CNC-FabAcademy-2018-2019

by Eduardo Chamorro

Transcript

1. CNC WORKSHOP by EDUARDO CHAMORRO MARTIN FABINSTRUCTOR@TIDEINSTITUTE.ORG
2. intro • Eduardo Chamorro • 1988 Spain • Master Architect • Mit FabLab Instructor Who? Loves Architecture Making/DIY New Trends and Tendencies Sport and relaxing Loves meeting new people Learning Openminded How? ASK EVERYTHING ! ! ! ! ALWAYS PLEASED TO ANSWER JUST STOP ME ! SERIUSLY ASK ! ! ! LETS MAKE IT FUN ! ! ! ! woooo hoooo ! ! ! LETS KNOW EACH OTHER (INTRODUCE YOURSELF) IF you don´t understand my awfull ENGLISH I can repeat or say it in FRENCH or SPANISH Learning has to be funny not boring, nobody evaluates nothing ! ! !
3. schedule INTRO DESING TOOLS FILES DESIGN WHAT IS A CNC AUTOCAD FIRST STEPS HOW TO SAVE TIME ! TYPES AND HOW IT WORKS LETS ENJOY DESIGN SOME THINGS DESIGNS/WHAT WE CAN DO IF WE GO FAST WE CAN ALSO USE THE SMALL ONES ! ! ! 1-2 day 3-4 day SAFETY (HOW TO TAKE CARE OF YOU AND THE MACHINES) FINISH THE DESIGNS HOW SHOPBOT WORKS ! LET´S SET THE MACHINE AND LEARNING HOW TO OPERATE HAVE FUN CUTTING ! ! ! ! ENJOY YOUR DESING 7-10PM 7-10PM
4. CNC “The Big Brother”
5. CAD-CAM CNC MEANS COMPUTER NUMERICAL CONTROL. THIS MEANS A COMPUTER CONVERTS TEHE DESIGN PRODUCED BY COMPUTER AIDED DESIGN SOFTWARE (CAD) INTO NUMBER. THE NUMBERS CAN BE CONSIDERED TO BE COORDINATES OF A GRAPH AND THEY CONTROL THE MOVEMENT OF THE CUTTER. IN THIS WAY THE COMPUTER CONTROLS THE CUTTING AND SHAPING OF THE MATERIAL
6. SUBTRACTIVE PROCEDURE CUTS AWAY Cuts away material from a big piece of material until getting the desired shape and model
8. POWERFULL BUT EASY TO USE USED CORRECTLY THE LIMIT IS YOUR IMAGINATION DESPITE BEING THE SAME AS PROFESSIONAL INDUSTRY MACHINERY IT CAN BE IMPLEMENTED IN ALL THE FABLAB AND MAKERSPACES
9. DOING ALMOST EVERYTHING.. MULTIPLE TYPES OF CUTTING TWO DIFFERENT PROCEDURES 2D CUTTING OF PARTS AND POST ASSEMBLY OR 3D CUT WITH READY A READY TO GO PART.
10. USUALLY USED FOR PRODUCING BIG DURABLE AND STRONG PARTS AS THE MOST USEFULL ONES ARE NORMALLY BIG SIZE
14. ECO HOUSE (Madrid,Spain) ECOLOGIC HOUSE DESIGNED BY IAAC AND FABARCELONA FOR INTERNATIONAL ARCHITECTURE CONTEST
15. ECO HOUSE (Madrid,Spain) FULLY CNC CUTTED IN THE MAIN FABARCELONA FACILITIES
16. ECO HOUSE (Madrid,Spain) ASSEMBLY PROCEDURE
17. ECO HOUSE (Madrid,Spain) HOUSE FULLY FUNTIONAL, SMALL HOUSE FOR A FAMILY WITH THE RESULTS OF 0 RESIDUES AND 0 POWER CONSUMPTION
18. ECO HOUSE (Madrid,Spain)
19. FABFI (AFGANISTAN) PROJECT MADE BY FABFOUNDATION AND SOME ONGS TO GIVE LONGRADIO COMMUNICATION ON ISOLATED AREAS WITH LOW RESOURCES ADAPTING A WIFI ROUTER WITH A CNC STRUCTURE THEY CAN COMMUNICATE BETWEEN VILLAGES MILES AWAY
20. ECO HOUSE (Madrid,Spain)
21. SMALL PRODUCTS FABLAB MANCHESTER DEVELOPED THIS PRODUCT FOR MASS STORAGE INCREASE ON MACBOOK COMPUTERS. THE FINAL PRODUCT IN ALUMINIUN MILLED WITH CNC NOT EVERYTHING IS BIG!!
22. ECO HOUSE (Madrid,Spain)
23. Metropol Parasol (Sevilla,Spain)
25. FINAL STEP OF PROTOTYPING %&4*(/
     -"4&3
    $65
    5&454
    y 3&%&4*(/y $/$
    130%6$5
    FINAL PRODUCT FABRICATION WITH PROFESSIONAL RESULTS THIS PROCEDURE : -SAVE MONEY - SAVE TIME -LESS WASTED MATERIAL - MISTAKE FORGIVING
26. PRESS FIT IS NOT ONLY FOR LASERCUT !!
28. ART PROJECTS The light result is a simple checkerboard pattern of square light on one side and a rotated checkerboard on the other. The torqued geometries allows light to be transmitted not only through the thin end plane, but also through the edges of each tunnel.
29. ART PROJECTS They used a large CNC mill to mill out a pattern of nested torqued tunnels of light. A square geometry is twisted 45 degrees as it is extruded from the base foam. This is done on both sides, but with a 45 degree difference.
30. 1$#
    130%6$5*0/ -NO CHEMICAL WASTE -NON POLLUTING -FAST -EASY TO PROTOTYPE Why CNC?
31. ELECTRONIC PROJECTS 1$#
    130%6$5*0/ PROFESSIONAL LOOK BOARDS VS BIG MESSY PROTOTYPE BREADBOARDS
33. Why CNC? Rapid prototyping furniture
34. SKETCHAIR NATURAL DESING
35. SKETCHAIR DIGITAL TESTING
36. SKETCHAIR AUTOMATIC PLANS EXPORT
37. SKETCHAIR ASSEMBLY TEST
38. SKETCHAIR FINAL MODEL CNC MADE! DURABLE-RESISTANT-BEAUTIFUL
40. • AUTOCAD www.autodesk.com • Layout www.omax.com • FreeCad www.freecadweb.org • Qcad www.qcad.org • Antimony www.github.com/ mkeeter/antimony • LibreCad www.librecad.org • Illustrator www.adobe.com • Iodraw www.libreoffice.org • Inkscape www.inkscape.org • A9 CAD www.a9tech.com • BLENDER www.blender.org • Ecabinet www.ecabinetsystems.com • gCAD3d www.cadcam.co.at • Google Sketchup www.sketchup.google.com • GraphiteOne CAD www.graphiteone-cad.com • Solid Edge www.solidedge.com/free2d/ • Wings 3d www.wings3d.com CAD SOFTWARE FOR ALL THE TASTES
41. • http://www.iscriptdesign.com/# • http://mattermachine.com/ • http://www.sketchchair.cc/ • http://flatfab.com/ • http://boxmaker.connectionlab.org/ COOL DESIGN TOOLS LETS DO IT ONLINE ! ! ! ! Parametric stools Parametric everything ! Lets make chairs ! Flat 3d models Parametric box
42. Why CNC? AUTOMATION This gives the CnC user several side benefits including reduced operator fatigue, fewer mistakes caused by human error, and consistent and predictable machining time for each work piece
43. Why CNC? ACCURACY The second major benefit of CnC technology is consistent and accurate work pieces. todays CnC machines feature a typical accuracy rate in the range of 2 to 4 thousandths of an inch or 0.05 to 0.10 mm and repeatability near or better his means that once a program is verified, two, ten, or one thousand identical work pieces can be easily produced with the same precision and consistency
44. Why CNC? FLEXIBILITY Since these machines are run from computer programs, running a different work piece is as easy as loading a different program. the resulting reduction in the number of machines needed in a wood manufacturing shop is yet another benefit worthy of noting Less Work-in-Progress (WiP) also translates into lower inventory and less investment in non value-added resources.
45. • CNC stands for Computer Numerical Control; the machines are usually platforms that allow a computer-driven cutting tool to carve a material in all three dimensions. • CNC routers can be programmed to make precise, repeatable cuts on flat or low-elevation wood or plastic projects, while CNC mills turn blocks of steel or other materials into engine components, brackets, and other incredible metal creations. The CnC machine takes no breaks and although the human operator does, he can prepare work for the machine to perform on its own while he is undertaking other work.
