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CNC Machine.md
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@ -59,6 +59,13 @@ When designing for CNC cutting:
#### Debris Management #### Debris Management
The CNC machine includes a built-in vacuum system that removes debris generated during cutting. This ensures: The CNC machine includes a built-in vacuum system that removes debris generated during cutting. This ensures:
<p align="center">
<img src="cnc-images/debris.jpg" style="border: 2px solid black;" />
</p>
<iframe src="https://giphy.com/embed/3apHw0wrSauGTP7yLf" width="480" height="269" style="" frameBorder="0" class="giphy-embed" allowFullScreen></iframe><p><a href="https://giphy.com/gifs/3apHw0wrSauGTP7yLf"></a></p>
- Cleaner work environment. - Cleaner work environment.
- Improved visibility and safety. - Improved visibility and safety.
- Better cut accuracy and finish. - Better cut accuracy and finish.
@ -67,6 +74,18 @@ The CNC machine includes a built-in vacuum system that removes debris generated
#### Importance of Dogbones #### Importance of Dogbones
<p align="center">
<img src="cnc-images/dogbone.png" style="border: 2px solid black;" />
</p>
<p align="center">
<img src="cnc-images/dogbone2.png" style="border: 2px solid black;" />
</p>
<iframe src="https://giphy.com/embed/Or8eV6iyuXgA9vTCIR" width="270" height="480" style="" frameBorder="0" class="giphy-embed" allowFullScreen></iframe><p><a href="https://giphy.com/gifs/Or8eV6iyuXgA9vTCIR"></a></p>
<iframe src="https://giphy.com/embed/5jqEdWh3tQpRXeuB7w" width="480" height="269" style="" frameBorder="0" class="giphy-embed" allowFullScreen></iframe><p><a href="https://giphy.com/gifs/5jqEdWh3tQpRXeuB7w"></a></p>
Due to the round shape of the cutting tool, internal corners in wooden joints are not naturally square. Adding **dogbone fillets** to these corners allows parts to fit tightly and accurately in press-fit constructions. Due to the round shape of the cutting tool, internal corners in wooden joints are not naturally square. Adding **dogbone fillets** to these corners allows parts to fit tightly and accurately in press-fit constructions.
--- ---
@ -94,46 +113,18 @@ Two materials are commonly available:
| MDF (Medium-Density Fiberboard) | - Smooth surface<br>- Easy to machine<br>- Less durable | | MDF (Medium-Density Fiberboard) | - Smooth surface<br>- Easy to machine<br>- Less durable |
| Plywood | - Layered structure<br>- Stronger and more resilient<br>- Harder to cut cleanly | | Plywood | - Layered structure<br>- Stronger and more resilient<br>- Harder to cut cleanly |
<!DOCTYPE html> <body>
<html lang="en"> <div class="row">
<head> <div class="column">
<meta charset="UTF-8"> <img src="cnc-images/mdf.jpeg" alt="Image 1">
<meta name="viewport" content="width=device-width, initial-scale=1.0"> <p class="caption">MDF Wood</p>
<style> </div>
/* Three image containers (use 33.33% for three images) */ <div class="column">
.column { <img src="cnc-images/plywood.jpeg" alt="Image 2">
float: left; <p class="caption">Plywood Wood</p>
width: 33.33%; </div>
padding: 5px;
border: 1px solid black; /* Add black outline */
}
/* Responsive images */
.column img {
width: 100%;
height: auto;
}
/* Image captions */
.caption {
font-size: 14px;
text-align: center;
}
</style>
</head>
<body>
<div class="row">
<div class="column">
<img src="cnc-images/mdf.jpeg" alt="Image 1">
<p class="caption">MDF Wood</p>
</div> </div>
<div class="column"> </body>
<img src="cnc-images/plywood.jpeg" alt="Image 2">
<p class="caption">Plywood Wood</p>
</div>
</div>
</body>
</html>
Cutting tests were conducted using MDF, optimizing speed and feed rate for best results. Cutting tests were conducted using MDF, optimizing speed and feed rate for best results.
@ -147,33 +138,6 @@ Machine calibration is required before each cutting job. For this CNC machine:
- A metal plate and wire clip are used. Once the drill touches the plate, an electrical signal finalizes the zero position. - A metal plate and wire clip are used. Once the drill touches the plate, an electrical signal finalizes the zero position.
- Regular checks are needed for worn parts and tool integrity. - Regular checks are needed for worn parts and tool integrity.
