machining

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Adding some details in the mouth, we have the final design.
<a title="Bender Final design"><img class="image center" src="images/week10/final.JPG"></a>
<h2>3D Machining</h2>
<h3>Material</h3>
To create the positive of the mold, a block of blue machinable wax with the dimensions of 77 mm x 160 mm will be use.
<a title="WAX"><img class="image center" src="images/week10/wax.jpg"></a>
This material is not a hazardous substance or mixture, you can read more about safety data sheet<a hred="http://www.freemanwax.com/pdfs/sdsFerrisBlueMachinable.pdf"> here</a>
<h3>Machining</h3>
We use the Roland mdx-540 machine with the SRP Player software to perform the positive machining of the mold. The first step is to indicate the measurements that our design will have, in my case is this size:
<div class="table-wrapper">
<table class="alt">
<tbody>
<tr>
<td>X</td>
<td>30mm</td>
</tr>
<tr>
<td>Y</td>
<td>67.5mm</td>
</tr>
<tr>
<td>Z</td>
<td>15mm</td>
</tr>
</tbody>
</table>
</div>
<a title="Size"><img class="image center" src="images/week10/size.jpg"></a>
For type of milling we use better surface finish, model with many curved surfaces and cut only top.
<a title="Type of milling"><img class="image center" src="images/week10/type.jpg"></a>
Now we choose material (polycarbonate) and create the measure with a small offset of the real size, that is necessary for casting, for material is not lost or incessant elements are manufactured
<div class="table-wrapper">
<table class="alt">
<tbody>
<tr>
<td>X</td>
<td>55mm</td>
</tr>
<tr>
<td>Y</td>
<td>82mm</td>
</tr>
<tr>
<td>Z</td>
<td>36mm</td>
</tr>
</tbody>
</table>
</div>
<a title="Type of milling"><img class="image center" src="images/week10/type.jpg"></a>
For roushing we use these parameters
<div class="table-wrapper">
<table class="alt">
<tbody>
<tr>
<td>Margin</td>
<td>5mm in all faces</td>
</tr>
<tr>
<td>Tool</td>
<td>4mm flat endmill</td>
</tr>
<tr>
<td>Feed rate</td>
<td>1000mm</td>
</tr>
<tr>
<td>Spindle</td>
<td>9000 RPM</td>
</tr>
<tr>
<td>Cutting-in amount</td>
<td>0.27mm</td>
</tr>
<tr>
<td>Path interval</td>
<td>1 mm</td>
</tr>
<tr>
<td>Finish margin</td>
<td>0.2 mm</td>
</tr>
</tbody>
</table>
</div>
<a title="Roushing process"><img class="image center" src="images/week10/roushing.jpg"></a>
For the finishing we use these parameters:
<div class="table-wrapper">
<table class="alt">
<tbody>
<tr>
<td>Margin</td>
<td>3.2mm in all faces</td>
</tr>
<tr>
<td>Tool</td>
<td>3mm ball endmill</td>
</tr>
<tr>
<td>Feed rate</td>
<td>800mm</td>
</tr>
<tr>
<td>Spindle</td>
<td>9000 RPM</td>
</tr>
<tr>
<td>Cutting-in amount</td>
<td>0.1 mm</td>
</tr>
<tr>
<td>Path interval</td>
<td>0.1 mm</td>
</tr>
<tr>
<td>Finish margin</td>
<td>0 mm</td>
</tr>
</tbody>
</table>
</div>
<a title="Finishing process"><img class="image center" src="images/week10/finishing.jpg"></a>
In the preview we can see that the estimated cutting time will be of 3,9 hours. Do not forget change of endmill in the process
<a title="Cutting process"><img class="image center" src="images/week10/cutting.jpg"></a>
Like the fabrication of all boards, we define zero position, but in this case will be in the middle of the wax, because the center o the software is in the middle of the design
<a title="Zero"><img class="image center" src="images/week10/zero.jpg"></a>
During the cutting process, we use a vacuum cleaner to remove all unnecessary material
<a title="Vaccum"><img class="image center" src="images/week10/vacum.jpg"></a>
We can appreciate a small video of the design cutting process.
<iframe width="560" height="315" src="https://www.youtube.com/embed/X_qVr9fDPcM" frameborder="0" allow="accelerometer; autoplay; encrypted-media; gyroscope; picture-in-picture" allowfullscreen></iframe>
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In order to start programming, it is necessary to first know very well the microcontrollers that we are going to use and those that we have used in the past weeks, so we must read the Attiny microcontroller datasheet.
The most used microcontrollers in the fabacademy are the attiny44 and the attiniy 45, another very used is the atmega328.<br>
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