Posted on FEB 14, 2018 as Assignment 4/Week 4

Computer Controlled Cutting

Computer Controlled Cutting

1. Calculate kerf of laser machine
2. Design a parametric design as press fit
3. Assemble the press fit
4. Vinyl Cutting

Kerf Calculation: Group Assignment

SIL Engraver

The machine works on a standard single phase AC supply of 230-240V there have been a special setup made of electric components, for fluctuating the electrical volts it needed the stabilizer and for backup power it has connected with on line UPS. (Images are in the below:)

The machine works on the basic principle of photon generation i.e the laser is created as result of electron bombardment over the anode surface. The entire process takes place in a chamber filled with CO2 which usually acts as a medium of flow for the electrons The light is transmitted to the engraver through various mirrors which work on the principle of a periscope, which is further focused using a concave lens, in the engraver. It has a bed size of 3 X 2 feet

For this, the group tested following things...

Kerf at different power and speed for MDF:- we are tested 8 squares and tested them at different speed between 22 to 28 and power between 55 to 67, and we found the best result at speed 26 and power of 59, where the kerf achieved was only 0.15mm

Acrylic 6mm: we made two patterns one with varying speed, another is different speed. The first pattern was having a constant power of 62% and speed ranging between 8 to 12. other has speed of 8 and the power ranging between 55% to 70% For this speed 8 and power at 68% is best result that was we found with the least kerf of 0.3mm.

Problem during Engraving

1. The engraver has a very high amount of kerf lining, this was mostly seen due to constant loss of focus after a certain use of the engraver
2. The kerf seen vertically is different than the kerf seen horizontally

3. The parameter of the settings changed on the panel board of the machine differ that to the parameters, considered in the software (RD Works)

Epilog Engraver: Group Assignment

This is the smaller than the SIL but this functionality is more more better than the SIL, Those include

1. A precision with the kerf on every side
2. Its made easy to command the engraver through many formats, including *.dxf and *.cdr, or even pdf
3. The machine has the ability to engrave on various layers in the 3rd axis of geometry and has very negligible kerf

For this assignment we are going to test the similar pattern design and by the once we kept constant speed, and later constant power for differentiation the kerf We uses the different color boundary and specified individually .

There are few more steps required in oder to work with Epilog, which are mentioned below:-

1. Once done with the adjustments of the design hit Ctrl + P, to open a menu as shown below, and follow the steps in the image

2. Once done with that select preferences to get a menu as shown below and manipulate the parameters (guided in the image) as required.

3. Then just hit enter, set the origin on the engraver manually and press go. Hence we made patterns for kerf calculation and got following results for individuals

MDF:For this we decided to keep the power constant, and vary the speed between the range of 30 to 60 percent as shown in the image about color mapping

The following were the results we received about the deflection in the kerf Out of which we concluded that 100% power and 50% speed was ideal for minimal kerf of 0.14mm

Acrylic For this assessment we did the same where we used same shapes of 40mm X 40mm with changing color maps, as shown below For this we had to feed the machine with multiple passes, which actually exceeded up to 8 passes, for the powers and speeds we wanted to test

After 7 to 8 passes we got the cut outs to produce following results.

Press fit: Solidworks/Fusion 360 (slicer)

First I used solidworks for designing press fit and did a design but i made a mistake for designing without parametric method.

Then I design another small press fit by using Fusion 360 and besides I used and plugin of Fusion 360 Slicer for making press fit

1. Solid block was design according to mobile alignment with sketch.

2. The 3D design now transfer to slicer360 (A plugin for Fusion360)

3. Cutting in horizontally and vertically by slicer

In slicer here the parameter are: a. Construction Technique: Interlocked slices; b.Slice Distribution: Method-By Count 5/5; Notch factor:-0.1; Notch Angle:45, Relief Type: Square. Thickness: 2.50mm, Slot offset: 0.254mm

4. Finally I got this file and cut it in laser.

5.Now save this DXF file in local computer

6. Laser cutting the design by SIL Engraver

7. Assembly the cutting parts after laser cut

This is the second design for press fit in parametric design

Sketch of the press fit square

1.Sketching the press-fit kit one part which has the 8 joint in one square

2. This is the second part and fix with the first part as jointing the other part to make a shape

3. Design transfer in corelDraw and give the command to cut it by EPILOG laser

4. This is the epilog preference panel to cutting the MDF board

5. Now laser is online to cut the MDF board as design

6.Final cut by laser, The epilog its need 3 passes for proper cutting of the board

7. Finally assebly the pressfit card to make some thing looks any toys or any shape, This Robot Shape for KIDS.

Vinyl Cutting

This is my first vinyl cutting, before cutting I have curiosity about vinyl how it's works. First i make a text design by illustrator named "FAB ACADEMy2018, VIGYAN ASHRAM". make a .png file and I use Fab Module to run the program. Now setting the vinyl paper and home origin the blade according the paper. But I made mistake here I don't check the vinyl where it is good or i has any previous cut. so after final cut when I peeling out by tweezer then I found a cut in V which is destroy my whole design. Image attached in below

After that i decided that to make another design for cutting by vinyl cutter. So I make solid design by illustrator and convert is .png, Whole process are describe in below.

1. Making vinyl cutting as like any sticker, here I try to make some TEXT based quotes like this year academy 2018

2. After making this and converting in .png and send it fab module to make .rml file for cutting this.

3. Vinyl is setup on the cutter and blade also setup with force of 80 and velocity 2 (cm/2)

4. After cutting this I pasted it on a PC of LAB

5. This is a another design for cutting by vinyl for my coffee mug
6. First, I make it by Illustrator, making ellipse and use PEN tools to make another outline as round as ellipse