16. Molding and casting¶

Reguirements¶

group assignment:¶

  review the safety data sheets for each of your molding and casting materials,
     then make and compare test casts with each of them

individual assignment:¶

  design a mold around the stock and tooling that you'll be using,
     mill it (rough cut + (at least) three-axis finish cut),
     and use it to cast parts

Group project¶

The members of the group:

Achille Achille’s site
Anssi Anssi’s site
Jari Jari’s site
Hannu

This week assignment is documented in Anssi Heikkinen page

Individual project¶

My object was half ball (hemisphere). I designed it using Autodesk Fusion 360.

Design¶

Step 1. I started by drawinf a sketch. I drew cross-section of objet and mold edges 2-point Rectangle and Center Diameter Circle

Step 2. Then I Removed lines so that I got cross-section (object and mold edges).

Step 3. Then I removed left side of cross-section. After that my sketch was ready and I clicked Finnish Sketch button.

Step 4. Then I use Revolve command to made 3d object. I rotated sketch around z-axis

Step 5. At last I got 3d model to make milling data. I exported model in STL format.

Milling process¶

I made milling with Roland SRM 20. I used same Milling machine in Electronics production week. Before I canned mill I made tree different milling files: Surfacing, Roughing and Finishing files. I used Roland’s MODELA Player 4 program to make files.

Milling files with MODELA Player 4¶

Step 1. First I opened STL file. Then I started to greate new process. Note you have chose right material (Modeling wax). I checked Size and Orientation.

Step 2. Then I cheked Origin in Model window. First I set origin to center but later I changed to Lower left.

Step 3. I opened New Process Creation window. I choosen Roughing and clicked Next button.

Step 4. Then I selected Top (+Z) to the cutting surface and clicked Next button.

Step 5. Next I chose 3 mm Square to tool and clicked Next button.

Step 6. Then I setted the cutting area and clicked Next button.

Step 7. I chose Up Cut to Contour Lines and clicked Next button.

Step 8. Then I set the cutting parameters and clicked Next button.

Step 9. And finaly I named process and clicked Finish button.

Next I made Finishing file and Surfacing file in the same way. I had to flatten the surfacing of the machinable wax because it was rugged. And finally I got Surfacing1.prn, Roughing1.prn and Finishing1.prn