46. 3 AXIS CNC Movement in X-Y-Z axis
47. 3 AXIS CNC Movement in X-Y-Z axis
48. GIANT 3 AXIS CNC
51. 4 AXIS CNC Movement in X-Y-Z axis and rotative tool
54. 5 AXIS CNC ROBOT ARMS WITH SPINDLE ADAPTED
56. HAND HELD/AUTOMATIC CNC https://www.youtube.com/watch?v=HInc-4Hc6BI MAYBE CNC EVOLUTION?
57. PARTS OF CNC
58. PARTS OF CNC Bridge T-slotted Table Spindle Stepper Cable carrier Lead Screw
59. The Spindle • Quieter! • More horse power • Precision bearings (smoother cuts) • Commercial quality (long life) • Variable speed, controllable within software
60. The Router • Less Expensive • You can get replacements at your local tool store... • Upgradeable • Works based of RPM • Can only cut soft materials ( wood, acrylic) • Speed only controled via hardware
61. The Collet A router bit is held in the router with a collet. A collet is designed to hold a bit with much more force than a typical drill chuckcollets for high end tools (spindles) are designed to be switched (changed) rapidly, some even have with ATC (automatic tool changers) Caution! Keep collets clean, a piece of debris or dust between the collet and bit can cause the bit to spin elliptically, harming bit, part or even operate anormaly
62. AUTOMATIC VS MANUAL LUBBING • EXPENSIVE-automatic cooling needs air or water compresor and bigger rooms • DIRTY-the coolant gets everywhere • POWERFULL-can cut metal and strong materials • CHEAP-less parts machinery • CLEAN-with a dust collector no need to clean everything • WEAK-can cut,wood,foam, plastic,softcomposites and soft metals with manual lubbing
63. Maintain Your Machine and Use the Correct End Mill. • As often as we’re reminded, everyone neglects one of the main workshop rules: Maintain your tools. This is crucial when it comes to CNC machines. If the CNC isn’t calibrated or is out of square, the output won’t match the input, no matter how long you’ve pored over the plans. • It’s very important to use an end mill that is specified for the particular material you are using, “There are end mills specific for wood, plastic, aluminum, steel, and so on.”
64. A Guide to CNC mills $IPPTF
    UIF
    CJU
    TIBQF
    TVJUFE
    GPS
    ZPVS
    QSPKFDU
65. A Guide to CNC mills "
    $/$
    SPVUFST OFFET NJMMT 5IFZ
    EFUFSNJOF
    UIF
    LJOE
    PG
    DBSWJOH
    ZPV
    DBO
    EP
    UIF
    SFTPMVUJPO
    PG
    ZPVS
    GJOJTIFE
    EFTJHOT
    BOE
    IPX
    GBTU
    ZPV
    DBO
    NPWF
    UISPVHI
    UIF
    NBUFSJBM
    Better Knowledge Of The Tools, Better Results You Get
66. The shape of the bit matters as well.
67. Drill Bits vs End Mills DRILLS ARE NOT END MILLS! Drill bits are designed to plunge directly into material, cutting axially and creating cylindrical holes. End mills are typically used for horizontal carving and cut laterally.
68. Drill Bits vs End Mills This is due to cutting flutes that extend to the end face and enable plunge cutting. To minimize tool breakage and stress on the material being cut, most CNC software will “ramp” the end mill slowly into lateral cuts.. Additionally, most mills are “center-cutting,” meaning they are able to cut both axially and laterally. DRILLS ARE NOT END MILLS!
69. Forensic on End Mills If you don´t understand your tools you don´t understand how it works!
70. • End mill bits with fewer flutes are better suited to side/horizontal cutting while bits with more flutes are better suited to end milling • Side cutting generally requires larger amount of material to be removed and the bits with fewer flutes allow the swawf to evacuate with less restriction. TIPS
71. Which Cutters so? • 2 flute upcut and downcut end mills (great for hardwood and plywood) • 2 or 4 flute ballnose mill (great for 3D contours) • Single or “O” flute mill (great for plastics like HDPE and acrylic) • 60° or 90° v-bit (great for cutting hardwood signs)
72. Flat end vs Ballnose vs V-bits VS VS Each end mill tip shape is designed for a particular purpose. Some common cutter shapes are ballnose, fish tail, surface planing, v‐carving, and straight. V‐bits produce a “V” shaped pass and are used for engraving, particularly for making signs. Ballnose mills produce a rounded pass and are ideal for 3D contour work Fish tail cutters will produce a flat surface
73. Are you carving large 3D contours or carvings ? You’ll want a ball nose bit that is appropriately sized for the level of detail in your model. Ballnose (aka contouring) bits are fantastic for 3d carving Ballnose Cutter
74. If you want to do lettering or detailed sign making, you’ll need to get a v bit They are available in many sizes and angles. The most common and useful angles in order are 60deg, 90deg, and 30deg. V - Cutter
75. If you are flattening large boards or you are responsible for maintaining the spoil board on your CNC router, you’ll want to have a spoil board cutter or flycutter bit. These bits are made to skim the surface and leave a smooth flat finish Spoil Board Cutter
76. Use the strongest bit you can Balance your need for speed with edge finish Choose the appropriate bit direction (The biggest decision you’ll need to make when picking your bit is cut direction. Your choice are uncut, downcut, and compression (a combination of upcut and downcut)) TIPS BIGGER IS ”BETTER”
77. Downcut tools do the opposite, producing a smooth upper surface. They are ideal for pieces that have been previously engraved or v-carved and cannot be flipped to hide tearout. In addition, as downcut mills pack the chips into the cut path, they can be used instead of tabs to hold down a workpiece and keep it from moving A CNC router spins a cutter clockwise. Upcut mills eject chips towards the top of the workpiece, producing a cleanly cut bottom surface. The downside is possible surface splintering or “tearout” on the top surface as the chips are ejected upwards.7
78. Importance of Flutes and Chipload • Flutes are the helical grooves that wrap around the sides of the end mill. Each flute has a single tooth with a sharp cutting edge (although there can be more than one) that runs along the edge of the flute. • As the tooth cuts into the wood, each flute whisks away a small section or “chip”. The fewer the flutes, the more material that is ejected with each tool rotation. The overall cutting depth should never exceed the length of the flutes on an end mill. If cutting deeper than the length of the flutes, the tops of the flutes will be blocked and chips won’t clear, building up heat and reducing tool life
79. • Chipload is the thickness of a machined chip as cut by a specific tool type. More flutes create a smoother surface finish, while fewer flutes remove material fastest, but make rougher cuts. • Proper chipload is important because chips dissipate heat. Hot cutters can lead to suboptimal results, including burned wood, a poor edge finish and dull tooling.
80. • Straight Flute – great all around bit, decent chip removal • Up Spiral – great chip removal, can tear- out the top of thin veneer such as finish grade plywood • Down Spiral – poor chip removal, no tear out, slower feed rate • Compression – combination of up and down spiral, great all around bit, great for plywood or laminated sheet goods.
81. MEASURES • SHANK– part inside the has to fit properly • CutLenght– determines the maximum amount of material removed • FLUTES– cutting part • DIAMETER – could be different shank and cut diameter
82. ?¿TiCN – TiAIN-CARBIDE?¿ WHAT ARE THIS CRAZY LETTERS! Solid materials for end mills are HSS (High Speed Steel) and Carbide. Carbide is the harder of the two, will last longer and can handle faster feedrates. To make carbide even better, there are various coating material applied • The gold coating on the left is TiN. No, not the material of cola cans, but a very resilient material (Titanium Nitride) that can withstand higher heat and provides a bit more hardness. • : TiCN (Titanium Carconitride) which is great for various metals, TiAIN (Titanium Aluminum Nitride) which is even better for metals (not aluminum which is in the coating itself) • AITiN (Aluminum Titanium Nitride) with similar characteristics as TiAIN, • Diamond, but don't get this for your loved one, unless they need a tool. Don't use diamond on metals either, but this material coating is superior on other materials especially composites and graphite
83. TO SUMMARIZE • More flutes create a smoother surface finish • Fewer flutes are best at chip clearing, keep heat from building up • One, two or four flute cutters are the most common.
