test runout, alignment, speeds, feeds, and toolpaths for your machine
On the to do list. At the moment, I do not have access to a milling machine.
There are still problems with the delivery of our large CNC machines. But I got the chance to use the CNC machine from Daniele. For this I have to take a somewhat longer trip. But with a little effort I got the wood into the car. So that I could verify this assiment.
To test whether the machine is correctly aligned. I will mill a square with 50 cm. Then I will move the machine to the other end in 50 cm steps. Then I let it return. And draw the same square again. If I don't have any misalignment, everything will fit.
I can do this test with the remote control of the Mahcine. I set the steps for x and y to 50 mm for the square.
At first sight, the device already looks good.
The external dimensions are 55 mm.
The inside dimensions are 44 mm.
Here you can see the result after I moved the machine. Here you can see an offset in y direction that is my mistake I forgot to switch to stepwise movement.
Here we have again 55 mm so there is no offset in the machine.
And the internal measures also agree with the first measurement.
It should also be mentioned that this week our laboratory was closed since Monday because of Corona. So I packed our company car with everything I might need for the next few weeks.
Since our fablab is closed since this week, I could only take some materials and machines with me, including the Shaper Origin. With this I wanted to make a few first tests and I had so much fun that I built a little bit further.
I built the first prototype with LEGO.
After I built the prototype. I started to work and step by step I build my soapbox and continued to construct.
Before I can start milling I have selected all the materials I need. Goggles, ear protectors and the necessary tools.
I connect a vacuum cleaner for two reasons: I want to be able to see what I'm doing, and workplace safety. An accumulation of wood chips could become a fire hazard.
First I have to install the appropriate milling head. To do this I disconnect the milling head from the power supply and remove the screw with an Allen key.
Then I can carefully remove the spindle upwards.
Now I can change the grinder.
Then I apply the shaving tape to my workpiece. Then I scan this surface with the original. To do this, I select the 2-symbol from above in the right menu and click on new scan.
Let us come to the third point in the menu for designing. Since I already have a finished sketch as .svg I can design this shop.
Now I choose the sketch I want to mill. The different colours of the lines and baskets indicate how I want to mill them, whether inside, outside, or on the line.
Next, I place the object. For this purpose I move the milling machine to the place where I want to mill later and then press 'place'.
Finally, I can start milling. For this purpose, I also have to chose the appropriate settings. Because the material is 18mm thick I will mill 2 times, the first time to a depth of 9mm and then to 18mm. I use a 6 mm milling cutter.
First I built myself a table to which I could attach the boards.
Then I started dovetailing/galvanizing the horizontal sides of my box.
Tested if the teeth of bottom and side panel fit together. Since no screws or familiar utensiles were allowed, the teeth had to fit very tight to stick together, therefore a hammer was needed to stick the two panels together.
Finished side panel with the neccessary teeth as well as the typical design of my final project.
Finished side panel with the neccessary teeth as well as the typical design of my final project.
The box is ready assembled and everything is super tight.
At the beginning I couldn't imagine exactly how everything should be built so I hadn't made any holes in the base.
Further holes were added.
To work with the Shaper Origin I first have to apply the shaper tape so that the router can orient itself.
In order to be able to move the steering later, I only mill up to half the thickness of the wood and leave a pin in the middle.
Of course I need that on both sides.
First part.
Here are once all the parts I need for the mobile steering.
Here you can see how I fixed the shafts on the underside by putting wood bolts through the holes.
First test sitting.
In this video you can see my building progress, what the finished vehicle looks like, and how it works.
By now, it has become dark and there is still a lot to do.
In the second video you can see how I drive my soapbox for the first time. It already works very well.
The driving is excellent. I still have to rework the steering, because at the moment it can only be operated with very high power. Additionally it would be good if I would install a brake ;)
Now I have to wait until it is possible to work in the fablab again. I would like to cut the seat with a milling machine, otherwise it will be too much work. I want to cut the wood in a way that it becomes flexible and doing that by hand would be very inefficient. Below you can see a sketch.
I try to create the flexible seat area again with the pattern of my system, this time only with the half blocks. Of course I have to do some tests when the labs are open again.
Now I have the chance to use a large cnc.
As the assiment is already a few weeks ago I changed my plan what I want to mill.
Our fablab is moving soon and we will have more space.
So we need new furniture.
We will have more space but we all know that space will never be enough.
Therefore we need furniture that is as flexible as possible.
Therefore I have designed a prototype for a modular high, cabinet, table, ceiling, grandstand system.
First I have to place all my parts so that it fits on the milling machine.
In the setup i set up the coordinate system and determine which are my models.
On the next page I lay down my raw part.
Next I have to choose how I want to mill. I start with the things that are not to be milled through completely. For this I choose 2D pocket.
I have to decide which tool I want to use. For this purpose I create the appropriate tool from scratch.
I use an flat end mill. I can set this and everything else in this window.
In this window I can select what I want to mill and I can select the bottom side of my milling machine so that I don't have to make any settings later.
Since I have chosen the right settings in the last step, I do not have to change anything here.
Since I cannot mill the height at once, I set the depth cuts to 3mm with each cut.
Then I set the same for the other bags. For the cuts I set the contour but otherwise the same settings as for the 2D pocket.
Now we come to the big CNC.
First I put on the material to not cut into the milling machine I put a sacrificial plate in between.
Afterwards I fix the material with screws on the heel so that it does not slip.
Now I move the milling machine to the lower left corner of my raw material.
Then I set this digit as x and y zero point.
And save it
The Z-axis can be calibrated with a sensor by placing it under the milling cutter and starting the calibration. The setting is then automatically saved.
The machine is started from this box. And also the milling speed is adjusted.
Now I can select the USB stick with the remote control.
Then I choose from which file I want to start.
Last stepp is to press Start. An look the hole time if evry thing works.
First I mill the pockets because the upper edge looked frayed I have the milling speed manually reduced by 20 %.
Then I milled out the parts.
Finally I have to remove the supports with hammer and maisel.
Now I get to put the pieces together.
Now i have all my parts.
The milling cutter was not suitable for wood so the top of the wood is frayed. Therefore I sanded the boards.
The parts fit together very well.
I then glued these together.
So that the sitting is not too hard I pad the covers.
The textile looks a bit old-fashioned but we still had dne in the lab.
Then I also glued the part together.
Here you can see a small stool with storage space.
You can stack the blocks.
You can also build a bank. From the system you can build other things if you have more blocks. For example cupboards, chests of drawers, tables and much more.
She's stable enough.
