Week 7:Computer Controlled Machining

Assignment Activities

1.Group Assignment

-do your lab's safety training.

-test runout, alignment, fixturing, speeds, feeds, materials, and toolpaths for your machine.

2.Individual Assignment

make (design+mill+assemble) something big (~meter-scale)

extra credit: don't use fasteners or glue

extra credit: include curved surfaces

1.Group Assignment.

use the test equipment in your lab to observe the operation of a microcontroller circuit board

You can access Group Assignment in details here

Individual Assignment.

-make (design+mill+assemble) something big (~meter-scale)

This week of the computer controlled machining was very interesting to me because I had time to design the cover of my final project though it ends designing like prototype(sample) because of the dimension to check if it can be possible to print it.

When we say Computer-controlled machining which also known as CNC (Computer Numerical Control) machining means a manufacturing process in which a computer controls the movement of tools and machinery to create precise parts and components.

CNC machines are programmed with instructions that dictate how the machine should move and cut the material. The instructions are created using specialized software, which allows the user to design the part or component and generate the necessary code(G-code).The CNC machine then reads the code and executes the instructions, cutting and shaping the material to the desired specifications,more.

After understanding the definition of Computer Numerical Control and the research on what I can design,This directs me to start the whole procedures to make my design touchable,Below are the steps I followed to make the design;

Firstly was identification of something that I needed to cut on CNC,I thought many things to design and for the sake of the period we do have in fabacademy is less i decided to design the cover of prototype of my final project.

and Book shelf.

1.Design My Project Prototype in Solidworks.

After identification of the design,the next thing was to design it ,and for me I used Solidworks because it's among the softwares i'm familiar with,Then I started to sketch my parts,this was first step was to sketch the design by using line,smart dimensions(for dimension of the parts),Below is the sketch on one part (Upper Base Part).

All Parts are here;

After done with the sketch in 2 dimensions(X and Y axis),I proceeded with extruded boss to create the thickness(to have the volume) and it means I used the thickness of the workpiece we used in our node it was 9mm and for the holes I decided to use the clearance of the 0.2 mm in order to assemble them smoothly after cutting on CNC, and I painted it to be something which understable.

All parts are here;

the next After extruding all my parts was remaning thing was to assemble the parts in order to check if it can work on CNC, I can call this testing.

As I said i proceeded with assembling the parts and before This i removed the clearance since it's software can't tolerate 1mm but for cutting I know that I have to add some clearance,and I coloured it with the wood.

Saving Parts in 2D model(.DXF).

After the verification of the assembly and it fitted, I saved the parts with extension of solidworks,and also for machining I saved it with DXF extension.

after clicking on save as file with an extension of DXF,I selected the face for 2D design and to be printed by selecting the face and clicking ctrl+8 for normal position.

The final output of the dxf file was 2D design which is the readable format of the our machine or you can save as pdf it's another option.

For all Parts;

Creating Tool Path in Vcarve Pro software.

FirstlyVcarve Pro: is basically software program used for creating 2D and 3D designs for CNC machines. It is commonly used in woodworking, sign-making, and engraving industries.

It provides a user-friendly interface for designing and programming CNC machines. It allows you to import vector graphics files, such as EPS, AI, DXF, and PDF, and then create toolpaths to cut or carve the design into a material, such as wood, plastic, or metal, more.

After saving DXF file(2dimensions)The next thing was to go on the machine and cut design, below are the steps I followed;

I first downloaded the software which we use to insert the 2D designs is called "V-carve pro" and then set some parameters according to the design, workpiece and cuting tool, here's the link, and I used the official license of my node.

After the installation of the software,I had to open it and create new file,by setting the parameters I started with the bed size of shop bot CNC which has width:2440 mm and height:1220 and other parameters I used default terms,and then ends by clicking ok.

Next was the to insert the parts by dragging the into the software in the Vinyl_cutter and set the parameters.

After inserting the bed size,I continued with parameters for setting uniform parameters and I have to first join the open vectors, to proceed with other modification.

Next was to group all vectors, so that it counts like one component,so I have to select all vectors and click on group tool at the left side below.

Next, i used tool called "dog-bone",The purpose of adding a dog bone to a corner is to ensure that the design's intended size and shape are maintained, even after cutting. Without a dog bone, the CNC machine would cut a slightly smaller design than the one intended due to the rounded corners.

the next parameters was to set toolpaths and because for me was to cut the parts and I selected the feature(profile tool path) this tool is used for cutting through all.

after selecting profile toolpath feature, I proceeded with parameters of cutting, first was the depth of cut , and it depends on the thickness of the workpiece(9mm) and I added the some tolerance for easy removing of the desired part on the workpiece and it becomes cutting depth 9.3 while starting depth is 0 , which means that the tool will reach on the sacrificial work-piece.

next was to select the tool to be used and we have to insert the diameter of the tool,depth of cut(is the length of the side of the flutes that are actually cutting),step over( one toolpath being offset from another by some distance) the spindle speed(means the speed of the tool to rotate around the axis), feed rate(is the distance which the cutting tool during one spindle revolution),plunge rate(the speed at which the router bit is driven down (or plunged) into the material when starting a cut), and click apply and ok.

Next step is to edit passes, this requires an exprience because according to the tool you use and the thickness of the work-piece affects you to know how many times to pass the same points, for me I used 4 passes for better output with smooth surfaces.

