ccm update4

docs/Computer-controlled Machining.md

 #Computer controlled machining
 
-This week is about making something big using a CNC milling/routing machine. I want to explore the possibilities of CNC machining - drill, pocket, dog-bones, nesting, etc. I tried to make a versatile furniture piece so that I can use different joints and experiment with them.
+This week is about making something big using a CNC milling/routing machine. I want to explore the possibilities of CNC machining - drill, pocket, dog-bones, nesting, etc. I tried to make a versatile furniture piece so that I can use different joints and experiment with them.  
+
+![](./images/ccm/table.jpg)  
 
 ### Page Summary
 1. Introduction
@@ -29,20 +31,17 @@ Later when I used FabLab SP, I did it again using Vcarve Pro.
 
 2. Design
 ---
-Then I started making individual joints so they can be digitally machined in 2-axes or 2.5-axes. I used some details from the [50 Digital Joints poster](https://makezine.com/2014/12/04/50-digital-wood-joints-poster/) to design some details.  
-
-<img src="https://4.bp.blogspot.com/--n9402OLTus/U_6noVXA59I/AAAAAAAACSc/oZ05jYxALrg/s1600/j118.jpg" alt="traces" width="400"/><img src="https://2.bp.blogspot.com/-jbDFz7SGcr0/U_ciJGzoTUI/AAAAAAAAB_k/I0WwxF5HTmo/s1600/j62.jpg" alt="traces" width="400"/>  
-<img src="https://4.bp.blogspot.com/-s0gWF8SllU4/U_cbds0bfQI/AAAAAAAAB-s/eU6Buz-VbYE/s1600/j66.jpg" alt="traces" width="400"/><img src="https://d2mgbjyendvdw0.cloudfront.net/27204/03423/9ae702/slot-joint-02.standard.png" alt="traces" width="400"/>  
+I learnt about some details from the [50 Digital Joints poster](https://makezine.com/2014/12/04/50-digital-wood-joints-poster/). For the group assignment, I made a joint using both profiling and pocketing.
+![](./images/ccm/1.png)  
 
-I made some slotted joints, and versions of the finger tennons, lapped finger tennons, throughhole finger tennons to design the trestle.
-![](./images/ccm/1.png)   
+I also made some versions of the finger tennons, lapped finger tennons, throughhole finger tennons to design the trestle.
 ![](./images/ccm/2.png)  
 ![](./images/ccm/3.png)    
 
 Here is how the final legs look. I need to make 2 of these and put any flat board on top to make a tabletop.
-
 ![](./images/ccm/final.jpg)  
 
+Here it is in 3D.  
 <div class="sketchfab-embed-wrapper"> <iframe title="Trestlelegs 15mm" frameborder="0" allowfullscreen mozallowfullscreen="true" webkitallowfullscreen="true" allow="autoplay; fullscreen; xr-spatial-tracking" xr-spatial-tracking execution-while-out-of-viewport execution-while-not-rendered web-share src="https://sketchfab.com/models/d3bdb40771c04b519edc3b9295fd026b/embed"> </iframe> <p style="font-size: 13px; font-weight: normal; margin: 5px; color: #4A4A4A;"></div>
 
 3. Nesting
@@ -54,7 +53,9 @@ I made some changes manually to fit it all in the available sheet. Like I put tw
 
 ![](./images/ccm/nested.jpg)  
 
-<div class="sketchfab-embed-wrapper"> <iframe title="Trestlelegs 17mm Parts" frameborder="0" allowfullscreen mozallowfullscreen="true" webkitallowfullscreen="true" allow="autoplay; fullscreen; xr-spatial-tracking" xr-spatial-tracking execution-while-out-of-viewport execution-while-not-rendered web-share src="https://sketchfab.com/models/18fa9069d1d9437d8119f77e63d15e40/embed"> </iframe> <p style="font-size: 13px; font-weight: normal; margin: 5px; color: #4A4A4A;"></div>  
+<div class="sketchfab-embed-wrapper">
+<iframe title="Trestlelegs 17mm Parts" width="600" height="450" frameborder="0" allowfullscreen mozallowfullscreen="true" webkitallowfullscreen="true" allow="autoplay; fullscreen; xr-spatial-tracking" xr-spatial-tracking execution-while-out-of-viewport execution-while-not-rendered web-share src="https://sketchfab.com/models/18fa9069d1d9437d8119f77e63d15e40/embed"> </iframe> <p style="font-size: 13px; font-weight: normal; margin: 5px; color: #4A4A4A;">
+</div>  
 
 4. CAM
 ---
@@ -74,7 +75,7 @@ Next I set the tool - Flatmill 6mm, refering to the class notes and some previou
 *   Shoulder length = 30mm  
 *   Flute length = 30mm  
 
-Feed and speeds:   
+**Feed and speeds:**   
 *   Speeds: 12000 rpm  
 *   Plunge: 2000 rpm  
 *   Approach: 2000 rpm  
@@ -90,11 +91,10 @@ I set 5 points in the rhino file to engrave markings for screws to be drilled wi
 
 
 #### Pocketing
-The insides of some parts that needed to be cleared were cut first. 2 parts needed pocketing at different heights, Safter making adjustments in 2 different layers I changed the cut depth for both. 15mm for all parts except 2 where iwas 10mm.
-
-![](./images/ccm/fullpocketing.jpg)  
+The insides of some parts that needed to be cleared were cut first. 2 parts needed pocketing at different heights, So after making adjustments in 2 different layers I changed the cut depth for both. 15mm for all parts except 2 where it was 10mm.  
+![](./images/ccm/fullpocketing.jpg)   
 
-Settings:  
+**Settings:**  
 *   Cut pattern: Offset  
 *   Cut direction: Conventional (Up cut) - standard for plywood  
 *   Start point: inside  
@@ -102,7 +102,7 @@ Settings:
 *   Finish depth: 3  
 
 #### Profiling
-To cut the outside profiles of the parts, I set the profiling for 2.5 axis. I also made another profiling - inside fo2 curves that needed to be cut on the inside.
+To cut the outside profiles of the parts, I set the profiling for 2.5 axis. I also made another profiling - inside for 2 curves that needed to be cut on the inside.
 
 ![](./images/ccm/outerprofiling.jpg)  
 
@@ -112,38 +112,43 @@ Settings same as pocketing, set toolpath OUTSIDE the curves
 ![](./images/ccm/simlulation1.jpg)  
 
 Then I ran a simulation and found some errors in the settings.   
-1.  The cutting height did not match the level of the stock. It was cutting in the air. I adjusted this by going bacto the material panel and changing the stock thickness to 15mm. (It was 300 by mistake)  
-2.  The tool path just ran once over all profiles and went in 15mm in one pass. I changed this by making the cut dept15mm in roughing and finishing at 12 and 3 respectively.  
+1.  The cutting height did not match the level of the stock. It was cutting in the air. I adjusted this by going back to the material panel and changing the stock thickness to 15mm. (It was 300 by mistake)  
+2.  The tool path just ran once over all profiles and went in 15mm in one pass. I changed this by making the cut depth 15mm in roughing and finishing at 12mm and 3mm respectively.  
 3.  Some parts were creating double paths - so I deselected them from one layer and generated toolpaths again.  
 
 After running another simulation, it seemed fine.
 ![](./images/ccm/simlulation2.jpg)  
+I didn't get a chance to actually cut using the RhinoCAM gcode. You can find the design files at the end of this page.  
 
 ### Vcarve Pro  
-
-I used the full version of [Vcarve Pro 11](https://www.vectric.com/products/vcarve-pro) in FabLab SP.
+The standard workflow at FabLab SP was to import the dxf in Vcarve Pro and generate the gcode.  
+I used the full version of [Vcarve Pro 11](https://www.vectric.com/products/vcarve-pro) at the lab.
 ![](./images/ccm/1.open.png)  
 
-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.  
-Next, import the dxf.  
-![](./images/ccm/2.newfile.png)  
+First step is to start a new file specifying the size. In my case Width 2440mm, Length 1220mm and Material thickness 17mm.  
+![](./images/ccm/5.nest.png)  
 
-To save material, Vcarve had in-built nesting capabilities, this is very convenient.  
+Using the 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.  
+Next, import the dxf.  
 ![](./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.  
+Make sure all the curve are closed. If not, you can join them (J) from the menu bar.  
 ![](./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)  
+Vcarve actualy has in-built nesting capabilities, this is very convenient.  
+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 experimenting and learning, I go ahead with this.  
 ![](./images/ccm/6.nesting.png)  
 
+Next, recheck and set up the material dimensions. Also, select material top surface as origin. And left bottom corner as XY datum. In the toolpath tab on the right >>
 
-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 path Settings:**  
+Cutting Start Depth: 0 mm
+Cut Depth: 17.5mm (I keep this more then the material thickness, to foolproof cutting through in case of uneven bed level or material inconsistency)  
+Tool: 6mm endmill
+Machine vectors: On the OUTSIDE (Vcarve automatically cuts inside curves on the inside)  
+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  
@@ -156,24 +161,32 @@ Next, adding tabs so that the cut parts do not fly out. I set the tab size to Le
 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.  
 
