Computer-Controlled Machining

Group assignments

do your lab's safety training
test runout, alignment, fixturing, speeds, feeds, materials, and toolpaths for your machine

My group assignments

west-harima week-assignments 07

Individual　Assignments

make (design+mill+assemble) something big (~meter-scale)
extra credit: don't use fasteners or glue
extra credit: include curved surfaces

Have you answered these questions?

Linked to the group assignment page
Documented how you designed your object (something big)
Documented how you made your CAM-toolpath
Documented how you made something BIG (setting up the machine, using fixings, testing joints, adjusting feeds and speeds, depth of cut etc.)
Described problems and how you fixed them
Included your design files and 'hero shot' of your final product

PC working environment

PC: MacBook Pro(16-inch,2019)
OS: Sonoma 14.7.2
Terminal: zsh

hero shot

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hero video

3D data with Fusion360

1.Model

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I designed the following model using Fusion360.

I wanted to make it as sturdy as possible, so the 18mm and 25mm boards and side panels were made by laminating them together. I wanted to make it as sturdy as possible.It is not our intention to paste without regard to clearance.Clearance was set based on the results of group assignments. (0.2mm)

1.0 Top Panel(18mm)

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1.1 Top Panel(25mm)

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1.2 Side Panel

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1.3 Bottom Pillar

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1.4 Side Pillar

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2. Assemble & Section Analysis

2.0 Assemble

It would be difficult to match joint, so I used Assemble in Fusion360 to check the joint of each part as we created it.

First, the base part was jointed, and then Toppanel was jointed.

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2.1 Section Analysis

Clearance was set based on the results of the group assignment. It is very important and was checked using Section Analysis.

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3.Tool paths

3.0 First, create a file of toolpaths

For safety reasons, the area of fixation and the area of part layout must be clearly defined. I was told by my instructor that the part layout area must be offset from the stock outline size by at least -50 mm. In fusion360, we used squares to create orange areas and laid out the areas of the area.

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Finish the design, and it's time to create tool paths.

3.1 Setup

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Stock setting

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3.2 2D Pockt

Create a tool path for a non-penetrating hole.
This is made to prevent the boards from shifting when they are pasted together.

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select tool

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Select the mill you will use. In my case, I selected Flat end mill.
The instructor told us that flat end mills are used for external contouring and drilling holes.

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Change the settings to match the mill to be used.

alt text Measure and correct the mill for actual use. The thickness of the material is also relevant. You must select a mill that is long enough to cut . See group assignment for details.

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Geometry

Select bottom of Pocket. Check "Select same plane

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Here I am not sure so I entered the instructor's recommended values.

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Passes

Multiple Depths:
In this time, select 4mm （The tool used this time is a flat end mill with a diameter (D) of 8 mm, so we set the pitch to 4 mm.)

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Linking / Leads & Transitions / Ramp / Positions

Ramp type changed to Pulange by instructor.

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3.3 2D Contou

2D Contou is set up in the same way as 2D Pockt.
The cut depth should be set according to the board to be cut.

4.Simulate

check the tool path and time. alt text

In fact, it took about 1.5 times longer than the simulation time.

5. Post Process

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Choose the tool pass you want to post

Post : Mach4Mill/mach4mill
Program name
output folder: Select folder

alt text Then out put tool path with ".tap file".

Then, it's time to machine operation.

Made Desk

I made a desk for use in the kitchen.

5.Fixing of materials

5.0 Fix

Secure the board with screws to prevent it from flying or moving. If the board is secured inwardly at this time, it may hit the mill, so check it carefully before securing it.

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5.1 Range check

Check the actual cutout area to make sure that the mill will not hit the screws that hold it in place.

6.Cutting

6.0 See group assignment for cut process.

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6.1 Use a trimmer to apply the process of rounding tabs and corners.
Be careful not to tilt the trimmer when using it.

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Sanding and pasting together

7.0 sanding
Sanding is used to clean and shape the surface.
This is a very time consuming process...

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7.1 gluing
Adhesive is used to laminate the boards together.

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We wanted to make the Top Panel as thick as possible, but there were no boards available with the right thickness, so we laminated 18mm and 25mm boards together. To strengthen the side panel, we laminated 18mm boards together.

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