried to ggogle it but nothing that helped me. I tried to change com ports, reinstalling drivers, power off, reboot and still on the same path.

You need to: stop background services from makerware, makerbot desktop so replicator can connect to the printer.

perfect. Solved that too.
Makerbot desktop have had taken background service and locked my printer for itself.
Now i tried a lot of adjustments and so far im getting pretty good prints, Walls are pretty smooth since i reduced speed as you said.
Now i was trying to print hexagonal nut. And thing is that right side of printing goes a bit curvy. and finish layers are not so good.
So far I red about calibrating scale. And dont know if i can enter printers settings such as checking axis values. It says i should measure every axis with digital calliper. I tried and got something. When i positioned caliper to x axis and moved it from replicator g control by 10 mm, on every step of 10 mm i got a bit different value. like 9,36, then second step 9,41 then 9,36 again then 9.38.
Now by reading topic about scale calibration i shoul enter printer axis settings and enter new values that were calculated by one formula.
First question is how to get to those settings. what programe should i use?
Thanks for all the answers by the way

Trying to get a good reading from a caliper in the printer is kind of complicated and not reliable, you need to print 2 hollow cubes, one as big as you can (that can fit in your caliper) like 120×120×4 and a small one 20×20×6 with a wall thickness of 5 or 6 mm. Set your slicer for 0.1 or 0.2 layer height, extrusion multiplier to 1, extrusion width to 0 or automatic and really slow printing speed 20 to 30mm max. You can print them together, but it is best if you do it separately. Once printer measure both and find the differences. The big print will give you the error in the steps per mm and the small one will give you extrusion errors.

To get the new value you just do a rule of 3: current steps × real size / actual size. So if your current steps are 97 and instead of 120mm you got 119.89 you just multiple 97 × 120 ÷ 119.89 = 97.08899825 you can reduce it to 97.089.

You can obtain and change all the info you need through the LCD screen or using the appropriate m code with replicator G.

[replicat.org]

perfect. I started printing cubes.
Since im pretty new with that could i please ask you if you could explain procedure of inputing info into printer. New scaling results
I acctually dont know where and what m code should i change in replicator g, And i tried to find it on lcd from printer i didnt know where to find it. Sorry for bugging you. Thank you

No problem, once you get the parts printed and measured let me know so I can guide you with changing the values.

Here are the pics. ok this is print of 20x20x6 cube
100x100x4 i could not print because i think extruder did not extrude enough filament on the start first and second loop of layers and rst did not attach on the surface of heating bed.
So results of smaller one are x/y/z 19,69/19,52/6,42

specs are; abs 1,75
230 extruder
110 heated bed
0.1 layer hight
20mm/s feedrate
20 travel feed rate
6 shells


One thing i realised. when i connected replicatorg to my wanhao duplicator 4s in skeinforge under dimensions i found that fillament diameter is 3,0 and i have 1.75 mm
and filament package density is 0.85.
Please help

Edited 1 time(s). Last edit at 06/05/2015 04:51PM by 3Davor.

My daughter have a tournament today, I'll be back at home tonight around 10p.m., since you printer is supported by my slicer (Simplify3d) I will create the g codes for your test cubes. The one you printed is too deformed to really use it for calibration.

[drive.google.com]

I had few minutes and generated the files.

Let me know how they come out.

Yes i know. It was very bad print.
Thank you thousand times for helping. I printed 100 x 100x 4 and print is smaller a bit. Here are the pics with caliper measures and how print went out.

and Second one is printed. so results are : x: 20.07 y: 19, 65 z:6,60

I realised something too. On every print i get first few layers wider then other layers for 0.15/0.20 mm.
and i have something like small balls of extruded plastic. it is when doing first few layers it looks like extruder extrudes like few small balls. and the last layer is full of texture that is full of dots.
ill put pics of it

Any ideas? :-( still stuck. Prints became better. Working fine, only thing is offscale.

Sorry, I've been busy the last few days. I'll get the info on how to change the values this afternoon.

