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CNC Machine.md
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@ -12,6 +12,12 @@ The CNC (Computer Numerical Control) machine used in this lab is a large-format
---
#### 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:
---
#### 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
- Feed Rate: 60 in/min (can vary based on tool condition and material)
- Optimal Speed: 8000 RPM
- 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.
- **Shared Cutting Lines:** When possible, let neighboring shapes share cut lines.
- **Group Parts Efficiently:** Nest your parts close together in CAD to use the least amount of space. [20mm space]
- **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.
---
@ -171,8 +187,15 @@ This section outlines the full workflow for using the CNC machine, from preparat
---
#### 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 **On** for
- Tabs: ++++++++
- Select **Inside/Left** for cutting internal shapes or holes.
- Select **On** for trimming directly along the vector line.
- 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).
- Start Depth: 0 mm.
- Choose **Pocket Toolpath**.
- 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
Click on the 3D View tab
Reset Preview
Preview Visible Toolpaths
#### 7. Changing the Drill Bit
- Turn off the CNC machine using the key (located at the bottom right) and remove it.
- Use two wrenches to loosen the collet assembly.
- 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).
@ -231,17 +284,17 @@ 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.
- Run the **Z-zeroing command** (machine lowers bit to touch the plate).
- System detects contact and sets Z = 0.
- After calibration, remove the clip and plate, then return them to their original location with the clip still attached to the plate.This ensures smooth CNC operation.
- After calibration, remove the clip and plate, then return them to their original location with the clip still attached to the plate. This ensures smooth CNC operation.
---
#### 7. Start Machining
#### 10. Start Machining
- Click **Start** to begin the operation.
- Monitor the machine continuously.