84. Adjust Your Feed Rate and Depth per Pass. • Spindle Speed – rotational speed of the cutting tool in revolutions per min Spindle speed that is too fast paired with a slow feed rate can result in burning or melting. • Feed Rate – Surface speed at the center of the rotating tool Spindle speed that is too slow paired with a faster feed rate can result in dulling of the cutting edge, deflection of the end mill and possibility of breaking the end mill. • Step down – the distance in the z direction per pass that a cutting tool is plunged into the material • Step over – the maximum distance in the x/y direction that a cutting tool will engage with uncut material Using the incorrect feed rate can have some interesting consequences, besides a broken mill and a creaky, inaccurate CNC. Generally • Plywood Cuts Best At A Rate Of 80 Inches Per Minute (Ipm) And 0.4 Inches Depth • Acrylic Plexiglas Works Best At 130 Ipm, With 0.03 Inches Depth. If you run your machine too slow, you risk burning the material or gumming up the cutting tool with melted material. In the case of milling aluminum, it can turn the end mill into a solid rod … not very useful for cutting
85. • chip load: ~ 0.001-0.010" = feed rate (inches per minute) / (RPM x number of flutes) • cut depth: ~ tool diameter/2 • step-over: ~ tool diameter/2 “Use your ears too, the tool should sound good when cutting … trust your gut” Feed Rate / Speeds Golden Rules The shopbot software includes a calculator for feed rates. OR http://www.carbidedepot.com/formulas-milling.htm The mill should be warm, maybe a little hot to the touch, but it should not burn you. If it is too hot, increase the feed rate or lower the spindle speed
86. Feed rate datasheet • Cut Diameter - 1/4 inch or 6.35mm Shank diameter - 1/4 inch or 6.35mm Excellent Quality on Top and Bottom Edges of Cut • Soft Wood, Soft Plywood, Laminate Chipboard and Laminated Plywood: Chip load: .015 to .017 Suggested Low End Feed Rate: 540 IPM Suggested High End Feed Rate: 612 IPM • Hard Wood and Hard Plywood: Chip Load: .014 to .016 Suggested Low End Feed Rate: 504 IPM Suggested High End Feed Rate: 576 IPM • MDF (Medium Density Fiberboard): Chip Load: .013 to .015 Suggested Low End Feed Rate: 468 IPM Suggested High End Feed Rate: 540 IPM • All Feed Rates are based on 18,000 Spindle RPM
88. CLIMB VS CONVENTIONAL MILLING • Climb milling is when the direction of cut and rotation of the cutter combine to try to "suck" the mill up over • It produces the best surface finish • The width of the chip starts at maximum and decreases. • More power required.. CONVENTIONAL TWO TYPES OF CUTTING TWO DIFFERENTS RESULTS CLIMB • Upward forces are created that tend to lift the workpiece during face milling. • Conventional milling is preferred for rough surfaces. • The width of the chip starts from zero and increases as the cutter finishes slicing. • Less power required
89. CLIMB VS CONVENTIONAL MILLING • When cutting half the cutter diameter or less, you should definitely climb mill • Climbing to rough and conventional to finish • In case of cutting some types of foam CONVENTIONAL When to use each one¿ CLIMB • - When cutting from 3/4 to 1x the cutter diameter, you should prefer conventional milling. • conventional milling for the finish pass Up to 3/4 of the cutter diameter, it doesn't matter which way you cut. There is a problem with climb milling, which is that it can get into trouble with backlash if cutter forces are great enough. In general, CNC machines shouldn't have any noticeable backlash, so these are more concerns on manual machines.
90. Common mistakes • Cutting too slow will burn the bit or worse... • Use the shortest bit that will do the job...Less deflection, fewer broken bits • Don’t forget to turn the router on! • In the battle between router bits and clamps ... the clamp wins everytime! BURNED MILL ! ! ! BROKEN MILL ! ! ! BENDED MILL ! ! ! DESTROYED MILL ! ! !
91. Common mistakes • Cutting too slow will burn the bit or worse... CHIPPING CRATERWEAR FLANKWEAR DOC NOTCHING THERMALCRACKS BUILT UP EDGE • Cutting too slow will burn the bit or worse... • Cutting too slow will burn the bit or worse... • Cutting too slow will burn the bit or worse... • Cutting too slow will burn the bit or worse... • Cutting too slow will burn the bit or worse... IF WE LOOK CLOSELY WITH AN AUGMENTATION LENS…
92. TIPS Just like a baby... Feed a screaming bit. Usually a bit that’s “screaming” wants a greater chip load Just like you.... A router bit shouldn’t smoke, it’s bad for its health. A smoking bit wants a greater chip load Keep it clean... A bit with built up tree resins, tars and sap are susceptible to pitting form the acids in those compounds. A published chipload isn’t gospel...Start out with the recommended chipload and increase the feedrate until finish starts to deteriorate, then back off 10%. Now decrease the RPM and repeat the same steps. This process also works when you don’t know the manufacturers recommended chipload. Breakin’ em left and right... Even a properly used tool will occasionally break. If you are experiencing multiple tool failures, STOP and ask yourself, Is this the right tool geometry for this job? Is the collet clean and is the bit properly installed? Recheck
93. Particularly for thin sheets of material, it is important to secure the work very well. Excessive vibrating of the material will generate additional heat and lead to premature bit failure or poor surface finish. It is also important however, not to overtighten the screws as they will cause bowing in the material that may effect the dimensional accuracy. Flat head screws are better than tapered head screws here. Hold Down
94. VACUUM TABLE: -expensive ( you can make your own?) -clamping over whole area -maintenance intensive -for large pieces Hold Down FIXATION
95. CLAMPS: -need sloted /threaded table -horizontal -vertical -easy cheap -bit can encounter the clamp -use more space of the material Hold Down FIXATION
96. SCREWS: -easy -adaptative -not easy to see -cheap -dangerous if you hit with the mill -don’t waste almost material Hold Down FIXATION
97. DOUBLE SIDED TAPE -easy -adaptative -not very strong fixation -difficult to use on a used sacrifice board -you can use all the surface of material -cheap Hold Down FIXATION Very used sacrifitial board
98. Use a Screw Instead of a Holding Tab. • To keep a part steady while being routed, many people insert holding tabs in the pattern. The tabs act as tiny bridges that hold the milled part to the stock material. The number of tabs depends on the part that you’re cutting. • There is a balance between using more tabs than necessary, and not enough,” • Not enough, and the tabs can snap during the milling process. More than necessary, and you waste much of your time breaking them away after the job is done.” • When holding tabs won’t do the job, use holding screws instead. Drill two or more holes into the part to be cut, and manually screw these holes to the spoil board (the sacrificial material supporting your project from underneath) before cutting around the perimeter of the object.
99. HOLD DOWN Needs maintenance Requires to have a spoilboardcutter mill Cheap allows a lots of materials and fixations Always check the thickness of you material to don´t cut it to much When the are very used the Z is inaccurate SACRIFICE BOARD
100. Shopbot Safety Reminders 1) Wear protective gear including eye protection, ear protection and steel toed boots. Avoid loose‐fitting clothing or dangling jewelry. 2) Keep eyes, hands, hair and clothing away from the ShopBot and router when it is operating. Tie long hair back. Do not use your hands to hold down parts that may come loose as they are cut out. 3) Read and follow the safety information that comes with your router, bits and other accessories. Unplug or shut down power to the router or spindle when changing bits. 4) Listen for changes in sound that may indicate a problem while running the tool. ALWAYS be near enough to the Remote Stop Switch or Space Bar on the computer keyboard to be able to stop the gantries should a problem arise.
101. 5) Use a bit that is appropriate to the task. Inspect your bits for wear, burning, dullness and cracks each time you use them. •Choose a bit with the largest shank and the shortest bit length to fit the task to avoid excessive bit deflection and stress. • Never cut deeper than 1⁄2 mes the diameter of the bit in a single pass. Not only will two passes make a cleaner cut but a shallower cut will cause less bit deflection and danger of breakage. • Check your collets frequently. Collets do wear out, and a loose collet can result in greater deflection and shimmy which equal poorer quality cuts and greater chance of breakage. 6) Avoid unsafe holddown practices that can shatter a bit or allow parts to move during cutting. • Make sure that the vacuum is sufficient to hold down small parts. Create templates or use the tabbing feature to hold small parts in place until you are ready to remove the machined pieces. 7) Locate mechanical holddowns such as clamps or sheet rock screws well clear of the cutting area. Design your files in such manner that the bit does not encounter the screws or clamps. Countersink holes for holddown screws. 8) Air cut your file before you put actually cut the file using the 3D offset option. Remember to deselect the 3D offset when you are ready to really run the file.
102. 9) Create cutting files that avoid small parts flying out when being cut 10) Set Z accurately before starting the cut file, and know exactly how thick the material is. 11) Plan your toolpaths so that you cut out details and small parts before cutting out the big parts and drill any holes in a file while the material is intact and positioned properly, then go back and cut out the pieces.
103. How to break a CNC 1) Moving over the machine limits 2) Drilling into the support. 3) Breaking the cutter/the support 4) Too high feed rates 5) Forgotting to switch on the spindle 6) Forgotting to fix properly Only if I should have take more care…..
104. Experiment Safely Don’t get too carried away with the numbers, use your common sense and trust your gut. Every bit is a little different and there is a wide range of densities in solid wood and different sheet goods Experiment Safely Experiment Safely Experiment Safely HOW MANY TIMES DO I HAVE TO SAY?
105. MATERIALS metals STEEL -Hardest -Needs high power spindle -High friction-heat -Cooling needed -Very hard and sharp chips ALUMINIUM -Relative hard -Need high power spindle -High friction-heat -Often lubrication/cooling needed -Low melting point – stick to cutter.
106. MATERIALS metals ALUMINIUM TEST TEST TEST SLOWDOWN AND CUT WITH SMALL STEPDOWN.
107. MATERIALS woods SOLIDWOOD/PLYWOOD -STRONG -GOOD SURFACE -EXPENSIVE MDF / HDF -VERY UNIFORM -CHEAP -DIFFICULT TO MAKE GOOD SURFACE FINISH
108. MATERIALS woods SOLIDWOOD/PLYWOOD MDF / HDF
109. MATERIALS plastics • ACRYLIC • POLYCARBONATE • POLYSTYRENE • POLYETHYLENE • HDPE • UHMWPE • POLYOXYMETHYLENE • POLYPROPYLENE • NYLON
110. MATERIALS plastics NYLON -VERY VERSATILE -AVAILABLE IN BLOCKS -HIGH MELTING POINT -ABSORBS WATER -SWELLS/NOT EASY FOR HIGH PRECISON -CAREFUL WITH COOLANT .
