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Group Assignment 7

Group 1

  • Evelyn Cuadrado

Group 2

  • Student
  • Student
  • Student

Group 3

  • Student
  • Student
  • Student

Group 1

Evelyn Cuadrado

For the group assignment, I gave a talk on workplace safety and health, as at the Fab Lab iFurniture, we consider this a fundamental activity. Additionally, I conducted tests on runout, alignment, fixturing, speeds, feeds, materials, and toolpaths for our machine.

1. Introduction to Lab Safety

For the group assignment, I organized a meeting with my academy colleagues via WhatsApp to coordinate and set a specific date to discuss the topic of occupational health and safety. For this, we gathered with Jonathan and Andrés from Colombia and Armando from Peru (Huancayo). Jonathan gave me a very nice comment, as this presentation was very useful to him for implementing some ideas at Fab Lab Colombia.

Those words were really motivating, as we realize that we are doing things right. It’s a boost to keep working with more dedication and continue learning and improving in what we do.



As Fab Manager at Fab Lab Fab Lab iFurniture, one of my main responsibilities is to give safety talks to the team, focusing on risk prevention. It is crucial that everyone thoroughly understands the physical spaces in which we work, as well as the specific safety measures for each area. Taking the appropriate precautions is essential to minimize risks and ensure a safe working environment. Safety is a priority, and making sure that everyone is well-informed and prepared is key to preventing accidents and promoting a healthy workplace.

Additionally, I conducted a training workshop for my colleagues at the academy with the goal of deepening our understanding of occupational safety and health related to machinery use. During the workshop, we covered the main safety measures to follow in the lab, such as the proper use of personal protective equipment (PPE), procedures to prevent accidents, and safe practices when operating machines. We also discussed the importance of maintaining a safe work environment and how to identify potential hazards. It was a great opportunity to reinforce the importance of safety at work and ensure that everyone was well-informed about how to prevent accidents. These types of training contribute significantly to fostering a culture of safety and responsibility in the workplace.


Here is a summary of the topics covered in the talk:

Safety Signs:

Personal Protective Equipment (PPE):

PPE is essential for protecting workers from potential risks. These include gloves, helmets, safety glasses, boots, masks, among others, depending on the task being performed.


Evacuation Signage:

Evacuation signs are crucial for guiding staff in an emergency, showing routes and exits to ensure a quick and orderly evacuation.

Link of the image

Fire Extinguishers:

Fire extinguishers are key tools in the fight against fires. They must be placed in strategic locations, easily accessible, and staff should be trained in their proper use.

Link of the image

OCCUPATINAL SAFETY AND HEALTH




With this, I would be concluding the topic of occupational health and safety at work. Now, I will proceed to document the signage in the Router area.


Safety Signage in the CNC Router Area:

We have a CNC Router machine at Fab Lab iFurniture, located in a spacious and well-ventilated area designed to ensure a safe and efficient working environment. Safety when using this machine is a top priority, so various safety signs have been installed in the area to warn of the existing risks.

Here we can see the area marked by yellow and black stripes, where the CNC Router of the Fab iFurniture is located.


To optimize space within the Fab, we created preventive stickers. One of them clearly states DO NOT PLACE ANYTHING ON THE MACHINES to prevent obstructions and ensure that the machines remain free from items that could interfere with their operation.


Additionally, the machine is equipped with electrical hazard signage and has a main control panel for its operation, ensuring safe and proper use of the equipment.


The environment around the CNC Router machine is equipped with signage reminding the mandatory use of Personal Protective Equipment (PPE), ensuring the safety of operators at all times.



2.Introduction to the Fab Lab iFurniture Router

The structure of the CNC Router is manufactured in Peru, while the DSP control system comes from China. The DSP control system is known for its high precision and reliability, widely used in numerical control machines. The combination of a robust structure made in Peru and an efficient control system ensures optimal performance in manufacturing processes. With a cutting area of 1220 mm x 2440 mm, it is capable of handling a wide range of medium to large-scale projects, offering excellent precision and performance.

A CNC Router can work with materials such as wood, plastics (acrylic, PVC), light metals (aluminum), and composites (carbon fiber). It is also useful for cutting foam, leather, and some resin composites. However, extremely hard materials like ceramic or concrete are not suitable for this type of machine.

The material thicknesses that can be used on a CNC Router typically range from 3 mm to 18 mm. To ensure that the wood remains fixed and stable during the cutting or engraving process, it is secured to the work table with screws, preventing it from shifting or warping. This technique ensures precise cuts and minimizes potential errors during operation.


Technical Specifications of the CNC Router Fab Lab iFurniture:

Specification Details
Cutting Area: 1220 mm x 2440 mm x 150 mm
XY Positioning Speed: Variable, max. 1800”/min
Z Positioning Speed: Variable, max. 900”/min
Input Voltage: Single-phase 220V

The operation of the CNC Router consists of 4 key steps:

  1. Project Design: The piece is designed using CAD/CAM software and then converted into G-code, which is the language the machine understands to carry out the operations.
  2. Machine Preparation: In this stage, the necessary parameters for the machine operation are set, such as cutting speed, depth, feed rate, and the selection of the appropriate tool.
  3. Milling and Cutting: The machine performs the milling and cutting operations according to the provided design, following the G-code.
  4. Verification and Adjustments: Once the cutting is done, the piece is verified to ensure it meets the specifications. If necessary, additional adjustments are made to the machine parameters.

