9. Molding and casting¶

Weekly Summary¶

Try multiple materials
Making molding

Assignment¶

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 + three-axis finish cut),
and use it to cast parts

Group Assignment Link¶

Kamakura Group Assignment Week09

Individual assignment¶

Designing a data on Fusion360

I created a nose on Blender at week2

I used this data.

Export with “.obj” on Blender

Open Fusion360

Wax side is 72 × 87 × 37mm

I sketched the box size and 5mm smaller box inside.

expand with 37mm thickness

And go to “Mesh” > Insert Mesh > select nose.obj

Modify > Convert Mesh

Select the box and expand.

Thickness is minas 5mm.

Select both boxes and “Combine”

Combine ;

Target Body : Box

Tool Body : Nose

Operation : Cut

Make another side

Select the small box of sketch > Expand > Tickness-3

Select the box of sketch > Expand > Tickness-5

Select the box of sketch > Expand > Tickness-20

Combine > Cut

Import nose.obj and scale down a bit.

Modify > Scale

Fitting as photo.

Combine > Join the nose and rid

Select big box sketch and Extend

Combine> Cut the top extra part of nose

Export “.stl” for top and bottom part

(Turn off the eye icon on the Bodies folder when you export one side)

Go to “MODELA Player 4”

Drag and Drop the “.stl” data and Set > Model…

Check the size (72×87×37mm) > OK

Check the Origin (Center this time) > OK

Create Roughing process.

Press “New Process”

Select “Roughing” > Next

Select “Top” > Next

Select Tool “3.18 SE4FL EM” > Next

Select “Partial” > Trim the Red area > Next

Select “Scan Lines : X” >Cutting Start Position : Lower left > Next

Cutting-in Amount : 1.5mm > Next

Press “Finish”

Create Finishing process.

Press “New Process” again

Select “Finishing” > Next

Another part is same as Roughing.

Select the Tool “3.18mm SE 4FL BN EM” > Next

Select “Scan Lines X+Y” > Next

Check the Cutting-in Amount and Path Interval (0.2mm) > Next and Finish

Preparing Wax.

I’d like to use Silicon for finishing.

So I used the Wax to pinch Molding.

Cutting the wax in half

Using those mills;

1/8 SE 4FL EM (Flat end mill) for roughing

1/8 SE 4FL BN EM (Ball end mill) for finishing

Write the cross line on the wax to see the middle point.

Setting the wax on “SRM-20”.

And setting the Origin of X, Y, Z.

Start Roughing cutting.

It took 15 min-ish.

Change the mill to Ball end mill and set the Z origin on corner of wax that you don’t cut.

Start Finishing cutting.

But It is stopped on the edge and warning…

The SRM-20 has performed an emergency stop.

- The spindle motor experienced an excessive load or it is not mounted.

Switch the equipment power off, then back on.
To prevent recurrence, revise the cuttting parameters.
(Error :009)

I tried to cut different data which I success to cut before.

But it start to make spin noise…and stop + warning

I opened inside to check the gear inside. It looks okay…

At the end I call customer center of Roland Japan.

Overall, I need to change the motor…

It will take a time (Hope couple days)…

04.01.2022¶

I finally got new motor for SRM-20 spindle.

I changed it and tested…

It sounds great!!!!!!!

Continue to shave finishing.

But it finished half of wax…

why…???

I exported the data from Fusion360.

Measure the mill:

Type : Ball end mill

Unit : Millimeters

Number of flutes : 4

Material : Carbide

Diameter : 3.5mm

Shaft diameter : 3.5mm

Overall length : 57mm

Length below holder : 40mm

Shoulder length : 20mm

Flute length : 19mm

Geometry > Machine Boundary > Selection > Select the edge of top nose

Because I only want to shaving deep part of nose. So I didn’t need to shaving another part.

Clearance Hight > Form > Selection > Top reference > Select the top edge >OK

Actions > Simulate

You can see how to move the mill. And time in “Statistics”

Right click on the set up that you want to export.

Select “Post Process”

Post : Roland RML / roland rml

Name/number : Type any “number” as file name

Output folder : select the folder that you want to save

Unit : Millimeters

Select Machine type MDX-40!!!! It is the same format with SRM-20.

I started to shaving again with this data.

But It seems not reaching the mill to the bottom…

And I found out that I set back the spindle to high spot when I changed the motor.

I should set back it at LOWER hall on the photo!!

And completely okay to reach to the bottom.

I restarted to saving and completed.

Change the Wax and saving the other side with MODELA Player 4 data that because I was prepared first.

Finish the roughing.

Change the mill

I put the mark on FT mill before taking off it that I used for roughing.

And add the mark on the same line on the BN mill.

Because I saved whole top part of Wax when roughing. So I wasn’t able to set the Z origin I thought.

Set the mill as photo

Finished pretty good.

It seems a little bit deeper than I set on the CAM that because I set the mill manually…

I think it wasn’t big deal.

Casting¶

Finally Casting!!

Using Mold Star 16FAST(medium soft silicon)

I used this for casting, because I would like to make my final project nose with silicon.

And It can’t be casting with silicon mold because of stick together. so I needed a heard material mold to silicon casting.

Mixing equal amount (30ml each on this time) and mixing well.

Pour in the silicon to nose.

It is medium soft silicon, so texture wasn’t that hard.

I just tap the wax, then bubble came up.

Set the top part.

And wait 24 hours

Take off the top part carefully.

I could add more silicone for around the nose.

But looks good as nose.

Inside is also good looking.

light on!! (Details on week10 documentation.)

What I learned¶

I really need to pay attention when I use silicon etc…

And I should add some oil to SRM-20 sometime especially after you don’t use it for couple months…

Appendix¶

Last update: May 1, 2022