About Me Assignments Projects

Week 12 Assignment

MOULDING AND CASTING

What an exiting week this is, as i am a tool and die maker by proffesion this week is really interesting for me

Group Assignment Week 12

Sample Image Group Assignment

SAFETY FIRST

Safety was the top priority as I rolled into this week, especially with milling, silicon, and resin casting on the agenda. With these processes, ensuring a safe working environment is crucial to protect both personnel and equipment. From wearing appropriate personal protective equipment (PPE) to following established safety protocols, every step was taken to minimize risks. When dealing with milling, attention was given to tool handling and machine operation to prevent accidents. For silicon and resin casting, proper ventilation and handling procedures were implemented to avoid exposure to harmful fumes and chemicals. By prioritizing safety, we aimed to create a workspace where everyone could focus on their tasks with peace of mind, knowing that their well-being was safeguarded.

Sample Image

STARTING WITH A DESIGN

so as this week i planned to make a small surf board as i really like surfing and skim boarding, and it will look a cool desktop toy

Sample Image

ASSESABLITY CHECK

I conducted a thorough accessibility check to ensure that the components are easily machinable, specifically focusing on tool accessibility. Using advanced CAD software and physical prototypes, I meticulously examined the design to guarantee that machining operations could be performed efficiently.

Sample Image

CAM

Utilizing Fusion 360's CAM capabilities, I'm preparing my surfboard design for manufacturing on a DPM RX 2 Vertical Milling Machine using machining wax blocks.

In Fusion 360, the CAM workspace facilitates milling operations, allowing users to select cutting tools, configure material properties, and set machining parameters. Within this environment, users generate and adjust toolpaths to direct the cutting tool's movements. Additionally, Fusion 360 offers simulation features to verify the accuracy of toolpaths and ensure alignment with desired specifications. Once finalized and validated, the toolpaths are exported as G-code, a programming language for CNC machines, guiding the milling machine to produce the desired part.

CAM Setup

  1. Navigate to the Manufacturing workspace by selecting Manufacturing Environment from the Machining dropdown menu.
  2. Configure the machining interface by selecting Setup > New Setup. Establish the stock and axes, setting the Work Coordinate Systems (WCS) offset to 1.
Sample Image

Tool Selection

  1. Access the Manage > Tool Library to add necessary tools to the library, including those from the FabLab.

Operations

Sample Image Sample Image

Additional Settings

Simulation

After setting each operation, simulate by right-clicking on the operation.

Sample Image

Post Processing

  1. Right-click on the job and select "Post Process."
  2. Specify the G-code's save location, select appropriate tools, and export the G-code. In this case, only 3 sets of G-code are generated as the second and third operations use the same tool.

MACHINE INTRODCUTION

DPM RX2 Vertical Milling Machine

The DPM RX2 Vertical Milling Machine is a robust and versatile tool used in various manufacturing settings for precision milling operations. It comes with a spacious table measuring 49" x 9", providing ample space for workpieces. Additionally, it has 3 T-slots, each measuring 0.63" x 2.5", offering flexibility in workholding setups. The machine provides a generous travel capacity of 31" in the X-axis, 16" in the Y-axis, and 22" in the Z-axis, enabling machining of large parts or multiple smaller parts in a single setup. With a quill diameter of 3 3/8" and a maximum quill travel of 5", it ensures stability and accuracy during drilling operations, allowing for deep hole drilling and versatile machining operations. The machine is equipped with an R8 spindle taper, which is commonly used in vertical milling machines and provides a secure and rigid connection between the spindle and the tooling. Sample Image

MACHINE SPECIFICATION CHART

Parameter Value
Table Size 49″ x 9″
T-Slots (Number x Width) 3 x .63″ x 2.5″
Travel (X, Y, Z Axis)* 31″ x 16″ x 22″
Quill Diameter 3 3/8″
Maximum Quill Travel 5″
Spindle Taper R8
Spindle Speed Range RPM 40 - 600, 300 - 5000
Spindle Center to Column Face 18.5″
Head Swivel (side to side) +/- 90°
Quill Feeds per Revolution of Spindle 0.0015/0.003/0.006″
Spindle Motor HP 3 HP
Power Requirements 200-240V, 3P, 27A
Maximum Weight of Workpiece 1320 lbs
Height Of Table From Bottom Of Bed 36.75″
Max Spindle Nose To Table 25.5″
Min Height 86.625″
Max Height 98.75″
Width Of Machine Including Table 71.25″
Overall Length With Electric Door Closed 73.31″
Overall Length With Electrical Door Open 93.88″
Overall Width Inc Full Table Traverse 102.53″
Footprint Of Machine 23.13″ x 40.5″
Weight Net / Shipping Lbs. 3200 / 3500
Rapid Traverse X, Y, Z Mechanical Handwheels: 250 IPM on X, Y and Z
Electronic Handwheels: 400 IPM on X and Y, 250 IPM on Z
Coolant Reservoir Capacity 10 gallons
Drilling Max Capacity (diameter) 1″ dia.
Milling Max Capacity 3 inch³/min
Tapping Max Capacity ¾ - 10

MARCHING OPERATION

Surfboard Milling Process

STOCK MATERIAL

i used a block of machining wax to machine the mould out of

Sample Image

Setting up the Machine

Before milling, several operations must be completed. Begin by setting the origin: attach the edge finder and adjust the tool offset. Once set, load the program and adjust the tool offset for each tool used to ensure precise machining.