-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.  
+Add a ramp.  
+I added a 15mm ramp so that the tool doesn't plunge directly into the material.  
 ![](./images/ccm/8.toolpathsettings.png)  
 
-On 'calculate' I got a warning popup 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.
+On 'calculate' I got a warning popup 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 accomodate the difference in material flatness and thickness. Also if there is any variation in the bed levelling. It will basically cut through 0.5mm through 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.
+The file is almost ready. Last step is to simulate the cutting and check if it works properly. This is important before actually cutting.  You can control the speed of the simulation and check the toolpaths in detail.
 ![](./images/ccm/13.3dtoolpath.png)  
 
-Save a tap format (gcode) file and send it to the computer of the CNC machine. There are multiple options of saving different profiles in one or multiple files.  
+Save a .tap format (gcode) file in mm and send it to the computer of the CNC machine. There are multiple options of saving different profiles in one or multiple files.  
 ![](./images/ccm/15.save.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.  
+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. I later found this was way off.  
 ![](./images/ccm/14.time.png)  
 
 5. Test settings
 ---
+Using a 17mm ply, I made the pockets 10mm deep and then made a slotted joint.  
+The wood I used for this was very soft, so it cut very clean in the milling machine, but cleaning it with a file was very difficult.  
+![](./images/ccm/G1.JPG)  
+
+On fixing the pieces togther, they weren't as clean as I imagined, and not as accurate.  
+![](./images/ccm/G2.JPG)   
 ![](./images/ccm/Gjoint1.png)  
 ![](./images/ccm/Gjoint2.png)  
 
@@ -192,7 +205,7 @@ Open NC-pro on the computer that is connected to the machine and check origin. I
 Next, start the dust collector.
 ![](./images/ccm/dustcollector.png)  
 
-On the remote, press 'start' and 'OK'.
+On the remote, press 'start' and 'OK'.  
 ![](./images/ccm/remote.png)  
 
 The spindle will start. The machine in the lab has a spindle regulator connected directly to it. So it doesn't use the setting from the gcode created in Vcarve.  
@@ -200,7 +213,7 @@ Cutting should now start. My file took approximately 2 hours to finish. It is ve
 The plunging created some burn marks in the holes.
 ![](./images/ccm/plunging.png)  
 
-I noticed that the toolpath doesn;t optimise paths by distance. Unlike in a lasercutter it cuts across the sheet in random(?) order.  
+I noticed that the toolpath doesn't optimise paths by distance. Unlike in a lasercutter it cuts across the sheet in random(?) order.  
 ![](./images/ccm/random.png)  
 
 After cutting is done, I unscrew the board from the base.
@@ -214,10 +227,10 @@ With Steven's help, I chiseled off all the tags from the pieces and found some p
 
 7. Assembly
 ---
-The machined parts have very rough edges, so I first used a burring tool to smoothen them.
+The machined parts have very rough edges, so I first used a burring tool to cut off chips.
 ![](./images/ccm/burr.png)  
 
-Used a file to clean joint details.  
+I use a file to clean joint details.  
 ![](./images/ccm/file.png)  
 
 And a hacksaw to cut off remains of tabs.  
@@ -234,17 +247,27 @@ So this is important to do before assembly. I wonder if in the future I can make
 Sanded and unsanded details:  
 ![](./images/ccm/difference.png)  
 
-I started assembling all parts together.  
-![](./images/ccm/assembly1.png)  
-
-
-Here's how it should look when done. (w/o the top surface)  
-![](./images/ccm/table.jpg)  
-
+I started assembling all parts together. Here are some pictures of details.  
 ![](./images/ccm/joint1.png)  
 ![](./images/ccm/joint2.png)  
 ![](./images/ccm/joint3.png)  
+![](./images/ccm/joint4.png)   
+![](./images/ccm/joint5.png)  
+
+Here's one finished part:   
+![](./images/ccm/onepart.jpg)  
+
+Here it is besides an actual IKEA Finnvard:  
+![](./images/ccm/ba.jpg)  
+
+Here are two of them:  
+![](./images/ccm/two.jpg)  
+
+And now by changing the height, its ready to use as a desk:  
+![](./images/ccm/two.jpg)  
 
+I has to recut these pieces as they were designed for 15mm thickness and not 17mm:  
+![](./images/ccm/redo.jpg)  
 
 8. References
 ---