111. MATERIALS plastics POLYPROPYLENE PP -ONLY IN THIN SHEETS -TOUGH AND STIFF -GOOD FOR LIVING HINGES EXPANDED PP ( EPP – FOAM) -VERY TOUGH FOAM -REGAINS SHAPE AFTER DEFORMATION
112. MATERIALS plastics POM POLYOXYMETHYLENE (acetal, delrin , kepital) -TOUGH -VERY LOW FRICTION -GOOD FOR SLIDING PARTS/GEARS -MACHINES VERY WELL -DOWCUT BIT RECOMMENDED -EXPENSIVE
113. MATERIALS plastics ACRYLIC -CLEAR -BRITTLE -METLS EASILY/EASY TO POLISH -SIGLE SPRIAL O-FLUTE CUTTER RECOMMENDED -VERY EASY TO BUY
114. MATERIALS foams EXPANDED POLYSTYRENE -Styrofoam -Most common -Large “bubbles” -Surface always rough Good for large objets Have to choose correctly compatible glue o coating (styrospray) EXTRUDED POLYSTYRENE -More expensive -Tougher / better surface -Very good for test runs -Smoother finish than expanded one
115. MATERIALS wax WAX -Very soft -Melts easily while machining -Easily breaks MACHINABLE WAX -Smooth surface finish -Soft -Expensive (relative) -1000ml ~ 20€
116. REMINDER MATERIALS CUTTING PRODUCES CHIPS • HIGH SURFACE AREA • FIRE HAZARD • DUST EXPLOSION • SHARP EDGES • VERY FLAMMABLE • ALU CHIP + LUBRICANT = FIRE HAZARD
117. WHERE TO BUY? MATERIALS ONLINE SHOPS MDF, Acrylic, Silicones and Polyurethane HOMI in Hongdae http://www.homi.co.kr/mall/index.php Brass small shops around here Machinable wax https://www.machinablewax.com/ Protoboard ‘raku‐tool’ http://www.ilbeom.co.kr/
118. WHERE TO BUY? MATERIALS ONLINE SHOPS Nylon and others http://www.platech.com/ Many shops is Incheon ‐ not many internet shops / naver can help Good online shop with much information: http://www.onlinemetals.com/ AND OF COURSE AROUND SEUN SANGGA ! ! ! !
119. Practice Lossless Design. If you place parts edge edge to edge, the end mill only cuts t material once along the shared edge. That saves you time and m also lengthens the lifespan of your end mill. Implement the principles of “lossless design” and lay each component as close to the other ones as possible. That is called ” N E S T I N G”
120. DESIGN TIPS • Scale: Draw in millimeters, scale 1:1 • Clean: Provide clean drawings; delete all objects that are not cutting or engraving lines • Nest: Combine all parts of the same material on one sheet. Our maximum board size is 2400x1220mm (ShopbotPRSalpha96-48) . Try to make a good fit to save material usage. • Multiple sheets: Need more parts than you can fit on one sheet? Create a new drawing and place your remaining parts here. • No fills: Disable all fills and hatches. (except for area engraving) • Explode text: Create outlines for all text. This can be done with the "Explode" function in most CAD applications and the "Create Outlines" in Illustrator. • Thin lines: Choose a line thickness of 0.2mm or hairline.
121. • ASPIRE www.vectric.com • Free Mill www.mecsoft.com • HSMexpress www.hsmworks.com • G-simple www.gsimple.eu • Heeks CAD-CAM www.heeks.net • EMC2 www.linuxcnc.org • Jedicut www.jelinux.pico-systems.com • FABMODULES www.fabmodules.org • Ace Converter www.dakeng.com/ace.html • DeskEngrave www.deskam.com • Modela4player www.rolanddg.com • Auto-Trace www.autotrace.sourceforge.net • Scan2CNC www.gravomaster.com • MaxCut www.maxcut.com.za • Rhino CAM www.rhino.com CAM SOFTWARE FOR ALL THE TASTES
122. D E S I G N
123. ?¿X–T –L–V – DOVEL JOINTS?¿ CNC WOOD JOINERY Later we'll see that the constraints of using CNC routers make clear that joints which are specifically designed or adapted to the process are the most suitable. TERMINOLOGY POCKET: a recess cut into a piece, usually to accommodate a mating part from the other member in the joint or to “ dig” on the material . CUT :is the most common on 2d cutting, it is just cutting like a laser cutter but with the cnc .
124. ?¿X–T –L–V – DOVEL JOINTS?¿ CNC WOOD JOINERY TERMINOLOGY GROOVE: A slot (U shaped flat bottom cut) or channel made with the grain. DADO :A slot made across the grain. RABBET: A slot cut parallel to, and along the edge of, a board. Half-Lap or Lapped: A dado or groove is cut into each workpiece to half their thickness to allow the parts to overlap one another.
125. ?¿X–T –L–V – DOVEL JOINTS?¿ CNC WOOD JOINERY TERMINOLOGY TENON: A projection on the end of a piece for insertion into a mortise. MORTISE :A cavity or hole in a workpiece, meant to receive a tenon. DOVETAIL: A joinery technique noted for its resistance to being pulled apart. This is an interlocking joint where an angled male part fits into a similarly shaped female pocket. BLIND JOINT: Refers to joinery with mating surfaces not protruding through the visible faces of the pieces being joined.
126. ?¿X–T –L–V – DOVEL JOINTS?¿ CNC WOOD JOINERY TERMINOLOGY HALF-BLIND JOINT: A joint where one part protrudes through the other piece. THROUGH JOINT :A joint where the other members are visible on both sides. CATEGORISED IN : 1 EDGE TO EDGE JOINTS 3 HOUSING JOINTS 2 CORNER JOINTS 4 FRAME JOINTS
127. ?¿inside corner problem?¿ CNC WOOD JOINERY LASER VS ROTARY CUTTERS Laser cutters can cut much finer details because they have very small “kerf”. - On the other hand, they’re more expensive and can’t do partial-depth cutting or “pocketing” like a CNC router can. -They also use heat, which can burn the substrate and/or generate nasty off-gassing. On the other hand, the burning effect can be used decoratively. -A CNC router can change bits and cut complex relieved surfaces, or make cuts with mitered or otherwise profiled edges. KERF: ‐A GROOVE OR NOTCH MADE BY A CUTTING TOOL, SUCH AS A SAW OR AN AXE,ETC ‐THE WIDTH OF A GROOVE MADE BY A CUTTING TOOL
128. ?¿inside corner problem?¿ CNC WOOD JOINERY LASER VS ROTARY CUTTERS Because of its very small cutting channel, a laser cutter can produce an inside corner with a sharp angle, whereas a rotary cutter using a physical tool is limited to inside corners rounded at the cutting tool’s radius:
129. ?¿inside corner problem?¿ CNC WOOD JOINERY LASER VS ROTARY CUTTERS The laser-cut version, with its sharp 90 corners, is suitable for use in a simple edge-lap joint The router-cut version, however, doesn’t work. The radiused corners bump into each other and the part edges don’t line up. You can cut each slot a bit deeper, of course, and in some applications this may be OK, but doing so leaves a void in the center of the joint and concentrates stress on the radiused corners
130. ?¿inside corner problem?¿ CNC WOOD JOINERY T BONE FILLET Now the inside faces of the edge laps mate cleanly. On the other hand, the round divots are visible in the assembled joint.
131. ?¿inside corner problem?¿ CNC WOOD JOINERY DOG BONE FILLET On average, this method offers the best compromise, IMHO: The flat areas between the divots seat against each other firmly and the divots themselves are concealed inside the joint. BUT YOUR TOOL HAS TO BE SMALL ENOUGH
132. ?¿oblique edge lap?¿ CNC WOOD JOINERY The rudimentary slotted joint, in which two slotted members are “halved” into one another, is often referred to as an “edge lap.” In the basic edge lap, the slot’s width and the stock thickness are essentially the same, and the two joined members are disposed at right angles to one another. In THE OBLIQUE EDGE LAP, both slots are wider than the thickness of the stock, the resulting edge lap is “loose” or “wobbly,” and the joined members can be disposed at acute or obtuse angles to one another. In this configuration, the edges of the slots do not lie flush against the surface of the stock, and the joint will be unstable without the presence of at least one other member. Nonetheless, the oblique lap can be indispensable for breaking out of the “boxy” limitations imposed by using only basic ninety-degree edge laps.
