Commit 592f817f authored by Neil Gershenfeld's avatar Neil Gershenfeld

wip

parent a518d5cd
......@@ -28,18 +28,7 @@ We toolpathed the microspline part at the full ~2" long scale. This would be cut
Given the long machining time, we ultimately decided to do a 1/3-scale test cut from a stack of 0.01" brass sandwiched between 0.25" aluminum. The perimeter of this toolpath measures 17.5 inches. With an expected cut speed of 0.18 inches/minute, the expected cut time is just about 100 minutes or 1 hr 40 mins.
## Micromachining using Zund G-3 L-2500
Despite being a very large-scale tool, the Zund was surprisingly effective at micromachining with its 50kRPM router spindle. To fixture the stock, we first faced a sheet of aluminum to provide a rigid surface. Then we applied PSA tape to both this surface and the underside of the stock. We burnished the tape using a small stainless rod. Then we applied CA glue to the tape and bonded the stock to the substrate.
Using a .030" diameter end mill with amorphous diamond coating (<a href='http://www.harveytool.com/ToolTechInfo.aspx?ToolNumber=72030-C4'>Harvey Tool 72030-C4</a>), we machined the flexure from .020" Aluminum 2024 sheet in 2.5 minutes (comparable to the waterjet). 300um step down, 20 mm/s, 50kRPM.
Here is a 50% scale flexure (.010" beams, .015" gaps) machined from .020" thick Aluminum 2024 sheet using a .015" diameter end mill with amorphous diamond coating (<a href='http://www.harveytool.com/ToolTechInfo.aspx?ToolNumber=72015-C4'>Harvey Tool 72015-C4</a>). This took about 8 minutes, but I think could be run faster.
<img src='images/flexure-0.5-penny.jpg' width=300px>
Here is a paper about micromachining aluminum using tools with diamond-like coatings: <a href='https://pdfs.semanticscholar.org/a9d5/532adaf5fa1b22940a921fc9cdf2ea76b555.pdf'>Diamond coatings for micro end mills: Enabling the dry machining of aluminum at the micro-scale, Heaney et. al.</a>
## ![Micromachining using Zund G-3 L-2500](Zund/README.md)
## [Fablight fiber laser](http://cba.mit.edu/tools/display/?type=tool&id=fablight_3000_laser_cutter)
......@@ -70,4 +59,4 @@ The brown seen on the edges of the piece are burn marks where the machine cut.
![fablight 8](../images/Fablight_08.JPG)
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# Zund
## Micromachining using Zund G-3 L-2500
Despite being a very large-scale tool, the Zund was surprisingly effective at micromachining with its 50kRPM router spindle. To fixture the stock, we first faced a sheet of aluminum to provide a rigid surface. Then we applied PSA tape to both this surface and the underside of the stock. We burnished the tape using a small stainless rod. Then we applied CA glue to the tape and bonded the stock to the substrate.
Using a .030" diameter end mill with amorphous diamond coating (<a href='http://www.harveytool.com/ToolTechInfo.aspx?ToolNumber=72030-C4'>Harvey Tool 72030-C4</a>), we machined the flexure from .020" Aluminum 2024 sheet in 2.5 minutes (comparable to the waterjet). 300um step down, 20 mm/s, 50kRPM.
Here is a 50% scale flexure (.010" beams, .015" gaps) machined from .020" thick Aluminum 2024 sheet using a .015" diameter end mill with amorphous diamond coating (<a href='http://www.harveytool.com/ToolTechInfo.aspx?ToolNumber=72015-C4'>Harvey Tool 72015-C4</a>). This took about 8 minutes, but I think could be run faster.
<img src='images/flexure-0.5-penny.jpg' width=300px>
Here is a paper about micromachining aluminum using tools with diamond-like coatings: <a href='https://pdfs.semanticscholar.org/a9d5/532adaf5fa1b22940a921fc9cdf2ea76b555.pdf'>Diamond coatings for micro end mills: Enabling the dry machining of aluminum at the micro-scale, Heaney et. al.</a>
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