Ok, here we go:

open: replicatorg-0040r30-Sailfish-windows\replicatorg-0040r30-Sailfish\machines in your computer (if you have a different version of replicatorg, just look for the "machines" folder in the replicator main folder. open with notepad or better Wordpad the following file: replicator-sailfish.XML in it you will find the current steps per mm for your X,Y,Z and A,B it will look like this:

Quote

<?xml version="1.1" encoding="utf-8"?>
The Replicator Dual (Sailfish)
<!-- different pulleys on X and Y axii -->
<!-- Pulley dia: 10.82mm / 1/8 step = 1/(10.82 * pi / 1600) -->
<!-- Pulley dia: 10.82mm / 1/8 step = 1/(10.82 * pi / 1600) -->
<!-- Actual length is 157mm, we reserve ~5mm for safety. TR-8x8 Z axis = 1/(8/1600) -->
<!-- stepspermm is incoming filament length, see comment at bottom for explanation -->
<!-- stepspermm is incoming filament length, see comment at bottom for explanation -->

at the bottom of the file you can find the formula to calculate the steps, just modify it to new values save and reflash the firmware.

Also on MakerWare, open: C:\Program Files\MakerBot\MakerWare\s3g\profiles and using WordPad open: ReplicatorDual.Json and change the values too. Just save it, don't flash it. This is to prevent from MakerWare to change again the values.

Let me know if you need more help.

Edited 1 time(s). Last edit at 06/10/2015 07:19PM by ggherbaz.

Now, before you start changing values, you need to first adjust your over extrusion issue. Print several cubes with different extrusion multiplier values, different feedrates until your parts look perfect without strings, blobs or any imperfection. Once you achieve this, then you can get a real calibration print that will let you fix your scaling problem. You also have the option of scaling the XYZ factors in the slicer without changing the firmware values.

But lets say that I just want to change the firmware values and I printed those parts with my printer.

My current values are:

X:94.139704
Y:94.139704
Z:400

the 20x20x6 came out x: 20.07 y: 19, 65 z:6,60. We know that we need to keep both axis with same steps value, we also know that the big print came as: 99.33, 99.22 and 4.34. lets figure out what to do:

X: big print short, small print exceed. if we change the steps to fix the big print, we will have to adjust extrusion width or multiplier to get there or small prints will come out even bigger.
Y: both prints came short, but if we use same values for Y and X, x will have oversize problems.
Z: this is the easiest to work with since it doesn't affect the other axis. but since we know we have some over extrusion, we don't know exact value, so you will have to experiment some....

lets try this: Y 94.139704 x 20 / 19.65 = 95.81649262086514
Y 94.139704 x 100 / 99.22 = 94.87976617617416

You can do two things, either use the smaller of the numbers (closest to original value) 94.87976617617416 or get the average 95.34812939851965.

Z 400 x 6 / 6.6 = 363.6363636363636
Z 400 x 4 / 4.34 = 368.6635944700461

Same here, use either 368.6635944700461 or the average 366.1499790532048

I will use this values: (some values might not fall to an exact micro step so the stepper will reach the one before or after the value)

X: 94.87976617617416
Y: 94.87976617617416
Z: 368.6635944700461

I use Simplify3d and as you can see in the attached picture, I can easily adjust it there. it is $150, but if you can afford it, get it.

Ok that is perfect explaining. In few days ill use S3D so i will input all that calculations with S3D without flasing. To be honest i would like to skip flasing since i dont have lot of expiriance doing that, so I dont want screw something.up
I dont know how to thank you for reply and answer.
I will write here results soon as S3D is in my hands

Ok.
So by this time while waiting for simplify to be ordered i made a full mech check of my wanhao. I found something interesting which made my prints not dimensionally correct. Y axis has two belts. one on each side. One belt had two teeth less than other. So i put whole printer apart and rebuildt it again. After i reasambled it i got same values on x and y axis. Perfect. Circle became circle
Simplify came. After 10 min of configuring and setting up everything first cube came out perfect if we talk about extrusion and printer works great. After few printed test cubes i have my desired value.
Wanted dimension is 20 20 10, output dimension was 20.01 20.03 and 9.98
Simplify rocks. and that is a fact.