Next is machine vectors where I have to click the path tool will take (it can be inside,outside or on the line), this affects the clearance I take and the decision that I take according to the experiment, when there are holes in the parts I will use inside and for the out frame is outside.

next is to tabs, in order for the cutted parts to not bounce while CNC continues to cut means there are small portion left uncutted to help part to remain in the position,for me I used 2 tabs

The next thing is to calculate according to parameters I have setted,once you click button"calcualte" they will warning showing depth of cut you have selected and you have to click ok button.

Then software can estimate the time it will take to cut the whole job.

Next is the output it will give on the table and how CNC will cut with red lines is the path.

Next is to save tool path by clicking on save icon.

Save the file with extension of shopbot.

CNC controls and cutting.

As our CNC machine is SHOPBOT machines are a type of CNC machine designed and manufactured by ShopBot Tools, Inc. ShopBot CNC machines are known for their durability, reliability, and versatility, making them popular among makers, small businesses, and educational institutions,Explore more about shopbot CNC and it's specifications,here

Then I proceeded with CNC controlling software called"Shopbot Easy", and before setting the origin of CNC starting, I have to set the workpiece(MDF of 9mm thicknessgit)on the bed with leveling it and then fix the workpiece on the bed by drilling machine, after insert the drill bit in the tool post and fix it tightly.

then set the starting point of CNC using shopbot Easy software ,you move the tool until it reaches where you want it, and save zero axes which means origin.

and then click cut part and start, then machine will automatically start cutting.

these are pictures while cutting and removing cutted parts on the bed.

After I had to make finished surface by using sand paper, and then assembling them smoothly

The Final Output was this After Assembling the parts, was my BMI prototype cover.

Video of CNC cutting My parts.

1.Design Bookshelf in Solidworks.

All Parts are here;

All parts are here;

the next After extruding all my parts was remaning thing was to assemble the parts in order to check if it can work on CNC, I can call this testing.

Saving Parts in 2D model(.DXF).

After the verification of the assembly and it fitted, I saved the parts with extension of solidworks,and also for machining I saved it with DXF extension.

after clicking on save as file with an extension of DXF,I selected the face for 2D design and to be printed by selecting the face and clicking ctrl+8 for normal position.

The final output of the dxf file was 2D design which is the readable format of the our machine or you can save as pdf it's another option.

For all Parts;

Creating Tool Path in Vcarve Pro software.

FirstlyVcarve Pro: is basically software program used for creating 2D and 3D designs for CNC machines. It is commonly used in woodworking, sign-making, and engraving industries.

After saving DXF file(2dimensions)The next thing was to go on the machine and cut design, below are the steps I followed;

I first downloaded the software which we use to insert the 2D designs is called "V-carve pro" and then set some parameters according to the design, workpiece and cuting tool, here's the link, and I used the official license of my node.

After the installation of the software,I had to open it and create new file,by setting the parameters I started with the bed size of shop bot CNC which has width:2440 mm and height:1220 and other parameters I used default terms,and then ends by clicking ok.

Next was the to insert the parts by dragging the into the software in the Vinyl_cutter and set the parameters.

After inserting the bed size,I continued with parameters for setting uniform parameters and I have to first join the open vectors, to proceed with other modification.

Next was to group all vectors, so that it counts like one component,so I have to select all vectors and click on group tool at the left side below.

Next, i used tool called "dog-bone",The purpose of adding a dog bone to a corner is to ensure that the design's intended size and shape are maintained, even after cutting. Without a dog bone, the CNC machine would cut a slightly smaller design than the one intended due to the rounded corners.

the next parameters was to set toolpaths and because for me was to cut the parts and I selected the feature(profile tool path) this tool is used for cutting through all.

after selecting profile toolpath feature, I proceeded with parameters of cutting, first was the depth of cut , and it depends on the thickness of the workpiece(9mm) and I added the some tolerance for easy removing of the desired part on the workpiece and it becomes cutting depth 9.3 while starting depth is 0 , which means that the tool will reach on the sacrificial work-piece.

next was to select the tool to be used and we have to insert the diameter of the tool,depth of cut(is the length of the side of the flutes that are actually cutting),step over( one toolpath being offset from another by some distance) the spindle speed(means the speed of the tool to rotate around the axis), feed rate(is the distance which the cutting tool during one spindle revolution),plunge rate(the speed at which the router bit is driven down (or plunged) into the material when starting a cut), and click apply and ok.

Next step is to edit passes, this requires an exprience because according to the tool you use and the thickness of the work-piece affects you to know how many times to pass the same points, for me I used 4 passes for better output with smooth surfaces.

Next is machine vectors where I have to click the path tool will take (it can be inside,outside or on the line), this affects the clearance I take and the decision that I take according to the experiment, when there are holes in the parts I will use inside and for the out frame is outside.

next is to tabs, in order for the cutted parts to not bounce while CNC continues to cut means there are small portion left uncutted to help part to remain in the position,for me I used 2 tabs

The next thing is to calculate according to parameters I have setted,once you click button"calcualte" they will warning showing depth of cut you have selected and you have to click ok button.

Next is to save tool path by clicking on save icon.

CNC controls and cutting.

Then I proceeded with CNC controlling software called"Shopbot Easy", and before setting the origin of CNC starting, I have to set the workpiece(MDF of 9mm thicknessgit)on the bed with leveling it and then fix the workpiece on the bed by drilling machine, after insert the drill bit in the tool post and fix it tightly,then set the starting point of CNC using shopbot Easy software ,you move the tool until it reaches where you want it, and save zero axes which means origin,and then click cut part and start, then machine will automatically start cutting.

After I had to make finished surface by using sand paper, and then assembling them smoothly,the Final Output was this After Assembling the parts, was my BMI prototype cover.

hereyou can download the files.