Computer-Controlled Machining

Hero Shot

Task: Electronics Design

Group assignment:

  • Use the test equipment in your lab to observe the operation of a microcontroller circuit board
  • Demonstrate the use of a multimeter and oscilloscope
  • Document your work on the group work page and reflect on your individual page

    • Individual assignment:

  • Use an EDA tool to design a development board
  • Ensure the design uses parts from the inventory to interact and communicate with an embedded microcontroller

    • Learning Experience

    This week, I experimented with computer-controlled machining by using SolidWorks and Fusion 360 to create 3D models, which I then used VCarve Pro to convert into G-code for CNC wood routing. Along with guaranteeing safe and effective machining procedures, I also obtained practical knowledge in machine operation, toolpath creation, and digital fabrication techniques.

    Key Accomplishments

    ✅ Created 3D models for CNC milling with SolidWorks and Fusion 360.
    ✅ Accurate machining was achieved by using VCarve Pro to generate exact G-code.
    ✅ Successfully finished the safety training for wood routers and used the CNC machine.
    ✅ Improved abilities in digital fabrication, such as the development of toolpaths and machining methods.
    Individual Assignment:

    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 Details
    Construction and Frame Material Steel or cast iron
    Size Table sizes range from 2’×3’ to 5’×10’ 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’×8’ or custom sizes
    Z-Axis Travel 0 inches to 12 inches
    Types of End Mill
    End Mill Type Image Description
    Square End Mills Square End Mill These mills are commonly used for straight cuts, slot creation, and surface finishing with a flat end.
    Keyway End Mills Keyway End Mill Designed to cut key-shaped slots in metallic parts to fit woodruff keys or other inserts.
    Ball End Mills Ball End Mill Perfect for contouring, 3D shapes, and making curved features due to their rounded tip.
    Roughing End Mills Roughing End Mill Ideal for fast material removal with reduced chatter due to their unique tooth profile.
    Corner Radius End Mills Corner Radius End Mill These tools have a slight radius at the corner, which helps prevent chipping and improves strength.
    Roughing and Finishing End Mills Combo End Mill This type performs both rough cuts and fine finishing in one go, saving time and effort.
    Corner Rounding End Mills Corner Rounding End Mill Useful for creating rounded edges on parts, making them smooth and less prone to damage.
    Drill Mills Drill Mill Multi-purpose tools used for drilling, chamfering, milling, and light profiling.
    Tapered End Mills Tapered End Mill These end mills taper towards the tip and are suited for mold making and angled surfaces.

    Flute Types and End Cut Types
    Flute Type Image Description
    Single Flute Single Flute Great for rapid cutting and soft materials due to its large chip clearance.
    Two Flute Two Flute Commonly used for slotting tasks with good chip ejection ability.
    Three Flute Three Flute Offers a balance between strength and chip removal — ideal for shallow cavities.
    Four/Multiple Flute Multi-Flute Provides smoother finishes and faster feed rates but limited chip space.

    We used a 6 mm end mill with a 6 mm collet for both our group and individual assignments. This particular end mill is strong, reliable, and performs well with MDF material. It also provides a 6 mm kerf, ensuring precise and efficient cutting results.


    Designing Process

    I thought of making a study table where students can sit and study comfortably while maintaining a straight posture. So, I designed one in Fusion 360 that allows students to sit and study with ease.


    In Fusion 360, I created four parts and assembled them:



    Part 1


    Part 2


    Part 3


    Part 4

    Assembly

    All files are saved in the DFx file.

    Creating Toolpath with VCarve

    Multi-purpose CAM software to integrate perfectly with PolyBoard and StairDesigner and a huge range of CNCs.
    Plus carving, engraving, moulding, sign making, nesting and many other design and manufacturing features.
    This image shows the parts from a PolyBoard project nested in VCarve, with full tool paths set up, ready for output to a CNC machine.



    First, we opened Vikar software and clicked on "Create a New File".


    Then, we set up the job setup according to 8/4 ply, 12 mm thickness, and adjusted the X-Y position.


    Click On Toolpath.


    I selected the size I wanted to cut inside, then clicked on the Profile Toolpath. After that, I went into the profile and calculated the file.


    I simulated it and checked whether the design was cut properly or not.


    Click on the Save toolpad


    File Save on Pradeep1.CNC


    Then, I selected the outer design, clicked on Profile Toolpath,


    generated the toolpath. After that, I clicked on Calculate.


    I simulated it and checked whether the design was cut properly or not.


    Click on the Save toolpad


    File Save on Pradeep2.CNC

    Loading the File For the Cutting


    Connected the RJ45 connector to the laptop, turned on the machine, and opened the Acorn software.


    The axis XYZ was set up at home, and then it was brought back to its original location.


    Loaded the inside file and cut it,


    Loaded the outside file and cut it,


    When the file is cut, a graph is generated that shows how many millimeters the end mill is cutting into the material.


    Job Finished.

    Machine cutting and setup process

    Before starting our machine, we focused on safety. Along with safety, we also checked the electricity connection, ensuring whether it was on a single phase or not, and secured the plywood with a clamp. This way, we ensured these precautions before starting the machine.



    1. First, we turned on the switch and wore safety equipment.


    2. I cleaned the Wood router and securely tightened the plywood by clamping it in place.


    3. turned on the glower and wood router and configured the laptop.


    4. Before give Design the Wood router, I set up a protective barrier in it for safety.


    5. I set the machine's origin properly.


    6. First, I gave the machine a command. Initially, we performed an inside cut, and in the second step, we performed an outside cut.


    7. Inside cut.

    8. Outside cut.


    9. Safety: When the machine is running, one should not go near it.


    10.Cutting complete.


    11. Carefully remove each part one by one.


    12. Assembled all the parts.


    13. Faced some difficulty while assembling, so I used a rubber hammer to gently press-fit the parts.


    14. Final object ready.


    Original file is hear