<!DOCTYPE html>
<html lang="en">
<head>
<meta charset="UTF-8">
<meta name="viewport" content="width=device-width, initial-scale=1.0">
<style>
/* Three image containers (use 33.33% for three images) */
.column {
float: left;
width: 33.33%;
padding: 5px;
border: 1px solid black; /* Add black outline */
}
/* Responsive images */
.column img {
width: 100%;
height: auto;
}
/* Image captions */
.caption {
font-size: 14px;
text-align: center;
}
</style>
</head>
<body> <body>
<div class="row"> <div class="row">
<div class="column"> <div class="column">
@ -186,7 +150,6 @@ Machine calibration is required before each cutting job. For this CNC machine:
</div> </div>
</div> </div>
</body> </body>
</html>
--- ---
@ -214,44 +177,18 @@ Choosing the right drill bit (end mill) is essential for clean, efficient cuts a
- Smooth on both sides. - Smooth on both sides.
- Ideal for plywood or double-sided finish materials. - Ideal for plywood or double-sided finish materials.
<!DOCTYPE html> <body>
<html lang="en"> <div class="row">
<head> <div class="column">
<meta charset="UTF-8"> <img src="cnc-images/drill.png" alt="Image 1">
<meta name="viewport" content="width=device-width, initial-scale=1.0"> <p class="caption">MDF Wood</p>
<style> </div>
/* Three image containers (use 33.33% for three images) */ <div class="column">
.column { <img src="cnc-images/drill2.png" alt="Image 2">
float: left; <p class="caption">Plywood Wood</p>
width: 33.33%; </div>
padding: 5px; </div>
border: 1px solid black; /* Add black outline */ </body>
}
/* Responsive images */
.column img {
width: 100%;
height: auto;
}
/* Image captions */
.caption {
font-size: 14px;
text-align: center;
}
</style>
</head>
<body>
<div class="row">
<div class="column">
<img src="cnc-images/drill.png" alt="Image 1">
</div>
<div class="column">
<img src="cnc-images/drill2.png" alt="Image 2">
</div>
</div>
</body>
</html>
--- ---
@ -276,6 +213,10 @@ Monitor chip formation and surface quality during tests to fine-tune settings.
#### Tips to Reduce Material Waste #### Tips to Reduce Material Waste
<p align="center">
<img src="cnc-images/material.png" style="border: 2px solid black;" />
</p>
- **Group Parts Efficiently:** Nest your parts close together in CAD to use the least amount of space. [20mm space] - **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. - **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. - **Add Labels:** Include engraved labels to organize parts and reduce re-cuts.
@ -292,13 +233,26 @@ This section outlines the full workflow for using the CNC machine, from preparat
#### 1. Preparation #### 1. Preparation
<iframe src="https://giphy.com/embed/3apHw0wrSauGTP7yLf" width="480" height="269" style="" frameBorder="0" class="giphy-embed" allowFullScreen></iframe><p><a href="https://giphy.com/gifs/3apHw0wrSauGTP7yLf"></a></p>
- Remove debris and previous sheets using a vacuum. - Remove debris and previous sheets using a vacuum.
- Unscrew and clear the CNC bed. - Unscrew and clear the CNC bed.
- Place the new sheet (MDF or Plywood). - Place the new sheet (MDF or Plywood).
- Adjust the sheet if bent; curve should face up with the middle touching the base. - Adjust the sheet if bent; curve should face up with the middle touching the base.
- Fasten using screws ~30 mm from the edges and along the center. - Fasten using screws placed within 20 mm from the edges.
- Use a minimum of 8 screws for secure attachment.
![Insert preparation image here](insert_image_path_here) <p align="center">
<img src="cnc-images/screw.png" style="border: 2px solid black;" />
</p>
<p align="center">
<img src="cnc-images/screw2.png" style="border: 2px solid black;" />
</p>
<p align="center">
<img src="cnc-images/sheet2.png" style="border: 2px solid black;" />
</p>
--- ---
@ -308,10 +262,10 @@ This section outlines the full workflow for using the CNC machine, from preparat
- Send the file to: `fablabbh.share@gmail.com` - Send the file to: `fablabbh.share@gmail.com`
- Open the file in **VCarve PRO**. - Open the file in **VCarve PRO**.
- Add a **30 mm offset** around the perimeter to avoid bolts. - Add a **30 mm offset** around the perimeter to avoid bolts.
- Use **Dogbone Fillet** tool (match radius to tool size, e.g., 3 mm for 6 mm bit).
![Insert VCarve screenshot here](insert_image_path_here) <p align="center">
<img src="cnc-images/vcarve.png" style="border: 2px solid black;" />
</p>
--- ---
#### Assigning Cut/Pocket #### Assigning Cut/Pocket
@ -324,34 +278,71 @@ Select the lines or shapes to define what will be cut or pocketed, then apply th
- Cuts along the outer or inner edge of a part. - Cuts along the outer or inner edge of a part.
- Defines the final shape by following the contour - Defines the final shape by following the contour
- Choose **Profile Toolpath**. - Choose **Profile Toolpath**.
