Commit 632e9a8b by Jake Read

nearly a machine

parent 46367789
......@@ -207,7 +207,7 @@ Talk about a CAD Marathon! Some notes:
- That's a lot of fasteners! I don't even want to count. I'm going to estimate 100 ? A real count gives me 140. A bit of a bummer, these screws are $10 / 50.
## Prepping Your Machine
## Prepping Your (already-existing) Machine
*CRITICAL NOTE*
These linear axis **absolutely** require you to face off the spoilboard on your milling machine. If the XY Plane that your material rests on is not truly parallel to the XY Plane that your gantry moves along<sup>TODO: imperfections note</sup> you will have axis whose chamfered-edges vary in width. This will cause some areas on the gantry to jam up, and others to be loose!
......@@ -229,19 +229,37 @@ Then I got on the shopbot, and ran the job! I set the Z (in the program, it just
![the-face-milling](https://gitlab.cba.mit.edu/jakeread/machineweek/raw/master/images/doing-the-face-milling.gif)
I ended up doing this a second time, with a better toolpath and a bigger bite.
*NOTE* objects in GIF appear faster than real life *NOTE*
![the-face-milling](https://gitlab.cba.mit.edu/jakeread/machineweek/raw/master/images/milling-second-face.jpg)
I ended up doing this a second time, with a better toolpath and a bigger bite.
![milling-second-face](https://gitlab.cba.mit.edu/jakeread/machineweek/raw/master/images/milling-second-face.jpg)
![pic](https://gitlab.cba.mit.edu/jakeread/machineweek/raw/master/images/pic.jpg)
## CAM:
Once I'm ready to do some manufacturing, I start by laying the pieces out - grouping them by material. Most things are in HDPE (or ABS - TBD!). The 'rails' are made with Delrin<sup>9</sup> of a similar thickness, and the pinon is made of thicker Delrin, about 3/4". Here's a chance to optimize your layout for the size of sheet stock you have. Keep in mind you'll want clearance between items for cutout tools, etc.
Once I'm ready to do some manufacturing, I start by grouping solids by material:
![cam-material-groups](https://gitlab.cba.mit.edu/jakeread/machineweek/raw/master/images/cam-material-groups.jpg)
And then laying them out in their respective sheets. Here, I'm using a 4x4' x 3/8" thick sheet of HDPE for 'most' of the machine, and I'm using a 12x24" sheet of Delrin for the guideblocks (slippery things). Additionally, I've got a 3/4"
![cam-material-sheets](https://gitlab.cba.mit.edu/jakeread/machineweek/raw/master/images/cam-material-sheets.jpg)
![laying out the x axis](https://gitlab.cba.mit.edu/jakeread/machineweek/raw/master/images/generate-x-axis-layout.jpg)
Then I brought this into Fusion to do some CAM. From Rhino, select the geometry for one material and Export as a *.step* file. Then you can upload this into Fusion.
![cam-fusion-setup](https://gitlab.cba.mit.edu/jakeread/machineweek/raw/master/images/cam-fusion-setup.jpg)
Now, I'm not going to try to relay exactly what I did - you can take a look at the Fusion files here TODO if you want to check that out. Instead, I'm going to try to (briefly-ish) do a rundown of how to approach CAM - feeds, speeds, fixturing... It's a lot, but hopefully this discussion and the example files above will be enough to get you off on the right foot.
- Setups, wcs, zeroing
- Fixturing
- Tool Selection
- Tool Libraries, Feeds, Speeds Calculator
- Path Type Selection
Now I brought this into Fusion to do some CAM. From Rhino, select the geometry for one material and Export as a *.step* file. Then you can upload this into Fusion.
![generating the x axis](https://gitlab.cba.mit.edu/jakeread/machineweek/raw/master/images/machine-x-axis-setup.jpg)
I go to the CAM section right away, and setup some stock. First thing, our Shopbots are setup in Inches, so check that in the 'units' in the top of the tree. I'll use a 0" offset on top of the model, 0.05" on the bottom (then we can be sure to cut through later on) and a 0.75" offset on the sides - I want to be sure to clear the screws I'll be using to fixture my HDPE sheet.
......@@ -249,6 +267,12 @@ For tools, I set up with a 1/8" 'O-Cutter' - as in, one flute. This is going to
A note on plastics - TODO heat, why single flute, sharp bits, what chips should look like
## Milling
I finished all the milling.
