Computer-Controlled Machining

Task: Computer-Controlled Machining

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

Forest CNC Router:

A computer-controlled device for accurate cutting, engraving, and creating is the Forest CNC Router. It can be used on light metals, composites, wood, and plastic. Fabrication, prototyping, signage, furniture manufacturing, and industrial applications are its primary uses.

Key Features

Accurate and clean cuts are guaranteed by precise cutting.

Supports Multiple equipment: It is compatible with a wide range of engraving and cutting equipment.

Computer programming is used to control automated operations.

Supports wood, MDF, acrylic, PVC, aluminium, and other materials.

Control the speed and feed according to the depth of cutting and the material.

Big Workspace: Ideal for both little and major tasks.

Safety features include a dust extraction system, spindle control, and emergency stop.

Specifications

Category	Specification
Construction and Frame	Material: Steel or cast iron Size: Table sizes range from 2’x3’ to 5’x10’ or more
Spindle	Power: 2.2 kW to 12 kW Speed: 6,000 to 24,000 RPM Cooling: Air-cooled or water-cooled
Axes	Number of Axes: 3-axis (X, Y, Z) Movement: Ball screws or rack and pinion Resolution: Down to 0.01 mm or better
Controller	Type: Dedicated CNC or PC-based controllers Software Compatibility: AutoCAD, SolidWorks, VCarve, etc. User Interface: Touch screen or handheld pendant
Cutting Area	Dimensions: Common sizes are 4’x8’ or custom sizes Z-Axis Travel: 0 inches to 12 inches

Reference Website –ChatGPT

End Mill Flute Types & End Cut Types

Category	Type	Description
Flute Types	Single Flute	Best for soft materials like plastic and aluminum; allows fast material removal.
	Double Flute	Balances speed and finish quality; commonly used for wood and soft metals.
	Three Flute	Ideal for hardwoods and aluminum; provides a smooth cut.
	Four Flute	Provides a high-quality finish; good for metals and fine detailing.
	Multi-Flute (5+)	Used for high-speed finishing with superior surface quality.
End Cut Types	Square End Mill	Creates sharp, straight edges; used for slotting and profiling.
	Ball Nose End Mill	Ideal for 3D contouring, curved surfaces, and mold-making.
	Flat End Mill	Used for pocketing and smooth surface milling.
	Corner Radius End Mill	A hybrid between a square and ball nose, reducing chipping.
	Tapered End Mill	Used for engraving and angled machining.

Reference Website –ChatGPT

Safety Measures

Prior to beginning the work, we carefully reviewed the safety procedures, the things we need to wear when operating the machine, and the precautions we should take.

1. First, we selected plywood, which was 18mm thick.

2. After that, we focused more on safety tools, using headphones, glasses, gloves, and a mask.

3.Then, we thoroughly cleaned the machine.

Useing CNC machine safety shield

5.We gained basic knowledge about the CNC machine.

6.Then, we measured the horizontal dimensions of the plywood.

7. Then, we measured the vertical dimensions of the plywood

Toolpath & Cutting Parameters

Different toolpaths include pocketing, profiling, and engraving. Parameters such as feed rate, spindle speed, and depth of cut impact the quality of the machining.

1. First, we gathered basic information about the V Curve Pro software on the laptop at the Vigyan Ashram and then opened the software. After that, we clicked on "Create a New File.

2. After creating the file, we set up the job.

3. On the drawing page, we gained basic information about vector design and then created a rectangle.

4. After that, we set the rectangle's size to a width and height of 300 by 300 mm and applied the changes.

5. We selected the Profile Tool Path and learned about the tool path operations.

6. We selected a 6 mm end mill for the tool path and gathered information about the tool and its flat.

7. To edit the passes, we set the pass depth to 3.6 mm, which resulted in 5 passes, allowing us to cut through the 18 mm plywood in 5 passes.

8. In the machine vector, we set it to "Outside/Right" because we needed to start the cutting from the outer side of the design at 300 mm. Next, we entered the tool path name and clicked on "Calculate."

9. We run the preview of the selected tool path, where we saw that our design was cut in 5 passes, and then we closed it.

10. In the material setup, we configured the material settings.

11. In the tool path section, we saved the tool path in (.CNC) file format, which generated our G-code.

12. Saved the G-code in .cnc file format on the local device.

13. This time, we drew a circle in the drawing workspace with a diameter of 200.

14. In the 2D profile tool path, we adjusted the settings according to the material and set the machine vector to "Inside (Slice)/Left" because this time we wanted the end mill to cut from the inside.

15.We entered into the tool path option and saved the tool path.

16. Saved the G-code in .cnc file format on the local device.

Machine Setup & Operation

1. First, we properly placed the plywood on the router bed in an organized manner.

2.Then, we securely tightened the C-clamps.

3.Since our machine operates on a single phase, we connected the switch to a single-phase power source.

4.Then, we turned on the machine's power, switched on the dust collector, and started the machine.

5.Then, we cleaned the area around the end mill and securely fixed it in place.

6. Then, we pressed the machine's power-on button and released the emergency stop button.

7. Then, we set the Z-axis to the corner of the router. .Then, we connected the machine's RJ45 connector to the laptop and executed the G-code command for the file, after which the machine started operating.

9. Finally, our object was successfully cut. The rectangle was completed in five passes.

8. curve of 6 mm.

10.Then, we moved the rectangle from the plywood and checked its dimensions. The rectangle measured 300 mm by 300 mm

11. Finally, we inspected the finishing of the extracted object.

12. We prepared the press-fit design as suggested by Neil, with dimensions of 18mm × 100mm. We cut the press-fit design by generating a toolpath.

13. We checked curve, and it was coming out well, 6 MM

14. We also checked the dimensions of the press-fit design, and it came out nicely as 18 x 100 mm

15. Finally, we press-fitted the design using a hammer, which resulted in a secure and precise fit. .

Challenges & Learnings

We discovered in the wood router lesson that we need to measure whether we want to use an external or inside design before we can create any kind of design. In order to cut with an appropriate press fit, this step is essential. We also concentrated on how to properly finish the design, giving safety measures the utmost consideration.

Group Assignment 7: Computer-Controlled Machining