Week 7. Computer-Controlled Machining¶
Group Assignment¶
During the group assignment, Rudolf introduced us to SAFE work on the CNC roughing machine.
Here are the outcomes we got during the group assignment:
- Learned how to safely operate the CNC roughing machine.
- Learned to use the VCarve software.
- Learned how to generate G-codes (operations: profile, pocket, drilling).
- Made tests to check tolerance.
- Learned about different mill types, speeds, and feeds.
- Identified common mistakes and how to avoid them.
Designing a Foosball¶
Since we were assigned to make something big using the CNC roughing machine, I decided to try making a table football, also known as foosball.
I started making a sketch with external dimensions of 1400mm by 800mm.
Then I started designing all the walls of the body.
After doing some research, I realized that there needs to be space behind the goals so that after scoring, the ball can be easily taken, and I decided to make small windows to take the ball from there.
I also decided to try making figures for my foosball and used all the photos from the internet to start creating a sketch of them.
Then I started extruding parts in different sizes to create a more realistic figure.
Here is the final view of figure.
Then I imported the figures into the foosball project.
After importing, I started aligning all the figures to create holes where the bushings would be cut and inserted.
After studying the principles of foosball, I positioned the figures so that when they rotate, they don’t touch each other.
This is the final positioning of the figures.
Then I created a sketch for the bushing.
After that, I extruded it and placed it in the holes.
I also made a very simple design for the handles, revolved it and put it in the tubes.
Here is final view of Foosball.
Roughing Parts¶
In our Fablab We have Shopbot PRSAlpha 9648 which working sizes are 1220x2440mm.
Since we have a plywood sheet with dimensions of 1520x1520mm, we will cut one side so that it can fit on the machine’s worktable.
After cutting, I placed the plywood on the table and started creating toolpaths.
1. I fix the plywood with clamps and create a toolpath for drilling. This makes a 1mm marking where I will use screws to fix the plywood to the table since the plywood is not flat.
Here is the fixed plywood photo.
2. There is fillet tool were I have selected “dogbone” type and set the radius 3.15mm to make dogbones on the edges of joints to have a clear connections.
3. Then I created a toolpath for making pockets on plywood.
4. At finishing I created a Profile toolpath to cut the contours of parts.
This is the simulation image.
I Used UpDown Cut end mill to get best surfaces on both sides of plywood, and here is the setting what I used for Speeds and Feeds.
Here is the result.
Trying to Flatten Warped Plywood¶
After cutting the parts, I noticed that the plywood was quite warped, so I decided to try to flatten it.
So this was how it looks before making flatten.
To flatten it, I used a sponge and hot water.
I applied hot water using a sponge.
Then I flipped it over and placed all the heavy items I could find nearby on top.
After 10 hours, I got this result. As you can see, it’s not completely flat, but it’s definitely better than before.
Assembling Part¶
I started assembling all the parts to make sure everything was cut correctly.
After confirming, I started sanding all the parts.
Then, on the main table, I applied the primer for wood.
And then green paint.
After the paint dried, I cut out a template for the white lines.
Then, I applied the white paint to it.
The result turned out to be quite good.
Then, I applied varnish to the body parts.
Here is the result of all parts.
Then, I 3D printed the parts, handles, and bushings.
When everything dried, I started assembling the entire structure.
I also 3D printed all the figures.
Since there are different numbers of figures on each rod, I took all the dimensions of the tubes from my project in Fusion and started cutting the tubes.
After cutting, I started inserting the figures into the tube and drilling through holes to screw them at the end so that the parts wouldn’t rotate.
After drilling each figure, I fixed them with screws. Then, I continued aligning the next ones so that they would all be on the same line. Using a meter and a ruler, I marked the positions for the figures.
Then, I started inserting the tubes into the wall, followed by the figures, and fixed them from the other side.
In the end, I finally painted all the visible joints with varnish and let them dry.
Here is the final Result!!
Everyone was happy with the tabletop game, as we didn’t have any like it, and from time to time, we can take a break from work or study and play foosball!