133. ?¿X–T –L–V – DOVEL JOINTS?¿ CNC WOOD JOINERY 3 AXIS CNC EDGE TO EDGE JOINTS LAPPED DOVETAIL: This example allows two boards to be joined along their edge. On the back side of the joint the edge is a straight line T o
134. ?¿X–T –L–V – DOVEL JOINTS?¿ CNC WOOD JOINERY 3 AXIS CNC EDGE TO EDGE JOINTS DOUBLE LAPPED DOVETAIL: Double dovetails in this version. So the decorative tails appear on each side of the piece (as opposed to a straight line in the example above). T o
135. ?¿X–T –L–V – DOVEL JOINTS?¿ CNC WOOD JOINERY 3 AXIS CNC EDGE TO EDGE JOINTS BOARD LENGTHENING WITH JIGSAW KEYS Joints such as the following two use removable keys to edge join the boards. In reality these keys are tough to get in and out of the pockets if the fit is good. So these are not suitable as knock‐down (take apart) joints. T o
136. ?¿X–T –L–V – DOVEL JOINTS?¿ CNC WOOD JOINERY 3 AXIS CNC EDGE TO EDGE JOINTS BOARD LENGTHENING WITH ASYMMETRICAL DOVETAIL KEYS Another version using more traditionally shaped dovetails. Butterfly keys are similar to this although they are symmetrical about their centerline (these are asymmetric). T o
137. ?¿X–T –L–V – DOVEL JOINTS?¿ CNC WOOD JOINERY 3 AXIS CNC EDGE TO EDGE JOINTS GOOSENECK MORTISE AND TENON JOINT The shape of this joint demonstrates the ease with which the CNC can cut complex curves into joinery. T o
138. ?¿X–T –L–V – DOVEL JOINTS?¿ CNC WOOD JOINERY 3 AXIS CNC EDGE TO EDGE JOINTS DOUBLE JIGSAW The two parts of this joint design are similar but are mirror images of one another. T o
139. ?¿X–T –L–V – DOVEL JOINTS?¿ CNC WOOD JOINERY 3 AXIS CNC EDGE TO EDGE JOINTS HALVING WITH ELLIPTICAL TENON A halving joint is one where the two parts are each thinned by half and overlap one another. The ellipse tenon in this joint provides mechanical resistance to pulling apart. This joint would be weak in hardwood because the sheer plane is parallel to the wood fibers T o
140. ?¿X–T –L–V – DOVEL JOINTS?¿ CNC WOOD JOINERY 3 AXIS CNC EDGE TO EDGE JOINTS DOUBLE DOVETAIL Standard dovetail shape (with rounded corners). In this joint the dovetails appear on both sides. T o
141. ?¿X–T –L–V – DOVEL JOINTS?¿ CNC WOOD JOINERY 3 AXIS CNC EDGE TO EDGE JOINTS SHOULDERED DOUBLE TAIL This joint uses a larger and smaller dovetail to interesting effect: T o
142. ?¿X–T –L–V – DOVEL JOINTS?¿ CNC WOOD JOINERY 3 AXIS CNC EDGE TO EDGE JOINTS TRIPLE DOVETAIL Single dovetail on one side, double on the other. Unlike the joint above these are not aligned laterally making it stronger. T o
143. ?¿X–T –L–V – DOVEL JOINTS?¿ CNC WOOD JOINERY 3 AXIS CNC CORNER JOINTS FINGER TENONS These joints are the simplest of the CNC compatible tenons. The joint is fully exposed at the corner. There is a lot of surface area for glue T o
144. ?¿X–T –L–V – DOVEL JOINTS?¿ CNC WOOD JOINERY 3 AXIS CNC CORNER JOINTS BLIND FINGER TENONS This example uses pockets along the edge of the joint to keep the tenons from showing through. This is referred to as a blind joint. The edges are visible from the outside making a nice detail to relieve the sharp edge T o
145. ?¿X–T –L–V – DOVEL JOINTS?¿ CNC WOOD JOINERY 3 AXIS CNC CORNER JOINTS BLIND FINGER TENONS EXAMPLE SPEAKER BOX
146. ?¿X–T –L–V – DOVEL JOINTS?¿ CNC WOOD JOINERY 3 AXIS CNC CORNER JOINTS FINGERTIP TENONS Through corner joint. The two parts are identical. They provide a lot of glue surface area making for a very strong connection. Here the narrower tenons are referred to as "fingertip" rather than "finger" T o
147. ?¿X–T –L–V – DOVEL JOINTS?¿ CNC WOOD JOINERY 3 AXIS CNC CORNER JOINTS HAMMER TENONS This joint is designed to mechanically keep the joint from pulling apart along one axis. T o
148. ?¿X–T –L–V – DOVEL JOINTS?¿ CNC WOOD JOINERY 3 AXIS CNC CORNER JOINTS FINGERTIP TENONS WITH KEY The lengthened tenons of this joint have a notch which accepts a key which secures the joint against tension. T o
149. ?¿X–T –L–V – DOVEL JOINTS?¿ CNC WOOD JOINERY 3 AXIS CNC CORNER JOINTS CATCH TENON This is another break‐down joint. The parts are slid together and the catch is pushed through the matching latch. When through far enough the tenon flips down and hooks to secure the joint from coming apart by tension. T o
150. ?¿X–T –L–V – DOVEL JOINTS?¿ CNC WOOD JOINERY 3 AXIS CNC CORNER JOINTS DOWELED MORTISE AND THROUGH TENON This example uses a dowel to prevent one part from sliding back through the other. When the dowel is tight against the face of the mating piece the joint is pretty solid. T o
151. ?¿X–T –L–V – DOVEL JOINTS?¿ CNC WOOD JOINERY 3 AXIS CNC HOUSING JOINTS THROUGH FINGER TENONS This is an example of a through joint where the tenons of the perpendicular member show through the side. T o
152. ?¿X–T –L–V – DOVEL JOINTS?¿ CNC WOOD JOINERY 3 AXIS CNC FRAME JOINTS OVAL SHOULDERED HALVING Simple curved edge half‐lap joint. The parts are identical. This joint is decorative compared to a normal half‐lap but is also stable. The curves provide some extra tensile strength as well as increased glue area along the sides of the joint. In all half lap joints the material thickness is critical to a accurate fit. T o
153. ?¿X–T –L–V – DOVEL JOINTS?¿ CNC WOOD JOINERY 3 AXIS CNC FRAME JOINTS DOVETAILED CROSS HALVING This joint has two identical parts. They provide a high degree of racking resistance and lot of glue area. T o
154. ?¿X–T –L–V – DOVEL JOINTS?¿ CNC WOOD JOINERY 3 AXIS CNC FRAME JOINTS CROSS MITER JOINT WITH JIGSAW KEY This joint allows four separate members to join at a common intersection point using a jigsaw key. In a tight fitting joint this is very difficult to take apart so it can't be considered knock‐down.In a joint loose enough where the joint can be easily taken apart the holding of the four members are not very rigid. T o
155. ?¿X–T –L–V – DOVEL JOINTS?¿ CNC WOOD JOINERY 3 AXIS CNC FRAME JOINTS STOP LAP WITH JIGSAW KEY The jigsaw key provides some tension resistance. This joint also has a notch cut in the edge so the cross member can resists lateral stresses as well. T o
156. ?¿X–T –L–V – DOVEL JOINTS?¿ CNC WOOD JOINERY 3 AXIS CNC FRAME JOINTS JIGSAW MITER JOINT Another decorative half‐lap corner joint that provides resistance to pulling apart due to the interlocking parts.. T o
157. ?¿X–T –L–V – DOVEL JOINTS?¿ CNC WOOD JOINERY 3 AXIS CNC FRAME JOINTS HALVED DOVETAIL Another half‐lap variant which resists tensile forces in pulling it apart. T o
158. ?¿X–T –L–V – DOVEL JOINTS?¿ CNC WOOD JOINERY 3 AXIS CNC FRAME JOINTS DOVE TAIL KEY CORNER This joint has a separate key to resist the tensile stresses on the joint. Note that the parts do not have to be at a right‐angle T o
159. ?¿X–T –L–V – DOVEL JOINTS?¿ CNC WOOD JOINERY 3 AXIS CNC FRAME JOINTS SHOULDERED DOVETAIL HALVING Another half‐lap variation with a dovetail. This joint has a notch cut in the edge so the cross member is less likely to shift laterally. Thus the joint resists forces in all directions. T o
160. ?¿X–T –L–V – DOVEL JOINTS?¿ CNC WOOD JOINERY 3 AXIS CNC FRAME JOINTS HOOKED JIGSAW HALVING These last two joints have one member extending beyond the edge of the other. In this case the hook extends fully through the piece providing some tensile resistance. T o
161. ?¿X–T –L–V – DOVEL JOINTS?¿ CNC WOOD JOINERY 3 AXIS CNC FRAME JOINTS DOUBLE JIGSAW-HOOK CORNER This is a decorative corner joint which provides resistance to tensile stresses. The extension could be used as a hook: T o MORE INFORMATION ABOUT JOINERY THE ART OF JAPANESE JOINERY (KIYOSI SEIKE) –BOOK JOINT BOOK : THE COMPLETE GUIDE TO WOOD JOINERY WOODWORKER´S GUIDE TO JOINERY 50 DIGITAL JOINS
