16.Wildcard Week

Individual Assignment

• Design and produce something with a digital process (incorporating computer-aided design and manufacturing) not covered in another assignment, documenting the requirements that your assignment meets, and including everything necessary to reproduce it. Possibilities include (but are not limited to):

Overview

This week i will be exploring the new machining process which i have not covered in my previous works.I have decided to work on OMAX 5555 JetMachining Center, (Water Jet Cutting machine).

source image from here.

It is based on the abrasivejet system which is suitable for cutting medium-sized stock like metal sheets and flats.You can learn more by going to details on my reference here.

Some of the main components of this equipment are controller with panel, cabinet and windows PC, X,Y, and Z-axes system, abrasive hopper, catcher tank and high pressure pump.

Specifications of 5555 JertMachining Center

Dimensions:

Footprint (standard layout): 11' 5" x 8' 9" (3.48 m x 2.67 m)

Weight (tank empty) : 6,220 lbs (2,821 kg)
Height: 10' 0" (3.05 m)

Operating weight: 14,142 lbs (6,415 kg)

Work envelope:

X-Y cutting travel:4' 7" x 4' 7" (1.39 m x 1.39 m)
Z-Axis travel (with motorized Z-Axis): 8” (203 mm)
Table size: 6' 8" x 5' 5" (2.03 m x 1.65 m)

Material support slats:4" x 1/8" (102 mm x 3.2 mm) galvanized steel

Maximum supported material load:400 lbs/sq ft (1,953 kg/sq meter)

Electrical requirements:3-Phase, 380-480 VAC ±10%, 50-60 Hz

Noise level:Below 80 dBA at one meter for submerged cutting
Speed:180 in/min (4.57 m/min)
Linear axis accuracy:±0.001” (±0.025 mm)

Workflows and the process.

1. Design.

I have designed a simple flower stand using Fusion 360 to cut it using the Water Jet machine.Here you can see my design briefly.

I selected top plane for this design.Firstly i designed top base of dharma wheel by drawing circles of diameter 40, 50, 220 and 230mm.I did offset to make pattern.

I kept thickness of 5mm between the pattern and added fillet and followed by drawing a circle as center reference.

I made circular pttern by selecting the patterns and made it into 6 parts.

I added fillets to my patterns and added a outer circle for mounting the stands.

I extruded my base of 3mm thickness to visualize.

Next, i designed a stand with slot to fit with my base and copied into 3 parts.

This is how it looked and i saved my file as DXF format to be cut using Water jet machine.

2. Machine setting and cutting operation.

Firstly, i had to swich on the power supply and air pressure line which are located at back of the machine.

Next, switched on the stabilizer lever, followed by switching on the chiller on switch.

Then, switched on the cabinet power supply swith, followed by switching on pump control switch, and green start button.

I put on the electrical cabinet under the monitor and started jogging the X, Y and Z-axes by making sure that i lift the z axis up to secure from obstruction and damaging the nozzle.

There are two software needed to interface this machine.The first one was OMAX LAYOUT which helps to edit and do basic designing, and also to generate tool path for drawing.OMAX MAKE is used to move and operate the machine as per users convenient and to select the material type as per our work piece.

I had imported my DXF file to be cut.

Then i did calibration by Auto Homing machine.This is the first step which is critical to operate machine after shut down in previous works.This will initialize the X-Y coordinate positions of the machine.

For ‘Auto Homing machine’, clicked on Homes > Auto home XY > Begin homing, and kept the Z-axis to zero.Next i followed same process for Auto Home-Tilt to ensure the nozzle’s tilt mechanism is accurately aligned.To do this i went to Homes > Auto-HomeTilt.

I used 3mm thickness mild steel sheet for my work and clamped bed of the machine.Then, i positioned the nozzle at the starting point for X and Y-axes and clicked on zero icon.

I have to set the Z-axis by using stand off tool to maintain the standard gap between nozzle and my workpiece.

I also made sure to fill the abrasive powders and keeping the spash gaurd into position and started the machine by setting the water level in the tank above the cutting material.

I clicked on dry run option to test to make sure it do not affect the mountin g and nozzle.

Then click to post arrow symbol and select the starting point and save it.Then, click on open ORD path in MAKE software.There i selected the material type.

After that i left clicked on ‘Begin Machining and start machining.

After finishing, i removed my base.

I followed same process to cut the stands for the base.

3. Assemblying and cleaning.

I assembled my base with stands and cleaned my working area.

Learning from the week.

I have got to learn a water jet machine and i got the basic on operating this machine.Safety for both operator as well as for machine nozzle is must as it will cause serious injurious or will cause damage to the nozzle if improper settings were given.This machine is more precise and accurate especially for mechanical professionals.This machines is very useful for fabrication purposes and can work on various metal sheets and flats.

Designed files for the week is here