![good-job](https://gitlab.cba.mit.edu/jakeread/machineweek/raw/master/images/good-job.gif)
#### HDPE:
Type | Flutes | Diameter | What For | Feed, XY (IPM) | Feed, Plunge (IPM) | Spindle Speed (RPM)
......@@ -275,10 +299,22 @@ Fly Cutter* | 2 | 2 & 3/8" | Facing the Bed | 130 | 50 | 6500
* I used a 1.5" stepover, and ~ 0.03" stepdown. I set the facing pattern up to only cut on the 'climb side' of the bit - that was pretty critical. I think it's possible to be more aggressive - the bit we have at the CBA is quite dull. The job ran about ~50 minutes.
## Doing the Milling
![milling teeth](https://gitlab.cba.mit.edu/jakeread/machineweek/raw/master/images/milling-teeth.gif)
![milling chamfers](https://gitlab.cba.mit.edu/jakeread/machineweek/raw/master/images/milling-chamfer.gif)
These are the chips you want. Machining plastic should be impressively smooth, silent and buttery.
![the-chips](https://gitlab.cba.mit.edu/jakeread/machineweek/raw/master/images/the-chips-you-want.jpg)
This is the chip-fountain you want:
![the-fountain](https://gitlab.cba.mit.edu/jakeread/machineweek/raw/master/images/the-fountain-you-want.jpg)
## Assembly
- Careful on Blocks! Trim and Align
......
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' delrin-rails-
SA
CN, 90
IF %(25)=1 THEN GOTO UNIT_ERROR
&PWMaterial = 0.375
&PWZorigin = Part Surface
' Trace1
C7
&Tool = 3
C9
TR, 4000
C6
PAUSE 2
JZ, 0.6
J2, 10.1141, 9.5465
J3, 10.1141, 9.5465, 0.6
J3, 10.1141, 9.5465, 0.199
MS, 1.3333, 1.3333
M3, 10.1141, 9.5465, -0.1219
M3, 10.1141, 0.8787, -0.1219
M3, 10.1141, 0.8787, 0.199
J3, 10.1141, 0.8787, 0.2
J3, 10.1141, 9.5465, 0.2
J3, 10.1141, 9.5465, 0.199
M3, 10.1141, 9.5465, -0.2219
M3, 10.1141, 0.8787, -0.2219
M3, 10.1141, 0.8787, 0.199
J3, 10.1141, 0.8787, 0.2
J3, 10.1141, 9.5465, 0.2
J3, 10.1141, 9.5465, 0.199
M3, 10.1141, 9.5465, -0.3219
M3, 10.1141, 0.8787, -0.3219
M3, 10.1141, 0.8787, 0.199
J3, 10.1141, 0.8787, 0.2
J3, 10.6351, 9.5465, 0.2
J3, 10.6351, 9.5465, 0.199
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J3, 12.9265, 9.5465, 0.199
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M3, 13.4475, 0.8787, -0.2219
M3, 13.4475, 0.8787, 0.199
J3, 13.4475, 0.8787, 0.2
J3, 13.4475, 9.5465, 0.2
J3, 13.4475, 9.5465, 0.199
M3, 13.4475, 9.5465, -0.3219
M3, 13.4475, 0.8787, -0.3219
M3, 13.4475, 0.8787, 0.199
J3, 13.4475, 0.8787, 0.2
J3, 15.7389, 11.1213, 0.2
J3, 15.7389, 11.1213, 0.199
M3, 15.7389, 11.1213, -0.1219
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M3, 15.7389, 0.8787, 0.199
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J3, 15.7389, 11.1213, 0.199
M3, 15.7389, 11.1213, -0.2219
M3, 15.7389, 0.8787, -0.2219
M3, 15.7389, 0.8787, 0.199
J3, 15.7389, 0.8787, 0.2
J3, 15.7389, 11.1213, 0.2
J3, 15.7389, 11.1213, 0.199
M3, 15.7389, 11.1213, -0.3219
M3, 15.7389, 0.8787, -0.3219
M3, 15.7389, 0.8787, 0.199
J3, 15.7389, 0.8787, 0.2
J3, 16.2599, 11.1213, 0.2
J3, 16.2599, 11.1213, 0.199
M3, 16.2599, 11.1213, -0.1219
M3, 16.2599, 0.8787, -0.1219
M3, 16.2599, 0.8787, 0.199
J3, 16.2599, 0.8787, 0.2
J3, 16.2599, 11.1213, 0.2
J3, 16.2599, 11.1213, 0.199
M3, 16.2599, 11.1213, -0.2219
M3, 16.2599, 0.8787, -0.2219
M3, 16.2599, 0.8787, 0.199
J3, 16.2599, 0.8787, 0.2
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J3, 16.2599, 11.1213, 0.199
M3, 16.2599, 11.1213, -0.3219
M3, 16.2599, 0.8787, -0.3219
M3, 16.2599, 0.8787, 0.199
J3, 16.2599, 0.8787, 0.6
C7
END
UNIT_ERROR:
CN, 91
END
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This source diff could not be displayed because it is too large. You can view the blob instead.