163. ENDLESS POSSIBILITIES CNC WOOD JOINERY IMPLEMENT THE JOINS ON YOUR DESIGN ! ! !
164. ENDLESS POSSIBILITIES CNC WOOD JOINERY THREE BASIC APPROACHES STACK OF SECTIONS GRID OF SECTIONS GRAPHIC PROFILE
165. ENDLESS POSSIBILITIES CNC WOOD JOINERY NEW APPROACHES BREAKPLANE HINGES Andy Kem’s
166. ENDLESS POSSIBILITIES CNC WOOD JOINERY HIDDEN HINGES
167. ENDLESS POSSIBILITIES CNC WOOD JOINERY NEW APPROACHES Gregg Fleishman´s router aesthetics
169. • Tools: Router bits are used rather than saw blades. Tear out on the edge of pieces is more problematic with router bits. This needs to be carefully setup so the tool approaches the work properly. Router bits also exert more force on the workpiece while cutting necessitating stronger fixturing. – When routing plywood contour cuts are usually machined with a compression bit. This bit pushed down from the top and lifts up from the bottom to reduce tearout in sheet goods. Pockets are usually cut with down shear bits to reduce tearout. • Corners: Square corners can’t be cut with cylindrical router bits. For many cases this means joints need to be designed with rounded corners. The rounded corners can be drilled out or routed. A key with routing these corners is that the tool must keep moving while making the cut. Otherwise excessive heat develops. This leads to greatly increased tool wear and the potential for fires. – See CNC Corner Fix Utility for a program to help in quickly drawing these rounded corners in Rhino. There are some issues associated with CNC cut joints which need to be understood. CONSIDERATIONS CNC WOOD JOINERY
170. CONSIDERATIONS CNC WOOD JOINERY • Tolerances: If two mating parts are cut to the same dimension they obviously won't fit together. A gap needs to exist between the parts for them to slide by one another and provide a small space for glue. In CNC work it's common to use a gap of 0.005" per side of the joint. So for example a tenon should be cut 2 times 1,2mm narrower than the mortise (1.2mm on each side). This is a fairly tight fit but will work if the machine is very accurate and the tools are sharp. If the tools are dull, the cut is not as clean and the accuracy can't be maintained. Therefore it is sometimes necessary to use 0,25mm per side. Most of the joints shown below were cut with 0,25mm per side. This was done to allow the pieces to slide apart easily for demonstration purposes. • Stock: Material thickness variations have a big impact on CNC cut joints. The toolpath programming will be done for a certain thickness. If the stock is not that thickness exactly it will affect the fit of the joint. For this reason using "Stock to leave" and "Floor to leave" parameters in the CAM software can provide offsets to compensate for the variation. • Fixturing: Rather than moving the work piece over the tool, the work must be held securely while the tool moves. The process of securing the work is called fixturing. In the case of 3-axis routing of plywood this usually just means tabbing the parts. In hardwood this often involves double-sided tape holding the parts to a spoilboard.
171. ?¿MATERIALS DATASHEET?¿ CNC WOOD JOINERY BIRCH PLYWOOD CASE When you see a deviation in thickness in some of the joints it is usually this material thickness difference which is the cause THAT IS WHY IS SO IMPORTANT TO MEASURE PRECISELY YOUR MATERIAL ! USUALLY THERE IS A DEVIATION OF 0,1-0,3MM
172. What are Toolpaths? A toolpath is the user-defined coded route which a cutting tool follows to machine a part. They are represented on the screen by lines and curves which represent the path of the bottom center of the cutting tool. Pocket toolpaths etch the surface of the material, while profile toolpaths cut all the way through.
173. CAM BASICS • KEEP TOOL DIAMETER IN MIND • FINAL CUTTING DEPTH ! • THINK ABOUT HOLDING YOUR SHAPE • MAKE A PLAN FROM START TO FINISH • THINK ALWAYS TWICE
174. ?¿G01 –M02–G21 – G00?¿ G - CODE MACHINES LANGUAJE Is the language that the machines talk, they can understand standart one of speak another “ dialect” depends on the firmware of the machine. Is just a series of numbers with letters, like directions on maps or a gps so the machine know what it has to do and with actions has to take. IMPORTANT CODES. • X / Y / Z ABSOLUTE POSITIONING • M02 / M30 END OF PROGRAM • G 20 PROGRAMING IN INCHES • G 21 PROGRAMING IN MM • G 00 RAPID POSITIONING • G01 LINEAR MOVEMENT (CUTTING)
175. ?¿ROUGHENING – FINISHING - ETC?¿ CAM TERMS STARTING POINT 0 , 0 , 0 IMPORTANT WORDS • ROUGHENING REMOVING MOST MATERIAL BUT NOT ALL • FINISHING FEMOVING MATERIAL UP TO DESIRED SHAPE • PROFILE CUTTING AROUND A LINE • STEP OVER HOW MUCH OF THE CUTTER IS CUTTING • STEP DOWN CUTTING DEPTH IN ONE PASS • FEED CUTTING SPEED • PLUNGE CUTTING STRAIGHT DOWN • LEAD IN/ENGAGE HOW TO MOVE INTO CONTACT • POCKETING CUTTING INSIDE OF SHAPE • FACING CUTTING ALL • STOCK THE PIECE YOU WANT TO CUT
176. FROM CAD TO CAM CAM START DIFFERENTS REQUIREMENTS DEPENDING ON THE PROGRAM • DXF ALWAYS A GOOD START, OLDER VERSIONS ALWAYS BETTER • STL BINARY TYPE ALSO IS USUALLY COMPATIBLE • PNG FOR 2D-3D WITH OUTLINES OR GRADIENTS • SVG FOR 2D FILES TROUBLESHOOTING • TRY WITH ONLY ONE SOLID NOT MULTIPLE SOLIDS • MESH OFTEN DIFFICULT TRY SOLID OR CURVES • ONLY SOLIDS? TRY TO CHANGE TO CURVES • ADD EXTRA CURVES ON CAD MODEL
177. V CARVE TUTORIAL SHOPBOT BIG CNC TOOLPATHING
178. LET´S MAKE THE TOOLPATHS V CARVE SET MATERIAL SIZE AND THICKNESS (CHECK UNITS)
179. LET´S MAKE THE TOOLPATHS V CARVE FILE – IMPORT – VECTOR/BITMAP OR DESIGN IN THE PROGRAM
180. LET´S MAKE THE TOOLPATHS V CARVE MOVE YOUR DESIGN TROUGHT THE MATERIAL
181. LET´S MAKE THE TOOLPATHS V CARVE SELECT YOUR VECTOR AND RIGHT CLICK, CHECK FOR OPEN VECTORS
182. LET´S MAKE THE TOOLPATHS V CARVE WE WILL GET A DIFFERENT TYPE OF TOOLPATH ALSO IN UPPER VIEW
183. LET´S MAKE THE TOOLPATHS V CARVE SELECT YOUR VECTOR AND RIGHT CLICK, CHECK FOR DUPLICATE VECTORS
184. LET´S MAKE THE TOOLPATHS V CARVE YOU CAN SCALE – ROTATE – MODIFY YOUR DESIGN -ETC
185. LET´S MAKE THE TOOLPATHS V CARVE EXAMPLE OF SCALING
186. LET´S MAKE THE TOOLPATHS V CARVE YOU CAN USE DIFFERENT LAYERS TO SET DIFFERENT TOOLPATHS
187. LET´S MAKE THE TOOLPATHS V CARVE CREATE FILLETS IF YOU NEED FOR SOLVING THE INSIDE CORNER ISSUE
188. LET´S MAKE THE TOOLPATHS V CARVE DIFFERENT TYPES OF FILLETS – SELECT YOUR RADIUS MILL
189. LET´S MAKE THE TOOLPATHS V CARVE NORMAL FILLET
190. LET´S MAKE THE TOOLPATHS V CARVE DOG BONE FILLET
191. LET´S MAKE THE TOOLPATHS V CARVE T BONE FILLET
192. LET´S MAKE THE TOOLPATHS V CARVE YOU CAN NEST OBJECTS FOR SAVING MATERIAL
193. LET´S MAKE THE TOOLPATHS V CARVE IN CASE YOU SCREW TO THE TABLE LET ENOUGH BORDER GAP, CHECK ALL THE VALUES ( MILL RADIUS, DISTANCE BETWEEN PIECES) AND PREVIEW.