The router bit available at FabLab iFurniture has a diameter of 3.175 mm, allowing for precise cuts and details in a wide range of materials.


The router's sensor is exposed, so frequent passage on the left side of the machine should be avoided to prevent interference or damage.


The electrical panel of the CNC Router is manufactured in Peru, using locally available components specifically designed for the operation of this type of machine, ensuring its reliability and efficiency.


2.1 Machine Alignment

First, we manually align the X axis arm. On the Router, there are guide lines that will help us perform this process with precision.


To start configuring and calibrating the XYZ axes, we click on 'All Axis Home,' which automatically positions all axes to their home positions, ensuring correct alignment before beginning the work process.


We align the X and Y axes to 0.000 and then press the 'XY ➡️ 0' button. This way, we correctly set the reference point for both axes.


To set the Z axis, we carefully lower the axis using the control. When the bit is close to the selected material (in this case, a material with a thickness of 15 mm), we manually adjust the bit until it makes contact with the material.


After completing the manual setup, I press the 'Z ➡️ 0' button, and now the Z axis is calibrated to 0.000.


Once this is done, we raise the Z axis to +20.000, which is the standard height at which the Fab Lab iFurniture machine operates. Then, we return to the origin to begin working with the machine.


To open the file, click on the 'Run/Pause/Delete' button, and then press only the green button.


2.2 Design Workflow in Rhino

The process begins in Rhino, a 3D modeling software used to create detailed and complex part designs. Once the design is completed, it's organized into different layers for cutting, engraving, and drilling. The design is then exported as a DXF file, which contains the necessary vector information for manufacturing.

Here, I created a simple design for my assignment, using two examples: one showing an interlocking design and another created to generate curves.


2.3 Manufacturing in ArtCam

The software I used for designing my tests is ArtCAM, a powerful CAD/CAM tool specifically geared towards creating 2D and 3D parts for CNC machines. ArtCAM offers great flexibility and precision in creating complex patterns and fine details, thus streamlining the manufacturing process.

To begin the design and preparation process for the CNC machine, I import the file into the ArtCAM software. Once imported, I set up the machine parameters, including material type, tool size, feed rates, and cutting depth. ArtCAM then generates the G-code, which guides the CNC machine through the cutting and milling process.


ArtCAM Configuration Process for Creating G-Code

Next, I go to Toolpaths and select Save Toolpath. This opens a window where I save the file in G-code format. To organize the files, we use specific codes to identify the type of operations being saved. For example: EX for exterior line, IN for interior line, and DES for roughing. Once the configuration is complete, we copy the G-code files to the Router machine's USB.


2.4 Cutting Tests in CNC Routing

For this activity, I used the slot join and a flexible design. The slot join is a technique that allows pieces to be joined simply and efficiently, ensuring precise alignment. On the other hand, the flexible design adapts to different configurations and is useful for making adjustments during the manufacturing process, allowing greater versatility in the construction of the project.

The software used at the Fab Lab iFurniture is ArtCAM, a powerful CAD/CAM tool specifically geared towards creating 2D and 3D parts for CNC machines. ArtCAM offers great flexibility and precision in creating complex patterns and fine details, streamlining the manufacturing process.

For this activity, I used the slot join and a flexible design. The slot join is a technique that allows pieces to be joined simply and efficiently, ensuring precise alignment. In addition, the flexible design adapts to different configurations, making it easier to adjust during the manufacturing process and providing greater versatility in project construction. However, I forgot to use the chamfer, so it's important to note this observation and correct it in future tests, as this detail would have optimized the functionality of the pieces.

Before starting the cutting process, it is essential to place the material on the sacrificial bed and secure it with screws. This step is crucial to ensure that the material does not move during the cutting process, which guarantees precision and quality in the work.


The joint is a connection method where components fit precisely to ensure stability without adhesives or screws. Parts are designed to fit into slots or notches, and anchoring involves securing them in place using pressure, gravity, or locking mechanisms. This technique is common in furniture and industrial components, offering strength, durability, and easy assembly without extra tools.


To conduct the material cutting tests, I chose 15 mm phenolic plywood, as the thickness I will use for my individual assignment will be this size. This material will allow me to check the precision and effectiveness of the CNC Router, ensuring that the cutting parameters are suitable for the specific thickness used in the final project.


With all of this, I was able to conduct joint fitting tests using 15 mm thick plywood phenolic pine material. Additionally, I carried out another test by cutting a prototype to create curves.


For this project, I used two types of joins: slot join and flexible join. Both joining techniques are used to assemble the pieces precisely and functionally.

  • Slot Join: This technique involves creating a slot or groove in one piece and a corresponding fitting in the other. This type of joint is commonly used in structures where stability and precise alignment are required. Technically, the slot is made with an "L" or "U"-shaped cut, allowing the pieces to fit securely and stably. It is ideal for applications where rigidity and ease of assembly are essential.
  • Flexible Join: This type of join allows some flexibility in how the pieces connect, which is useful for enabling movement or for applications that require easy and quick adjustments. Flexible joins are particularly useful when the pieces need some play or adaptability in their assembly, without compromising the overall stability of the structure.


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