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CNC Machine.md

@@ -12,6 +12,12 @@ The CNC (Computer Numerical Control) machine used in this lab is a large-format
 
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+#### Video - Full Explanation
+
+The video below showcases how the system works with explanation.
+
+---
+
 #### Safety Requirements
 
 Strict safety protocols must be followed when operating the CNC machine:
@@ -31,6 +37,18 @@ Strict safety protocols must be followed when operating the CNC machine:
 
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+#### Design Requirements
+
+When designing for CNC cutting:
+- Maintain at least **20 mm gap** between each design part.
+- Keep designs at least **30 mm away** from each sheet corner.
+- Ensure holes in your design are **larger than the drill bit’s diameter** so they can be cut cleanly.
+- Select drill bits **larger than your material’s thickness** for full cuts.
+- Export files in **DXF format** for compatibility.
+- Double-check that the design size suits the tool (e.g., drill bit not larger than the smallest detail).
+
+---
+
 #### Debris Management
 
 The CNC machine includes a built-in vacuum system that removes debris generated during cutting. This ensures:
@@ -56,7 +74,7 @@ Proper material positioning is crucial to cut accuracy. A **sacrificial sheet**
 **Tips for Alignment:**
 - Max sheet size: 2440 x 1220 x 12 mm (L x W x T).
 - If the sheet is curved, place the concave side down.
-- Secure with bolts, ~30 mm away from corners and across the center.
+- Secure with bolts placed within 20 mm of the corners and across the center.
 
 ---
 
@@ -122,8 +140,8 @@ Proper speed and feed rate settings are critical for effective cuts:
 - **Feed Rate (in/min):** Determines how fast the tool moves across the material.
 
 For MDF using a 6mm tool:
-- Optimal Speed: 17,000 RPM
+- Optimal Speed: 8000 RPM
-- Feed Rate: 60 in/min (can vary based on tool condition and material)
+- Feed Rate: 80 in/min (can vary based on tool condition and material)
 
 Monitor chip formation and surface quality during tests to fine-tune settings.
 
@@ -131,12 +149,10 @@ Monitor chip formation and surface quality during tests to fine-tune settings.
 
 #### Tips to Reduce Material Waste
 
-- **Group Parts Efficiently:** Nest your parts close together in CAD to use the least amount of space.
+- **Group Parts Efficiently:** Nest your parts close together in CAD to use the least amount of space. [20mm space]
-- **Shared Cutting Lines:** When possible, let neighboring shapes share cut lines.
 - **Use Off-Cuts:** Save and reuse unused areas of the sheet for future small projects or test cuts.
 - **Add Labels:** Include engraved labels to organize parts and reduce re-cuts.
 - **Test on Scrap:** Run test cuts on scrap wood or corners before running the full job.
-- **Design for Sheet Size:** Design parts to maximize standard sheet dimensions (2440 x 1220 mm).
 - **Minimize Tabs:** Use just enough tabs to hold parts in place without excess material.
 
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@@ -171,8 +187,15 @@ This section outlines the full workflow for using the CNC machine, from preparat
 
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-#### 3. Toolpaths: Cut
+#### Assigning Cut/Pocket
 
+Select the lines or shapes to define what will be cut or pocketed, then apply the relevant toolpath operation (profile/pocket).
+
+---
+
+#### 3. Toolpaths: Cut
+  - Cuts along the outer or inner edge of a part.
+  - Defines the final shape by following the contour
 - Choose **Profile Toolpath**.
 - Set:
   - **Start Depth:** 0 mm
@@ -188,38 +211,68 @@ This section outlines the full workflow for using the CNC machine, from preparat
       - Second Pass Depth: 13mm
 - Specify Machine Vectors:
   - Select **Outside/Right** for vector machining to preserve size.
-  - Select **Inside/Left** for 
+  - Select **Inside/Left** for cutting internal shapes or holes.
-  - Select **On** for
+  - Select **On** for trimming directly along the vector line.
-- Tabs: ++++++++
-
 - Click **Calculate**, then read the warnings, if it is within your expectations click **OK** to confirm.
 
 ---
 
 #### 4. Toolpaths: Pocket
-
-- **Pocket Toolpath:**
   - Used to hollow out an internal region.
   - Useful for engravings or fitting one piece into another.
-  - Cut Depth: As required (example: 5 mm).
+- Choose **Pocket Toolpath**.
-  - Start Depth: 0 mm.
+- Set:
+  - **Start Depth:** 0.0 mm
+  - **Cut Depth:** 2.0 mm
+- Recheck "Tool" Parameters:
+  - Press "Edit": 
+    - Geometry:
+      - Diameter: 6mm
+    - Cutting Parameters:
+      - Pass Depth: 6mm
+      - Stepover: 4.002mm || 66.7%
+    - Feeds and Speeds:
+      - Spindle Speed: 8000 RPM
+      - Feed Rate: 80 in/min
+      - Plunge Rate: 15 in/min
+    - Tool Number: 1
+    - Press "OK"
 
-- **Tabs:**
+#### 5. Tabs
   - Small, uncut sections to keep parts attached to the sheet.
   - Prevents shifting or flying parts.
   - Size: Usually 3 mm wide and 2 mm high.
   - Automatically added in the Toolpath menu.
+  - Best used manually to avoid tabs at the edges. 
 
 ---
 
-#### 5. Preview Toolpaths
+#### 6. Preview Toolpaths  
+- Go to the **3D View** tab.  
+- Click:
+  - **Reset Preview**  
+  - **Preview Visible Toolpaths**  
+- If the toolpath appears erratic, the design may be **too small for the selected drill bit**.  
+- Fix it by:
+  - Returning to the **project tab**  
+  - Resizing the design (drag from its edge)  
+  - Or adjusting in your design software and re-exporting  
+- In the **Toolpath List**:
+  - Double-click **"Pocket 1"**  
+  - Click **Calculate**  
+- Repeat the adjustment if the toolpath still behaves erratically.
 
-Preview Visible Toolpaths
+#### 7. Changing the Drill Bit  
-Click on the 3D View tab
+- Turn off the CNC machine using the key (located at the bottom right) and remove it.  
-Reset Preview
+- Use two wrenches to loosen the collet assembly.  
-Preview Visible Toolpaths
+  - Hold both wrenches in one hand to stabilize, and twist the lower wrench to loosen the collet nut.  
+- Remove the collet and clean both the collet and nut for a secure fit.  
+- Reinsert the collet into its housing.  
+- Insert the new drill bit, leaving ~20 mm (or two fingers) exposed for cutting clearance.  
+- Tighten the collet assembly firmly using both wrenches.  
+- Reinsert the key, power on the machine, and re-calibrate the Z-axis.
 
-#### 5. ShopBot 3 Setup
+#### 8. ShopBot 3 Setup
 
 - Open **ShopBot 3** software.
 - Load the toolpath file (.sbp).
@@ -231,7 +284,7 @@ Preview Visible Toolpaths
 
 ---
 
-#### 6. Z-Axis Calibration
+#### 9. Z-Axis Calibration
 
 - Clip the wire to the collet nut or the spindle body of the CNC machine.
 - Place the **metal calibration plate** on the surface of the sheet.
@@ -241,7 +294,7 @@ Preview Visible Toolpaths
 
 ---
 
-#### 7. Start Machining
+#### 10. Start Machining
 
 - Click **Start** to begin the operation.
 - Monitor the machine continuously.