WEEK 07 Computer-Controlled Machining

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All group assignments can be found on the official website of FAB LAB BENFICA

TRAINING

INTRODUCTION:

Hobby CNC machining and resin casting is a very good document explaining how to work with CNC machines.

IMPORTANT SAFETY RULES:

During the CNC cutting process, safety is a top priority. I received proper training on both the software and hardware. I familiarized myself with the key emergency protocols, including how to use the emergency stop button, and ensured a colleague was nearby to assist if needed.

Safety button:

In situations where it is necessary to stop the machine, the emergency button must be activated immediately

Here are some key safety measures I followed:

• I wore safety glasses to protect against splinters and dust, closed-toe shoes, and avoided loose clothing and accessories. Long hair needs to be tied back securely.
• No gloves during operation: While gloves can be useful for material handling, they are not worn during machine operation, as they pose a serious entanglement risk.
• Look, Listen, Smell: I continuously monitored the machine for abnormal sounds, burning smells, or irregular tool behavior.
• Tool integrity: I made sure the end mill was in good condition and properly tightened before starting the job.
• Stay clear: I never reached into the work area while the machine was active. My hands remained away from the cutting tool at all times.
• Mental state: I only operated the CNC when I was fully alert and focused. Fatigue or distraction can increase the risk of mistakes and accidents.

These practices ensured a safe and controlled environment while using powerful equipment like the CNC router.

How to Use the CNC Machine

The Ouplan 3020 ATC CNC is equipped with an automatic tool change (ATC) system. This capability ensures greater efficiency and versatility, as it allows the tools to be changed quickly and automatically according to the needs of the project.

The diversity of cutters allows the machine to perform everything from simple cuts to complex shaping, increasing the quality and precision of the work.

Setting up and preparing the machine:

Turn on the machine:

Switching on the compressor

Before starting any stage of the machine's operation, the compressor must be switched on:

• the red button button (above a warning sign) must be pressed;

  

• The orange button must be turned on

  

Preparing the plate for cutting

Before you can start cutting, the material to be used must be securely fixed to the table. This requires

• Place the plate in the desired position and as straight as possible;
• Use the clamps provided to secure the plate to the table - place the head of the screw in the grooves in the table and a remnant of valchromat to press down if necessary

Preparing the machine for cutting

When you turn on the computer, click on the scissors symbol at the top of the screen. This symbol gives access to the software used to configure all the machine's settings. Once you have opened the software, you need to open the document to be cut.

symbol giving access to the software

icon to open the files

choose the file you want

Once the file is open, it's time to prepare the machine for cutting. The following steps must be followed:

• Always start with the "origin" symbol

  

• Choose the option "Tool loading" > "Unload tool in use" (if another tool is required) > Change/load tool number x" > "ok"

  

  

• Configure the tool length measurement - "Automatically measure tool length";

  

  

Cutting

With the tool previously calibrated and its length measured, the part cutting phase begins. This process is controlled via the InoControl software, where the operator enters the parameters needed to start the cutting path.

• In the Manual Control window we can adjust the positions of the axes (X, Y and Z), set the tool speed and start the movement with the "Run" button. It also allows you to manually select the tool to be used and raise or lower the machine head as required.

• Through the "Jog" menu, we can ensure that the machine starts cutting at the exact point defined by the G-code. The correct positioning of the axes guarantees the precision of the cut, respecting the programmed coordinates and depths.

  

• The easiest way to adjust their position is via the computer keyboard itself. Using the arrows, we position the cutter in the best way, taking into account the space to be used.

• After the previous configuration, to start the cutting process, simply click on Start

  

Completing the cut

Once the journey is complete, the operator checks that all the operations have been carried out correctly and removes the workpiece. To do this, he must turn off the program to ensure that the cutter returns to its original position and remains stationary.

Then turn the compressor off again, following the same steps as for turning it on

To remove the workpiece, once the cutter is out of the cutting plane, simply remove the clamps holding the plate, remove the plate and the cut object.

•I•N•D•I•V•I•D•U•A•L• •A•S•S•I•G•N•M•E•N•T•

TREADMILL

MODEL

The model was created in Fusion 360 by simple sketches and extrudes

The most challenging part was making the model parametric by using functions (which I learned in previous weeks). Here’s a list of the mathematical equations I used to create the basic shape

And that’s the more detailed update:

For the dogbones I used this extension and created two types:

MANUFACTURE MODEL

Firstly you need to change the workspace to MANUFACTURE

Then SETUP > Create Manufacture Model

Inside Manufacture Model choose ARRANGE from MODIFY tab

Firstly choose the object that you want to cut and then set up the ENVELOPES that is the area where the model will be distributed- flat. After everything is ready FINISH EDIT.

Before set up we need to import the CNC tools (libraries)

Now it’s time to create New Setup

in SETUPS: Setup of orientation and choosing machine ZERO Stock, which is the material we’re going to cut

After the general set up we need to choose machine operations we want to do. In this case we have two: 2D POCKETS which is type of engraving

2D CONTOUR which is a full cut

Settings that I changed:

Conventional Milling

Lead in and out OFF

Stepdown set to 4mm

And also I added tabs for the pieces to stay in place

It is important to think about the order of the cut. Firstly we need to make pockets Secondly- smaller object inside the big rings Lastly the biggest, outer objects

By clicking particular actions you can see the paths that machine will do

Also you can see the simulation, to check if everything is right

Finally save the G-CODE file to send to the machine

FINAL RESULT

I change the arrangement before the final cut, but settings stayed the same.

FILES:

FUSION 360

TREADMILL:

• Treadmill_Parametric_CNC.zip

•C•H•E•C•K•L•I•S•T•

Group assignment:

• Complete your lab's safety training
• Test runout, alignment, fixturing, speeds, feeds, materials and toolpaths for your machine
• Document your work to the group work page and reflect on your individual page what you learned

Individual assignment:

• Make (design+mill+assemble) something big

Learning outcomes:

• Demonstrate 2D design development for CNC milling production
• Describe workflows for CNC milling production

Have you answered these questions?

• Linked to the group assignment page
• Documented how you designed your object (something big)
• Documented how you made your CAM-toolpath
• Documented how you made something BIG (setting up the machine, using fixings, testing joints, adjusting feeds and speeds, depth of cut etc.)
• Described problems and how you fixed them
• Included your design files and 'hero shot' of your final product