194. LET´S MAKE THE TOOLPATHS V CARVE CLICK “SWITCH TO TOOLPATHS TO CHANGE BETWEEN “DESIGN” TO “TOOLPATHING”
195. LET´S MAKE THE TOOLPATHS V CARVE PROFILE / POCKETING / DRILLING / ENGRAVING / FLUTTING / TEXTURING / PRISM CARVING, LOT OF CHOICES BUT CUTTING AND POCKETING THE MOST COMMON ONES
196. LET´S MAKE THE TOOLPATHS V CARVE SELECT OUTSIDE CUT VECTORS CHECK CUTTING DEPTH
197. LET´S MAKE THE TOOLPATHS V CARVE SELECT YOU MILL ( DON´T MODIFY ANY VALUE HERE OR YOU WILL CHANGE THE DATABASE)
198. LET´S MAKE THE TOOLPATHS V CARVE IN EDIT CHANGE THE FEEDS AND SPEEDS
199. LET´S MAKE THE TOOLPATHS V CARVE EDIT PASSED TO SELECT THE DEPTH CUTTED IN EACH PASS REMEMBER ALWAYS LESS THAN HALF THE MILL DIAMETER
200. LET´S MAKE THE TOOLPATHS V CARVE SELECT TYPE OF CUT OUTSIDE/INSIDE/ON
201. LET´S MAKE THE TOOLPATHS V CARVE ADD TABS IN CASE YOU NEED THEM
202. LET´S MAKE THE TOOLPATHS V CARVE IN TABS MENU YOU CAN ADD THEM MANUALLY OR USE AUTOMATIC TABS
203. LET´S MAKE THE TOOLPATHS V CARVE WE ADD RAMPS
204. LET´S MAKE THE TOOLPATHS V CARVE NAME THE TOOLPATH AND CALCULATE
205. LET´S MAKE THE TOOLPATHS V CARVE WE WANT TO CUT TROUGHT SO IT IS NORMAL BUT YOU NEED A SACRIFICE BOARD
206. LET´S MAKE THE TOOLPATHS V CARVE WE CAN PREVIEW THE TOOLPATHS IN 3D VIEW
207. LET´S MAKE THE TOOLPATHS V CARVE EN PREVIEW AN ANIMATION
208. LET´S MAKE THE TOOLPATHS V CARVE NOW WE SELECT THE INSIDE CUT VECTORS
209. LET´S MAKE THE TOOLPATHS V CARVE WE CHECK THE MILL SELECTED
210. LET´S MAKE THE TOOLPATHS V CARVE WE SELECT INSIDE CUT
211. LET´S MAKE THE TOOLPATHS V CARVE ADD TABS IN CASE WE NEED THEM, RAMPS, NAME THE FILE AND CALCULATE
212. LET´S MAKE THE TOOLPATHS V CARVE WE CAN PREVIEW ALL THE TOOLPATHS AT THE SAME TIME
213. LET´S MAKE THE TOOLPATHS V CARVE LET´S TRY POCKETING
214. LET´S MAKE THE TOOLPATHS V CARVE WE SELECT THE CUTTING DEPTH
215. LET´S MAKE THE TOOLPATHS V CARVE TYPE OF POCKETING RASTER VS OFFSET
216. LET´S MAKE THE TOOLPATHS V CARVE CHECK IN 3D VIEW THE TOOLPATH
217. LET´S MAKE THE TOOLPATHS V CARVE DIGITAL WOOD PREVIEW
218. LET´S MAKE THE TOOLPATHS V CARVE WE HAVE FINISH MAKE TOOLPATHS LET´S MAKE THE FINAL STEPS
219. LET´S MAKE THE TOOLPATHS V CARVE TOOLPATHS RELCALCULATION IN CASE WE MODIFY OF MOVE THE VECTORS
220. LET´S MAKE THE TOOLPATHS V CARVE WE CAN NOW THE ESTIMATED CUTTING TIME
221. LET´S MAKE THE TOOLPATHS V CARVE SELECT AND SAVE ONLY TOOLPATHS WITH THE SAME MILL ! ! !
222. LET´S MAKE THE TOOLPATHS V CARVE SAVE THE FILE TO OPEN WITH SHOPBOT 3
223. FABMODULES SHOPBOT/MODELA CNC TOOLPATHING
224. LET´S MAKE THE TOOLPATHS FABMODULES SELECT YOU INPUT FORMAT
225. LET´S MAKE THE TOOLPATHS FABMODULES IN THIS CASE WE ARE GOING TO 3D CNC WITH A GRADIENT PNG IF YOU ARE GOING TO USE STL REMEMBER TO SAVE AS BINARY TYPE
226. LET´S MAKE THE TOOLPATHS FABMODULES SELECT SHOPBOT, G-CODE FOR STANDAR,ROLAND MILL IN CASE OF MODELA
227. LET´S MAKE THE TOOLPATHS FABMODULES SELECT YOUR TYPE OF TOOLPATHING PLYWOOD-HDPE FOR 2D FOAM TYPE FOR 3D
228. FABMODULES SELECT YOU INPUT FORMAT CHECK ALWAYS ALL THE VALUES ! AND CALCULTE
229. LET´S MAKE THE TOOLPATHS FABMODULES AFTER SOME SECONDS OR MINUTES ( DEPENDS ON YOUR MODEL/COMPUTER) YOU WILL GET THE TOOLPATH IN UPPER VIEW
230. LET´S MAKE THE TOOLPATHS FABMODULES ROTATE / ZOOM / CHECK THE MODEL TO SEE IF EVERYTHING SEEMS FINE
231. LET´S MAKE THE TOOLPATHS FABMODULES SAVE THE FILE OR SEND IT IF THE MACHINE IS CONNECTED
232. FABMODULES SELECT YOU INPUT FORMAT NOW WE ARE GOING TO DO THE FINISH CUT IN CASE YOU HAVE SELECTED PREVIUSLY ROUGH CUT
233. LET´S MAKE THE TOOLPATHS FABMODULES CHECK AGAIN ALL THE VALUES AND YOU TYPE OF MILL ( FLAT OR BALL END)
234. LET´S MAKE THE TOOLPATHS FABMODULES WE WILL GET A DIFFERENT TYPE OF TOOLPATH ALSO IN UPPER VIEW
235. LET´S MAKE THE TOOLPATHS FABMODULES ROTATE TO CHECK WOOOH ! IT LOOKS AWESOME !! DON´T FORGET TO SAVE
236. MESHCAM CNC TOOLPATHING
237. LET´S MAKE THE TOOLPATHS MESHCAM • EASY TO USE • ALMOST EVERYTHING GRAPHIC INTERFACE • AUTOMATIC TOOLPATH WIZARD • PC´S AND MACS • CHEAP • INTUITIVE
238. LET´S MAKE THE TOOLPATHS MESHCAM LOAD YOUR DESIGN
239. LET´S MAKE THE TOOLPATHS MESHCAM CHOOSE THE TYPE OF MACHINING
240. LET´S MAKE THE TOOLPATHS MESHCAM DEFINE MATERIAL AND REGION TO MACHINE
241. LET´S MAKE THE TOOLPATHS MESHCAM
242. LET´S MAKE THE TOOLPATHS MESHCAM
243. LET´S MAKE THE TOOLPATHS MESHCAM CHECK YOUR TOOLPATH AND SAVE !
244. CAMBAM CNC TOOLPATHING
245. LET´S MAKE THE TOOLPATHS CAMBAM • 500 LINES OF G-CODE IN FREE TRIAL • 2D OR 3D • SMALL PROGRAM • CHEAP • NO 4 AXIS • SOMETIMES PROBLEMATIC WITH ARCS • ATL+MOUSE FOR CHANGING VIEW
246. LET´S MAKE THE TOOLPATHS CAMBAM
247. LET´S MAKE THE TOOLPATHS CAMBAM
248. LET´S MAKE THE TOOLPATHS CAMBAM
249. LET´S MAKE THE TOOLPATHS CAMBAM
250. LET´S MAKE THE TOOLPATHS CAMBAM
251. LET´S MAKE THE TOOLPATHS CAMBAM
252. LET´S MAKE THE TOOLPATHS CAMBAM
253. RHINO CAM CNC TOOLPATHING
254. LET´S MAKE THE TOOLPATHS RHINO CAM • PLUGIN FOR RHINO CAD • BASED ON VISUAL MILL • TIERED SOFTWARE (STANDARD/PRO) • EXPENSIVE • ALWAYS NEED FIRST RHINO CAD • NOT EASY • VERY POWERFULL
