Computer Controlled Cutting¶
Group assignment:¶
- Do your lab’s safety training
- Characterize your lLaser Cutter’s focus, power, speed, rate, kerf, joint clearance and types
Work Distribution¶
| People | Discription |
|---|---|
| Tyler, Zijia (Angel), Kathryn | Documentation |
| Tyler | Frequency,Power,and Speed Test |
| Tyler | Kerf Test |
| Zijia | Focus Test |
| Kathryn | Clearance Test |
Kerf Test - Tyler¶
To test the kerf I decided to create a 1 inch by 1 inch vector line in CorelDraw and then Cut it out to test the Kerf. The square was 0.98 by 0.97 inches which meant the combined Kerf of both sides was 0.03 inches which divided by 2 is 0.015. This means that the Kerf of our laser cutter is 0.015 inches.
Frequency, Power, and Speed - Tyler¶
It was heck. Moving on from the dramatic bit it was not fun. I had to do a lot of busywork that in the end resulted in a finished product but I really wish I had found a more efficient way to show the difference between Frequency, Power, and Speed.
Process¶
a. I really had no idea how to test these features of the laser so I decided to look at the Richard Shan, Angelina Yang, Alana Duffy Group Work for ideas and models. Their documentation really helped me this week so big thanks to them for everything.
b. They talked in detail about the model they used which had 27 different combinations of settings for Power, Speed, and Frequency, and they had linked it in their documentation so I decided to use it.
c. The different setting were of 100%, 66%, and 33% for each of the 3 settings for a grand total of 27 different types of lines for me to measure. After finding the Kerf of course.
c. After downloading the file I brought it to CorelDraw where I had to find a way to distinctly separate all the lines shown to give them the different settings. At first I choose to try and separate them by making each of them a different color in the color format CMYK and then choosing separate by color. Unfortunately because there were so many of the lines I had no way of accurately knowing which color was which unless I wanted to take picture of each color format. Then I found out that the Laser cutter only displayed the values as RGB colors not as CMYK so after taking 27 pictures of CMYK formate colors I would have to go back and do the exact same thing in RGB. Then I had a great idea. I decided to go into RGB and create colors that would have the same distinction as the wording next to it. For examples the lin with 100% Power 66% Speed and 33% Frequency would have the RGB distinction R:100 G:66 B:33.
The reasoning behind this was that the lines were named after the RGB distinction so instead of needing pictures I could just go off of the names of the lines them selves to alter the settings for them. However this still took a very long time and to enter 81 values into CorelDraw. Hence that is why I believe there has to be a better way to distinguish lines.
Pictures¶
The front of the testing
The back
Focus Test - Angel¶
First Version¶
For the focus test, I decided to use Fablab Logo to test it out. I imported the Fablab logo and convert it to Bitmap image using Week 2 skills. I was testing 5 different focus following Richard Shan, Angelina Yang, Alana Duffy Group work .
I asked my fellow student Noah Smith for help because I did not know how to measure the focus. He told me about how to manual focus the laser cutter. When the metal chip showing below is barely touching the surface, that means it is at focus of 0.00.
When I set up the laser cutter (Fusion M2), I realized that I needed to change the outline to anything but hairline since hairline is for vector. However, I realized that because the focuses are different, I needed to raster the image 5 different times. So I deleted all the thing except the first logo. Then I started to set up the cutting settings. Since I only needed to raster, I turned the Vector feature off in the Preference. I set up the setting using carboard raster setting reference.
Then I hit Print and sent my file to the laser cutter. When I hit Start button on the laser cutter, nothing happen. I asked Noah Smith again for help. He pointed out that I forgot to change the piece size to the size of my CorelDraw layout which should be the size of the cardboard. After I changed it into the the right size. It worked!
Then I realized that I can change the focus on the laser cutter using the joystick.
I rastered the other 4 using different focus settings. Then I vectored a box around it and cut the part off.
This is my first version of the focus test.
Problem Encountered¶
After I showed Mr.Dubick, he pointed out that at some angles, the icons were not very clear. So he suggested me to raster again and add morepower when rastering.
Second Version of the Focus test¶
The next day, I increased the Power in the Raster tab of preference by 10% and rastered it twice. Although it was slightly better, it still did not meet my expectations. However, I can see the patterns on changing the focus.
When doing +0.1 and +0.15 focus, the logos seemed to be the lighter ones. The focus 0.00 and +0.2 are the best options for rastering since the logos were reastered really dark.
You can download my focus test file here.
Joint Clearance Test¶
For the joint clearance test, I made a comb cardboard shape with differing widths for the gaps to see which one was the most suitable for the cardboard at our lab.
Using calipers, I measured the cardboard to be 0.148 thick. I made the widths of the gaps change in increments of 0.025 in, so 1.43, 1.455, 1.48, 1.505, and 1.53. I designed the comb shape in CorelDRAW using the rectangular shape tool and virtual segment delete to design the desired object.
I changed all of the lines to hairline and saved it as a CorelDRAW file (.cdr). After downloading and opening the file on the computer connected to the laser cutter, I went into preferences. For the vector settings, I went with 25s, 100p, and 15f.
I also needed to change the Job Type to vector, because I did not plan on doing any engraving. For the Piece Size, I changed it to 30in x 20in, aligning with the dimensions of the cardboard piece I was using (I should have changed my canvas size to the same for better placement). With all of those settings changed, I cut my design out.
(From left to right, thinnest to thickest)
After testing them all out, I realized that there was not much difference of a difference between how the cardboard fit into the gaps, especially for the ones that are wider than the cardboard thickness. So, I changed my design to be in increments of 0.05 in as opposed to 0.025, which I originally considered to be significant. I added number labels to it as well:
This time, I made sure to make my canvas size 30in x 20in.
I kept the same cutting settings, but for engraving I made power 40. The cut went well!
I found that the smaller values made it way too tight, to the point where pushing it through required a lot of force.
On the opposite end, the widest was really loose and unable to securely hold the carboard. The exact center was also a rather tight fit and a little bit wider was a little too loose.
I thought that right between 0.148 and 0.152 was the perfect fit, so 0.15!
This is the file for my final joint clearance printed design.
