ccm update

docs/Computer-controlled Machining.md

@@ -118,11 +118,82 @@ After running another simulation, it seemed fine.
 
 ### Vcarve Pro  
 
+Measure the material thickness with a vernier calliper in different parts of the material to use. My ply varied between 16.9 and 17.1mm. So I will use na average of 17mm as material thickness.  
 
+I used the full version of Vcarve Pro 11 in FabLab SP.
+
+First step is to start a new file specifying the size. In my case Width 2440mm, Length 1220mm and Material thickness 17mm.
+Using th rulers on the side, optionally set margin guides. I do this with an offset of 20mm inside the edge of the material. This 20mm space is for screwing the material on to the base before cutting.  
+![](./images/ccm/1.open.png)
+
+Next, import the dxf.  
+![](./images/ccm/2.newfile.png)  
+
+To save material, Vcarve had in-built nesting capabilities, this is very convenient.  
+![](./images/ccm/3.import.png)  
+
+To save more space, I try nesting with 45deg and enable part mirroring. This changes the grain of material for the same parts, but since I'm trying it out, I go ahead with this.  
+![](./images/ccm/4.joinvectors.png)  
+
+Next, recheck and set up the material dimensions. Also, select material top surface as origin. And left bottom corner as XY datum.
+![](./images/ccm/5.nest.png)  
+![](./images/ccm/6.nesting.png)  
+
+
+I;m using a 6mm flat compression endmill made of T carbide. So from the database, I select the correct bit and change the settings a little.  
+Tool diameter = 6 mm  
+No of flutes = 2  
+
+Spindle Speed = 12000 pm  
+Feed rate = 5000 mm/min  
+Plunge rate = 600 mm/min  
+Pass depth = 6 mm (=tool diameter)  
+![](./images/ccm/7.tool.png)  
+
+Next, adding tabs so that the cut parts do not fly out. I set the tab size to Length 12mm and depth 3mm to make it easy to cut later on. Again Vcarve has a convenient automatic tab generator. This can be customised using no of tabs, distance between tabs or even done manually by clicking on the lines. I found setting tabs by distance 200mm gave optimal results, with a slight extra effort to move around some tabs.  
+![](./images/ccm/9.addtabs.png)  
+
+After manually checking for all tabs, set machine vectors to outside, so that the kerf is outside the actual curve.
+![](./images/ccm/10.edittabs.png)  
+Single click to add a tab, double click to remove, and drag to move an existing one.  
+
+The software automatically places the inside nested curve toolpath inside without making a different layer for it. I also added a 12mm ramp so that the tool doesn't plunge directly into the material.  
+![](./images/ccm/8.toolpathsettings.png)  
+
+On 'calculate' I got an error saying the cutting depth exceeds the material thickness. I bypass this warning as the deeper cutting dimensions allows to cut the material without burr and accomodates the difference in material flatness and thickness. Also if there is any variation in the bed levelling. It will basically cut through 0.5mm thorough the waste sheet.
+![](./images/ccm/11.warning.png)  
+
+The file is almost ready. Last step is to simulate the cutting and check if it works properly. This is imporatant before actually cutting.  You can control the speed of the simulation and check the toolpaths in detial.
+![](./images/ccm/12.2dtoolpath.png)  
+
+Save a tap format (gcode) file and send it to the computer of the CNC machine.
+![](./images/ccm/13.3dtoolpath.png)  
+
+You can click the clock symbol on the tool path taskbar and by setting scale and feed, simulate the time it will take for cutting that particular profile. This is not super accurate, but helps in approximating the actual time exclusing the material setup and cleaning later on.  
+![](./images/ccm/14.time.png)  
+
+Save the profile. There are multiple options of saving different profiles in one or multiple files.  
+![](./images/ccm/15.save.png)  
 
 5. Machining
 ---
-Will do this part when I return to the lab.
+First mount the sheet on to the bed of the machine. Align properly with the waste board.
+Using a power drill, drill in screws to fix the sheet. Do this within 20mm from the edges of the sheet, so the tool doesnt interfere with the screws. Also use countersunk screws so that the cap height remians flush with the material surface.  
+
+Set X, Y origin at the left bottom of the sheet.  
+
+Open NC-pro on the computer that is connected to the machine and check origin. I do not change X and Y as they are set already as default. To set Z origin, I use a tool sensor. By temp moving XY to 150,75, put the probe below the tool and set 'tool Measure'. This basically sets the Z at the top of the material.  
+
+Next, start the dust collector and on the remote, press 'start' and 'OK'.
+
+Cutting should now start. My file took approximately 2 hours to finish. It is very shrill and loud, so it is important to wear ear protection.  
+
+After cutting is done,
+
+
+
+I found some pieces had to be cut again because they hadn't cut through.  
+![](./images/ccm/16.redo.png)  
 
 6. Assembly
 ---

docs/Molding & Casting.md

@@ -20,6 +20,10 @@ Materials are available in the lab:
 * EasyMold Silicon Putty  
 * Smooth-on mold release agent   
 
+Polytek EasyFlo 90 Liquid plastic
+EZFLO90
+https://polytek.com/products/easyflo-90-liquid-plastic
+
 **[Smooth-on Sorta Clear 37](https://www.smooth-on.com/products/sorta-clear-37/)**  
 
 This series of rubbers by Smooth-on are white translucent silicone rubbers that cure at room temperature with negligible shrinkage. They are very versatile because they offer a lot of easy features like: