Perfecting Pulleys Redux
The self proclaimed "pulley nirvana" from a previous post didn't last long. It seems that changing extruder, filament, or perhaps the weather, had caused a regression in the pulley prints I need for my upcoming Huxley/MiniMendel, even though the same gcode was used  with the cool setting and a slower feed/flow rate. The print goes fine until a third through the spurs of the gear, and then the flow splutters and starts, causing a very deformed (and unusable) gear.
At first I thought the cause might lie in too high a temperature, and so I reduced the hot end temperature to 180°C (from 195°C), and also placed a desktop fan adjacent to the bed, on the lowest setting. The results were still poor.
It seems that the Dimension module in Skeinforge was retracting the filament too much (because the speed was so much lower, it had more time to retract) and consequently the beginning of each layer on the spurs was receiving less and less material. Hence the deformity. Changing this value from 1.3 to 0.2 brought about much better results.
Not perfect, but usable, and a step in the right direction.
Below are the Skeinforge settings used in case they are useful.
Skeinforge Settings
Important  

Layer Thickness (mm):  0.4 
Perimeter Width over Thickness (ratio):  1.4 
Infill Solidity (ratio):  0.3 
Feed Rate (mm/s):  25.0 
Flow Rate Setting (float):  25.0 
dimension  
Absolute Extrusion Distance  True 
Relative Extrusion Distance  False 
Extruder Retraction Speed (mm/s):  20.0 
Filament Diameter (mm):  2.85 
Filament Packing Density (ratio):  1.0 
Retraction Distance (millimeters):  0.2 
Restart Extra Distance (millimeters):  0.0 
carve  

Add Layer Template to SVG  True 
Extra Decimal Places (float):  2.0 
Import Coarseness (ratio):  1.0 
Infill in Direction of Bridge  True 
Layer Thickness (mm):  0.4 
Layers From (index):  0 
Layers To (index):  912345678 
Correct Mesh  True 
Unproven Mesh  False 
Perimeter Width over Thickness (ratio):  1.4 
SVG Viewer:  webbrowser 
chop  
Add Extra Top Layer if Necessary  True 
Add Layer Template to SVG  True 
Extra Decimal Places (float):  2.0 
Import Coarseness (ratio):  1.0 
Layer Thickness (mm):  10.0 
Layers From (index):  0 
Layers To (index):  999999999 
Correct Mesh  True 
Unproven Mesh  False 
Perimeter Width (mm):  2.0 
SVG Viewer:  webbrowser 
comb  
Activate Comb  True 
cool  
Activate Cool  True 
Bridge Cool (Celcius):  1.0 
Orbit  False 
Slow Down  True 
Maximum Cool (Celcius):  2.0 
Minimum Layer Time (seconds):  10.0 
Minimum Orbital Radius (millimeters):  10.0 
Name of Cool End File:  cool_end.gcode 
Name of Cool Start File:  cool_start.gcode 
Turn Fan On at Beginning  True 
Turn Fan Off at Ending  True 
dimension  
Activate Dimension  True 
Absolute Extrusion Distance  True 
Relative Extrusion Distance  False 
Extruder Retraction Speed (mm/s):  20.0 
Filament Diameter (mm):  2.85 
Filament Packing Density (ratio):  1.0 
Retraction Distance (millimeters):  0.2 
Restart Extra Distance (millimeters):  0.0 
fill  
Activate Fill:  True 
Diaphragm Period (layers):  100 
Diaphragm Thickness (layers):  0 
Extra Shells on Alternating Solid Layer (layers):  0 
Extra Shells on Base (layers):  0 
Extra Shells on Sparse Layer (layers):  0 
Grid Circle Separation over Perimeter Width (ratio):  0.2 
Grid Extra Overlap (ratio):  0.1 
Grid Junction Separation Band Height (layers):  10 
Grid Junction Separation over Octogon Radius At End (ratio):  0.0 
Grid Junction Separation over Octogon Radius At Middle (ratio):  0.0 
Infill Begin Rotation (degrees):  45.0 
Infill Begin Rotation Repeat (layers):  1 
Infill Odd Layer Extra Rotation (degrees):  90.0 
Grid Circular  False 
Grid Hexagonal  False 
Grid Rectangular  False 
Line  True 
Infill Perimeter Overlap (ratio):  0.15 
Infill Solidity (ratio):  0.3 
Infill Width over Thickness (ratio):  1.3 
Solid Surface Thickness (layers):  1 
Lower Left  True 
Nearest  False 
Infill > Loops > Perimeter  False 
Infill > Perimeter > Loops  False 
Loops > Infill > Perimeter  False 
Loops > Perimeter > Infill  True 
Perimeter > Infill > Loops  False 
Perimeter > Loops > Infill  False 
home  
Activate Home  True 
Name of Homing File:  homing.gcode 
inset  
Add Custom Code for Temperature Reading  True 
Bridge Width Multiplier (ratio):  1.0 
Ascending Area  True 
Descending Area  False 
Overlap Removal Width over Perimeter Width (ratio):  0.6 
Turn Extruder Heater Off at Shut Down  True 
limit  
Activate Limit  True 
Maximum Initial Feed Rate (mm/s):  80.0 
Maximum Z Feed Rate (mm/s):  1.0 
multiply  
Activate Multiply:  True 
Center X (mm):  50.0 
Center Y (mm):  50.0 
Number of Columns (integer):  1 
Number of Rows (integer):  1 
Separation over Perimeter Width (ratio):  15.0 
preface  
Name of End File:  end.gcode 
Name of Start File:  startMendel05l04PLA.gcode 
Set Positioning to Absolute  True 
Set Units to Millimeters  True 
Start at Home  False 
Turn Extruder Off at Shut Down  False 
Turn Extruder Off at Start Up  False 
raft  
Activate Raft  True 
Add Raft, Elevate Nozzle, Orbit:  True 
Base Feed Rate Multiplier (ratio):  1.0 
Base Flow Rate Multiplier (ratio):  1.0 
Base Infill Density (ratio):  0.5 
Base Layer Thickness over Layer Thickness:  2.0 
Base Layers (integer):  0 
Base Nozzle Lift over Base Layer Thickness (ratio):  0.2 
Initial Circling:  False 
Infill Overhang over Extrusion Width (ratio):  0.05 
Interface Feed Rate Multiplier (ratio):  1.0 
Interface Flow Rate Multiplier (ratio):  1.0 
Interface Infill Density (ratio):  0.5 
Interface Layer Thickness over Layer Thickness:  1.0 
Interface Layers (integer):  0 
Interface Nozzle Lift over Interface Layer Thickness (ratio):  0.45 
Name of Support End File:  support_end.gcode 
Name of Support Start File:  support_start.gcode 
Object First Layer Feed Rate Infill Multiplier (ratio):  0.4 
Object First Layer Feed Rate Perimeter Multiplier (ratio):  0.4 
Object First Layer Flow Rate Infill Multiplier (ratio):  0.4 
Object First Layer Flow Rate Perimeter Multiplier (ratio):  0.4 
Operating Nozzle Lift over Layer Thickness (ratio):  0.5 
Raft Additional Margin over Length (%):  1.0 
Raft Margin (mm):  3.0 
Support Cross Hatch  False 
Support Flow Rate over Operating Flow Rate (ratio):  1.0 
Support Gap over Perimeter Extrusion Width (ratio):  1.0 
None  True 
Empty Layers Only  False 
Everywhere  False 
Exterior Only  False 
Support Minimum Angle (degrees):  60.0 
speed  
Activate Speed:  True 
Add Flow Rate:  True 
Bridge Feed Rate Multiplier (ratio):  1.0 
Bridge Flow Rate Multiplier (ratio):  1.0 
Duty Cyle at Beginning (portion):  1.0 
Duty Cyle at Ending (portion):  0.0 
Feed Rate (mm/s):  25.0 
Flow Rate Setting (float):  25.0 
Orbital Feed Rate over Operating Feed Rate (ratio):  0.5 
Perimeter Feed Rate over Operating Feed Rate (ratio):  0.7 
Perimeter Flow Rate over Operating Flow Rate (ratio):  0.7 
Travel Feed Rate (mm/s):  30.0 
stretch  
Activate Stretch  True 
Cross Limit Distance Over Perimeter Width (ratio):  5.0 
Loop Stretch Over Perimeter Width (ratio):  0.11 
Path Stretch Over Perimeter Width (ratio):  0.0 
Perimeter Inside Stretch Over Perimeter Width (ratio):  0.64 
Perimeter Outside Stretch Over Perimeter Width (ratio):  0.1 
Stretch From Distance Over Perimeter Width (ratio):  2.0 
Comments

John Oddy
23082011 17:59
On my newly built Prusa I had tried all sorts of skeinforge settings without much success, but these gave me some great prints. Thanks Gary.

Gary Hodgson
23082011 18:36
That's great to hear! Glad they proved useful.