This source diff could not be displayed because it is too large. You can view the blob instead.
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' hdpe-mb-
SA
CN, 90
IF %(25)=1 THEN GOTO UNIT_ERROR
&PWMaterial = 0.375
&PWZorigin = Part Surface
' Trace5
C7
&Tool = 3
C9
TR, 4500
C6
PAUSE 2
JZ, 0.6
J2, 35.9272, 2.1156
J3, 35.9272, 2.1156, 0.6
J3, 35.9272, 2.1156, 0.199
MS, 1.3333, 1.3333
M3, 35.9272, 2.1156, -0.0535
M3, 0.0728, 2.1156, -0.0535
M3, 0.0728, 2.1156, 0.199
J3, 0.0728, 2.1156, 0.2
J3, 20.0054, 10.53, 0.2
J3, 20.0054, 10.53, 0.199
M3, 20.0054, 10.53, -0.0535
M3, 5.4109, 10.53, -0.0535
M3, 5.4109, 10.53, 0.199
J3, 5.4109, 10.53, 0.2
J3, 20.0054, 13.7909, 0.2
J3, 20.0054, 13.7909, 0.199
M3, 20.0054, 13.7909, -0.0535
M3, 5.4109, 13.7909, -0.0535
M3, 5.4109, 13.7909, 0.199
J3, 5.4109, 13.7909, 0.2
J3, 26.1886, 15.4734, 0.2
J3, 26.1886, 15.4734, 0.199
M3, 26.1886, 15.4734, -0.0535
M3, 2.1453, 15.4734, -0.0535
M3, 2.1453, 15.4734, 0.199
J3, 2.1453, 15.4734, 0.2
J3, 26.1886, 18.7344, 0.2
J3, 26.1886, 18.7344, 0.199
M3, 26.1886, 18.7344, -0.0535
M3, 2.1453, 18.7344, -0.0535
M3, 2.1453, 18.7344, 0.199
J3, 2.1453, 18.7344, 0.2
J3, 35.9272, 21.8844, 0.2
J3, 35.9272, 21.8844, 0.199
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J3, 0.0728, 21.8844, 0.2
J3, 35.9272, 2.1156, 0.2
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J3, 20.0054, 10.53, 0.199
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J3, 2.1453, 15.4734, 0.2
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J3, 26.1886, 18.7344, 0.199
M3, 26.1886, 18.7344, -0.1535
M3, 2.1453, 18.7344, -0.1535
M3, 2.1453, 18.7344, 0.199
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J3, 35.9272, 21.8844, 0.2
J3, 35.9272, 21.8844, 0.199
M3, 35.9272, 21.8844, -0.1535
M3, 0.0728, 21.8844, -0.1535
M3, 0.0728, 21.8844, 0.199
J3, 0.0728, 21.8844, 0.2
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J3, 20.0054, 10.53, 0.199
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M3, 5.4109, 10.53, 0.199
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J3, 20.0054, 13.7909, 0.2
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M3, 5.4109, 13.7909, -0.2535
M3, 5.4109, 13.7909, 0.199
J3, 5.4109, 13.7909, 0.2
J3, 26.1886, 15.4734, 0.2
J3, 26.1886, 15.4734, 0.199
M3, 26.1886, 15.4734, -0.2535
M3, 2.1453, 15.4734, -0.2535
M3, 2.1453, 15.4734, 0.199
J3, 2.1453, 15.4734, 0.2
J3, 26.1886, 18.7344, 0.2
J3, 26.1886, 18.7344, 0.199
M3, 26.1886, 18.7344, -0.2535
M3, 2.1453, 18.7344, -0.2535
M3, 2.1453, 18.7344, 0.199
J3, 2.1453, 18.7344, 0.2
J3, 35.9272, 21.8844, 0.2
J3, 35.9272, 21.8844, 0.199
M3, 35.9272, 21.8844, -0.2535
M3, 0.0728, 21.8844, -0.2535
M3, 0.0728, 21.8844, 0.199
J3, 0.0728, 21.8844, 0.6
C7
END
UNIT_ERROR:
CN, 91
END
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This source diff could not be displayed because it is too large. You can view the blob instead.
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