<p align="center">
<img src="cnc-images/cut.png" style="border: 2px solid black;" />
</p>
- Set: - Set:
- **Start Depth:** 0 mm - **Start Depth:** 0 mm
- **Cut Depth:** 13 mm (12 mm material + 1 mm into sacrificial sheet) - **Cut Depth:** 13 mm (12 mm material + 1 mm into sacrificial sheet)
- Specify Machine Vectors:
- Select **Outside/Right** for vector machining to preserve size.
- Select **Inside/Left** for cutting internal shapes or holes.
- Select **On** for trimming directly along the vector line.
<p align="center">
<img src="cnc-images/cut2.png" style="border: 2px solid black;" />
</p>
- Tool Settings (6 mm bit): - Tool Settings (6 mm bit):
- Spindle Speed: 8000 RPM - Spindle Speed: 8000 RPM
- Feed Rate: 80 in/min - Feed Rate: 80 in/min
- Plunge Rate: 15 in/min - Plunge Rate: 15 in/min
<p align="center">
<img src="cnc-images/cut3.png" style="border: 2px solid black;" />
</p>
- Specify the Number of Passes: - Specify the Number of Passes:
- Press "Edit Passes" - Press "Edit Passes"
- Number of Passes: 2 - Number of Passes: 2
- First Pass Depth: 6.5mm - First Pass Depth: 6.5mm
- Second Pass Depth: 13mm - Second Pass Depth: 13mm
- Specify Machine Vectors:
- Select **Outside/Right** for vector machining to preserve size. <p align="center">
- Select **Inside/Left** for cutting internal shapes or holes. <img src="cnc-images/pass.png" style="border: 2px solid black;" />
- Select **On** for trimming directly along the vector line. </p>
- Click **Calculate**, then read the warnings, if it is within your expectations click **OK** to confirm. - Click **Calculate**, then read the warnings, if it is within your expectations click **OK** to confirm.
<p align="center">
<img src="cnc-images/calculate.png" style="border: 2px solid black;" />
</p>
<p align="center">
<img src="cnc-images/warning.png" style="border: 2px solid black;" />
</p>
--- ---
#### 4. Toolpaths: Pocket #### 4. Toolpaths: Pocket
- Used to hollow out an internal region. - Used to hollow out an internal region.
- Useful for engravings or fitting one piece into another. - Useful for engravings or fitting one piece into another.
- Choose **Pocket Toolpath**. - Choose **Pocket Toolpath**.
<p align="center">
<img src="cnc-images/pocket.png" style="border: 2px solid black;" />
</p>
- Set: - Set:
<p align="center">
<img src="cnc-images/pocket2.png" style="border: 2px solid black;" />
</p>
- **Start Depth:** 0.0 mm - **Start Depth:** 0.0 mm
- **Cut Depth:** 2.0 mm - **Cut Depth:** 2.0 mm
- You can specify this value for engraving operations to achieve precise and consistent depth.
- Recheck "Tool" Parameters: - Recheck "Tool" Parameters:
<p align="center">
<img src="cnc-images/pocket3.png" style="border: 2px solid black;" />
</p>
- Press "Edit": - Press "Edit":
- Geometry: - Geometry:
- Diameter: 6mm - Diameter: 6mm
@ -365,6 +356,16 @@ Select the lines or shapes to define what will be cut or pocketed, then apply th
- Tool Number: 1 - Tool Number: 1
- Press "OK" - Press "OK"
#### Dogbone Fillet
<iframe src="https://giphy.com/embed/Or8eV6iyuXgA9vTCIR" width="270" height="480" style="" frameBorder="0" class="giphy-embed" allowFullScreen></iframe><p><a href="https://giphy.com/gifs/Or8eV6iyuXgA9vTCIR"></a></p>
- Apply Dogbone Fillet to all internal corners used as joints
- Match radius to tool size (e.g., 3 mm radius for 6 mm bit)
- Allows square parts to fit snugly despite round tool paths
- Ensures clean, accurate assembly in CNC-milled joints
#### 5. Tabs #### 5. Tabs
- Small, uncut sections to keep parts attached to the sheet. - Small, uncut sections to keep parts attached to the sheet.
- Prevents shifting or flying parts. - Prevents shifting or flying parts.
@ -374,40 +375,137 @@ Select the lines or shapes to define what will be cut or pocketed, then apply th
--- ---
#### 6. Preview Toolpaths #### 6. Preview Toolpaths
- Go to the **3D View** tab. - Click on **Preview Toolpaths**.
- Click:
- **Reset Preview** <p align="center">
- **Preview Visible Toolpaths** <img src="cnc-images/preview.png" style="border: 2px solid black;" />
- If the toolpath appears erratic, the design may be **too small for the selected drill bit**. </p>
- Fix it by:
- Returning to the **project tab** - In the drop-down, select **Preview Visible Toolpaths**.