255. LET´S MAKE THE TOOLPATHS RHINO CAM
256. LET´S MAKE THE TOOLPATHS RHINO CAM
257. LET´S MAKE THE TOOLPATHS RHINO CAM
258. LET´S MAKE THE TOOLPATHS RHINO CAM
259. LET´S MAKE THE TOOLPATHS RHINO CAM
260. LET´S MAKE THE TOOLPATHS RHINO CAM
261. LET´S MAKE THE TOOLPATHS RHINO CAM
262. LET´S MAKE THE TOOLPATHS RHINO CAM
263. LET´S MAKE THE TOOLPATHS RHINO CAM TOOL SETUP
264. LET´S MAKE THE TOOLPATHS RHINO CAM TOOL GEOMETRY
265. LET´S MAKE THE TOOLPATHS RHINO CAM TOOL SETUP FEEDS
266. LET´S MAKE THE TOOLPATHS RHINO CAM MACHINING REGIONS
267. LET´S MAKE THE TOOLPATHS RHINO CAM SELECT EDGES
268. LET´S MAKE THE TOOLPATHS RHINO CAM SELECT REGION
269. LET´S MAKE THE TOOLPATHS RHINO CAM CONFIRM WITH RIGHT CLICK
270. LET´S MAKE THE TOOLPATHS RHINO CAM DIFFERENT MACHINING OPTIONS Roughening Finishing Horizontal Parallel
271. LET´S MAKE THE TOOLPATHS RHINO CAM HORIZONTAL ROUGHENING
272. LET´S MAKE THE TOOLPATHS RHINO CAM PLUNGE ROUGHENING
273. LET´S MAKE THE TOOLPATHS RHINO CAM PARALLEL FINISHING
274. LET´S MAKE THE TOOLPATHS RHINO CAM HORIZONTAL FINISHING
275. LET´S MAKE THE TOOLPATHS RHINO CAM PENCIL TRACING
276. LET´S MAKE THE TOOLPATHS RHINO CAM WORK ZERO
277. LET´S MAKE THE TOOLPATHS RHINO CAM WORK ZERO
278. LET´S MAKE THE TOOLPATHS RHINO CAM HORIZONTAL ROUGHENING
279. LET´S MAKE THE TOOLPATHS RHINO CAM HORIZONTAL ROUGHENING
280. LET´S MAKE THE TOOLPATHS RHINO CAM HORIZONTAL ROUGHENING
281. LET´S MAKE THE TOOLPATHS RHINO CAM HORIZONTAL ROUGHENING
282. LET´S MAKE THE TOOLPATHS RHINO CAM HORIZONTAL ROUGHENING
283. LET´S MAKE THE TOOLPATHS RHINO CAM HORIZONTAL ROUGHENING Remember Downcut and Endmill cutter?
284. LET´S MAKE THE TOOLPATHS RHINO CAM HORIZONTAL ROUGHENING ! Attention •If stepdown distance > available space •‘Toolpath could not be generated
285. LET´S MAKE THE TOOLPATHS RHINO CAM HORIZONTAL ROUGHENING
286. LET´S MAKE THE TOOLPATHS RHINO CAM HORIZONTAL ROUGHENING
287. LET´S MAKE THE TOOLPATHS RHINO CAM GENERATE TOOLPATH
288. LET´S MAKE THE TOOLPATHS RHINO CAM GENERATE TOOLPATH
289. LET´S MAKE THE TOOLPATHS RHINO CAM SIMULATE
290. LET´S MAKE THE TOOLPATHS RHINO CAM SIMULATE
291. LET´S MAKE THE TOOLPATHS RHINO CAM SIMULATE
292. LET´S MAKE THE TOOLPATHS RHINO CAM SIMULATE
293. LET´S MAKE THE TOOLPATHS RHINO CAM SIMULATE
294. LET´S MAKE THE TOOLPATHS RHINO CAM OOOPS
295. CONTROL SOFTWARE from CAM TO CNC
296. SHOPBOT 3 CONTROL SHOPBOT BIG CNC
297. SHOPBOT 3 CNC CONTROL OPEN SHOPBOT 3 OOOPS MAYBE YOU FORGOT TO SWITCH ON THE CNC ?
298. SHOPBOT 3 CNC CONTROL OPEN SHOPBOT 3 TURN ON THE SHOPBOT TURN UP THE MAIN POWER SWITCH AND IN CASE YOU HAVE TURN THE SECURITY KEY LOCATE THE POWER SWITCH (CONTROL BOX) AND THE 2 EMERGENCY STOP BUTTONS
299. SHOPBOT 3 CNC CONTROL EMERGENCY STOP BUTTON LOCKED
300. SHOPBOT 3 CNC CONTROL OPEN SHOPBOT 3 TURN ON THE POWER SWITCH UNLOCK BY TURNING CLOCKWISE THE EMERGENCY STOP BUTTONS IN CASE THEY WERE LOCKED PRESS THE BLUE RESET BUTTON TO RESET THE DRIVERS
301. SHOPBOT 3 CNC CONTROL SIMPLE INTERFACE If it is the first time of the day the shopbot has been run you must run the warm up routine.Type C5 and press start button on the machine, it will take 9 min.
302. SHOPTBOT 3 CNC CONTROL LET´ S MOVE THE MACHINE Let´s move up the spindle to make the mill/collet install easier.
303. SHOPTBOT 3 CNC CONTROL MOVE TO RAISE UP Z JOG NEXT SUPERFAST MOVING ( BE CAREFULL)
304. SHOPTBOT 3 CNC CONTROL MOVE TO MAKE X-Y-Z Loosen the thumb screw to drop the dust shroud for better access to the spindle Unscrew using the provided wrenches so you don´t damage the collet. Clean properly the collet and collet nut from dust. Assemble again with your bit and tight everything. Don´t forget to secure your material properly.
305. SHOPTBOT 3 CNC CONTROL MOVE TO MAKE MATERIAL ORIGIN X-Y-Z JOG NEXT SUPERFAST MOVING ( BE CAREFULL)
306. SHOPBOT 3 CNC CONTROL CLICK (Z)ERO TO RESET THE POSITION TO 0,0,0
307. If you have a Z plate use it for automatic Z zeroing!
308. MACH 3 CNC CONTROL LOAD G-CODE
309. MACH 3 CNC CONTROL LOAD G-CODE DON´T FORGER TO TURN ON THE SPINDLE BY PRESSING THE GREEN BUTTON WHEN THE PROGRAM ASKS FOR IT. NOW YOU CAN START CUTTING ! ! !
310. MACH 3 CNC CONTROL HAVE FUN CUTTING ! ! ! DON´T FORGET TO TURN ON THE SPINDLE! ! ! BE SAFE! ! ! https://www.youtube.com/watch?v=1_eTz0Jk6rw
311. MACH 3 TUTORIAL TABLE CNC
312. CONTROLLER MACH 3 CNC CONTROLLER • MOST COMMON CNC CONTROL SOFTWARE • BUNDLED WITH MANY CNC MACHINES • TIMING SENSITIVE • KEEP PC CLEAN! • LAPTOP NOT GOOD (POWER SAVING,ETC) • NEED PARALLE PORT • SUPPORT 2.5D MACHINING FROM BMP/JPEG
313. MACH 3 CNC CONTROL MAIN WINDOWS
314. MACH 3 CNC CONTROL JOG MODE
315. MACH 3 CNC CONTROL CONFIGURATION
316. MACH 3 CNC CONTROL CHOSE UNITS
317. MACH 3 CNC CONTROL CHECK INPUT PINS
318. MACH 3 CNC CONTROL MOTOR SETUP
319. MACH 3 CNC CONTROL RESET BUTTON
320. MACH 3 CNC CONTROL LOAD G-CODE
321. MACH 3 CNC CONTROL EDIT G-CODE
322. MACH 3 CNC CONTROL ZERO WORK COORDINATES
323. MACH 3 CNC CONTROL ROTATE COORDINATE SYSTEM?
324. MACH 3 CNC CONTROL TOOLPATH WINDOW
325. MACH 3 CNC CONTROL OFFSETS
326. MACH 3 CNC CONTROL SETTINGS WINDOWS
327. MACH 3 CNC CONTROL DIAGNOSTICS WINDOW
328. MACH 3 CNC CONTROL RUN G-CODE ! ! !
329. CAM REVIEW • YOU NEED A CAD MODEL • DXF PREFERABLE ( OLDER IS BETTER) • NO UNDERCUTS • REASONABLE SIZE/DEPTH • THINK ABOUT YOUR MATERIAL
330. COMMMON MISTAKES BAD QUALITY CUTTING FIRE ! ! ! OR BREAKING SACRIFICE BASE
331. COMMMON MISTAKES BAD TOLERANCES BAD TROUGH CUTTING
332. FROM CAD TO CAM COMMON SPINDLE SPEEDS DEPENDS ON TYPE OF BITS AND MATERIALS Frequency on VFD Rounds per minute Material x 3000 Aluminium 150 x Model Wax 200 10000 Plastics 270 13500 Most plywood, MDF, and so on. 300 15000 Hardwood DIFFERENTS REQUIREMENTS DEPENDING ON THE PROGRAM WARM UP THE SPINDLE, ONLY IF THE MACHINE HASN´T BEEN USED RECENTLY AND THE BEARING ARE COLD
333. HOW TO ? TROUBLESHOOTING CHATTER - RESONANCE / EIGENFREQUENCY REDUCES ACCURACY AND TOOL LIFE NOISY WORKPIECE CLAMPED PROPERLY? CUT AWAY TOO MUCH? LEAVE BIGGER TABS BASED ON TOOL DEFLECTION? INCREASE RIGIDITY / TOOL DIAMETER REDUCE CUTTING SPEED CHANGE SPINDLE SPEED CHANGE NUMBER OF FLUTES UPCUT / DOWNCUT
334. REF: • https://www.snijlab.nl • http://mkmra2.blogspot.kr/ • http://www.cnccookbook.com/ • http://makezine.com/ • www.fabacademy.org • www.mkmra2.blogspot.kr • http://academy.cba.mit.edu/ • Alex Jahn ( KUZAO81@GMAIL.COM ) by EDUARDO CHAMORRO MARTIN FABINSTRUCTOR@TIDEINSTITUTE.ORG