Edge Finder

Secure the material, then use Manual wheels or the machine interface with an edge finder to establish X and Y coordinates. Next, set the absolute X and Y axes. Adjust the Z axis by lowering the tool, and set the reference Z axis by moving the tool downward again to maintain the fixed origin during tool changes.

Sample Image

X and Y Jog

Adjust the X and Y axes using the rotary handles.

Sample Image

Z Jog

Use the rotary handle to adjust the Z axis; lock the movement with a small lever.

Sample Image

Coolant

For wax, use only air to remove chips; coolant is unnecessary.

Sample Image

In and Out

Press "Out" to remove the tool module from the spindle and "In" to add a new module.

Sample Image

Uploading Program and Tool Setup

Once the origin is set, the next step is to upload the program. Click on "Prog In/Out" on the screen and add the file. Then, add the tool details such as diameter, number of flutes, etc., by clicking on "Tool Table". Before running the milling codes directly, a "trial run" can be performed to ensure all parameters are correct and the work is done properly. Once satisfied, click on "CNC Run" for the machine to start milling.

machining Processes

Sample Image

Visual Representation and Monitoring

The machine provides an extra feature of giving a live visual representation of the toolpath during the process, which helps in monitoring and optimizing the milling process.

Sample Image

Completion and Finishing

i repeted this procces for the other 2 setups using thier respective milling bits

this is the final output that i have recived and it works well for the job

Sample Image

MOULD MAKING

Sample Image

Silicone RTV 1010 is a two-component silicone rubber designed for mold making and prototyping. It includes a silicone rubber base and a curing agent that must be mixed in a precise ratio to initiate the curing process.I used a ratio of 30 ml of curing agent for every 1000 ml of silicone rubber base, which successfully hardened the mold.

To determine the amount of silicone needed, I first measured the approximate volume of the surfboard using water. Based on this measurement, I calculated the required amount of silicone and added the appropriate amount of hardener to ensure proper curing. Once the silicone mixture was ready, I poured it into the mold, ensuring even coverage and eliminating any air bubbles. To aid in releasing the cured mold from the surfboard, I applied a mold release spray. This process resulted in a high-quality mold that accurately replicated the shape of the surfboard, ready for casting.

Sample Image

i used around 130 grams of slilcon and it was said to use 30grams of hardener for 1000grams of silicon so did teh math and found out i need around 3.9 milligrams

i used a heavy-duty silicon spray to make sure that the mould will be easy to remove

then i pored the silicon into my wax master mould

Sample Image

and i let it cure for 24 hrs and then i removed the mould using compressed air it made it very easy and came out easyly

Sample Image Sample Image

CASTING

Sample Image

Aditya Ultra Clear Cast Epoxy 37

the resin i used is Aditya Ultra Clear Cast Epoxy 37 which is a general quality epoxy for table top casting. It is comparable to any epoxy available in the market.

It can also be cast into Silicone Moulds to Create Crafts. Pigments are available to make Opaque Colour Castings. It comes in Part A and Part B.

Features

i followed the same procedure above to determine the volume like teh silicon

Then, I used a 2:1 resin mixture to cast the part. I mixed the resin and added the necessary colorant, thoroughly mixing it until the desired color was achieved. Once the resin was ready, I poured it into the prepared silicone mold, ensuring complete coverage and filling any intricate details.

i used around 30 milligrams of resin to cast the surfboard, and i slowly poured the resin to the silicon mould

Sample Image
Sample Image

after poring i found out there are some bubbles visible so i planed a diy method to fix it

DEGASSING

Before pouring the resin, I used our DIY degassing chamber, which is made from a pressure cooker (india is not for beginners). I employed a vacuum pump to pull out the air and degas my resin, ensuring a smooth and bubble-free casting.

Sample Image

When I degassed the part after it was molded, the resin started to overflow. This overflow occurred because the degassing process caused the resin to expand and exceed the capacity of the mold, resulting in spillage.

Sample Image

and it took around 24hrs to harden but i was stillflexing so i kept it for 72 hours and it was hardened well

Sample Image

volla the final surfboard looks nice and detailed

Sample Image

DOWNLOAD DESIGN

download the design here