- Resizing the design (drag from its edge)
- Or adjusting in your design software and re-exporting <p align="center">
- In the **Toolpath List**: <img src="cnc-images/preview2.png" style="border: 2px solid black;" />
- Double-click **"Pocket 1"** </p>
- Click **Calculate**
- Repeat the adjustment if the toolpath still behaves erratically. - Go to the **3D View** tab.
- Click on **Toolpaths** in the top-right corner.
<p align="center">
<img src="cnc-images/preview3.png" style="border: 2px solid black;" />
</p>
- Then do the following:
<p align="center">
<img src="cnc-images/preview4.png" style="border: 2px solid black;" />
</p>
- Manually lower the **Speed** setting.
- Select **Reset Preview**.
- In the **Toolpath List**, select the part to inspect.
- Select **Preview Visible Toolpaths**.
- If the toolpath preview appears erratic, the design may be *too small for the selected drill bit*.
<p align="center">
<img src="cnc-images/example.png" style="border: 2px solid black;" />
</p>
<p align="center"><em>Example</em></p>
- To fix this:
<p align="center">
<img src="cnc-images/preview5.png" style="border: 2px solid black;" />
</p>
- Return to the **Project** tab.
- Resize the design by dragging from its edge.
- Or adjust the design in your original software and re-export it.
- Back in the **Toolpath List**:
<p align="center">
<img src="cnc-images/preview6.png" style="border: 2px solid black;" />
</p>
- Double-click the part to re-inspect.
- Scroll down and click **Calculate**.
- If the toolpath still appears irregular, repeat the adjustment steps above.
#### 7. Changing the Drill Bit #### 7. Changing the Drill Bit
- Turn off the CNC machine using the key (located at the bottom right) and remove it. - For a better understanding, watch the first video on this page starting at 14:40.
- Use two wrenches to loosen the collet assembly. - Turn off the CNC machine using the key (located at the bottom right) and remove it.
- 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. <p align="center">
<img src="cnc-images/preview7.png" style="border: 2px solid black;" />
</p>
- Use two wrenches to loosen the collet assembly.
<p align="center">
<img src="cnc-images/preview8.png" style="border: 2px solid black;" />
</p>
- 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.
<p align="center">
<img src="cnc-images/preview9.png" style="border: 2px solid black;" />
</p>
- Reinsert the collet into its housing. - Reinsert the collet into its housing.
- Insert the new drill bit, leaving ~20 mm (or two fingers) exposed for cutting clearance. - Insert the new drill bit, leaving ~20 mm (or two fingers) exposed for cutting clearance.
- Tighten the collet assembly firmly using both wrenches. - Tighten the collet assembly firmly using both wrenches.
- Reinsert the key, power on the machine, and re-calibrate the Z-axis. - Reinsert the key, power on the machine, and re-calibrate the Z-axis.
#### 8. ShopBot 3 Setup #### 8. ShopBot 3 Setup
- After checking that every toolpath is using Tool 1, Click **Save**.
<p align="center">
<img src="cnc-images/save.png" style="border: 2px solid black;" />
</p>
- Click **Save Toolpath(s) to File** -> save it as **all**
<p align="center">
<img src="cnc-images/save2.png" style="border: 2px solid black;" />
</p>
- Open **ShopBot 3** software. - Open **ShopBot 3** software.
- Load the toolpath file (.sbp).
- Move the drill head to desired origin (corner of the sheet). <p align="center">
<img src="cnc-images/1.png" style="border: 2px solid black;" />
</p>
- 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.
<p align="center">
<img src="cnc-images/2.png" style="border: 2px solid black;" />
</p>
<p align="center">
<img src="cnc-images/3.png" style="border: 2px solid black;" />
</p>
- Run the **Z-zeroing command** (machine lowers bit to touch the plate).
<p align="center">
<img src="cnc-images/4.png" style="border: 2px solid black;" />
</p>
- A warning will pop-up, and press **OK**.
<p align="center">
<img src="cnc-images/ok.png" style="border: 2px solid black;" />
</p>
- System detects contact and sets Z = 0.
<iframe src="https://giphy.com/embed/hiA4oUAEYvE0RDByUW" width="480" height="269" style="" frameBorder="0" class="giphy-embed" allowFullScreen></iframe><p><a href="https://giphy.com/gifs/hiA4oUAEYvE0RDByUW"></a></p>
- 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.
- Then, move the drill head to desired origin (corner of the sheet).
- Set: - Set:
- **X = 0** - **X = 0**
- **Y = 0** - **Y = 0**
- Run Z-axis calibration.
--- ---