Week 7: Computer-Controlled Machining

Group Assignment

Individual Assignment

Inspiration:

For the individual assignment, I cut two pieces of wood using the CNC machine:

• Floor Lamp:

I was inspired by a modern wooden floor lamp design.


• Spice Rack:

I was inspired by the need for a spice rack in my kitchen.

Design Process:

1. Floor Lamp:

• I used this picture as a reference to design the floor lamp in Fusion 360.


• Here is my 3D model of the floor lamp that I designed in Fusion 360:

lamp by malak-alsharqawi on Sketchfab

2. Spice Rack:

I designed the spice rack in Fusion 360, and I used the CNC machine to cut the pieces of wood. I also used a drill to make holes for the screws.

Setting Up the Model for Cutting:

• Using Fusion 360.

I will explain the full setup process for the floor lamp using the Fusion Manufacture workspace.

1. First, I had to create a 2D projection of my model so I could cut it using the CNC machine. To do this, I used the Arrange tool, which is under the Modify tab in Fusion.

   Here is the model after using the Arrange tool.

   
2. Then I went to the Manufacture workspace so I could define the toolpath and other specifications for the cutting process.
3. In the Manufacture workspace, I created a new setup for the model and set its specifications, such as the operation type, stock size, and origin point.
• Stock Settings


I set the mode to Fixed Size so I could select my model and set the stock dimensions according to the wood dimensions I would cut. I also set the origin point at the top-left corner of the stock and set an offset of 40 mm to leave enough space for screws to secure the stock on the CNC machine.

• Setup Settings


For setup, I specified the operation type and selected one edge to be parallel to the X-axis and another edge to be parallel to the Y-axis.

💡 Note: When setting the X and Y axes, they can flip (making the Z-axis point downward). To fix this, flip the X and Y directions so the Z-axis points upward.
4. After finishing the setup, I had to create a new operation.
• Create New Operation

To create a new operation, right-click the setup, select the operation type, then choose the path strategy you want to use.


• Select tool:

After creating a new operation, I selected the tool for cutting. I used a flat end mill with a 6 mm diameter and set all the required parameters.


💡 Note: I had to add a new tool to Fusion because my tool was not in the Fusion library.
• Define the cutting parameters:

After selecting the tool, I defined the cutting parameters, such as the feed rate and spindle speed.



To find the exact values for these parameters, I used the FSWizard website: link.

• Geometry Settings

After defining the cutting parameters, I selected the contour and highlighted the areas that needed to be cut from the bottom. I also enabled Tabs, which I could place manually or automatically, to prevent the piece from moving after cutting and damaging the process.


💡 Note: Set the tab height above 50% of the piece height to make sure that the piece will remain fixed.
• Height Settings

In the height settings, I set the top height to the stock top and the bottom height to 3 mm below the stock bottom to ensure the tool would cut through the wood.


• Passes Settings


In the passes settings, I enabled Multiple Depths, checked "Use even Stepdown & Order by Island," and enabled feed optimization.

💡 Note: Tolerance affects the M-code length.
• Simulation

After finishing all the settings, I ran the simulation to make sure everything was correct before cutting.



Here is the simulation result, showing the toolpath and how the CNC machine would cut the piece.