Finished documentation for CNC Milling / Electronics Production with Dhanu!

docs/assignments/week04/week04-milling-pcb.md

@@ -8,25 +8,142 @@
 
 ### Cheatsheet
 
-**Context**: You already have the design of the board you'd like to use, and you are happy with it (no design changes required).
+**Context**: You already have the design of the board you'd like to use, and you are happy with it (no design changes
+required).
 
-1. Load the design into [mods](http://modsproject.org/) and load the custom program for the Roland SRM-20 that you can find in the Barcelona Lab.
-   1. You can find [the customized programs for milling and cutting](https://fabacademy.org/2022/labs/barcelona/students/eduard-almasque/assignments/04-electronics-production/week04-creating-basic-boards/#automating-these-almost-perfect-programs) in Edu's documentation
+This assumes that the designs have been customized for the machine that you will be using: e.g. Since the machine will
+use a 1/64th inch milling bit, the traces will need to be at least 1/64th inch separated from each other, etc..
+
+If this is not the case, you might have to customize your board design. Check out our documentation from **Week 06
+Electronics Design**.
+
+#### Creating the milling programs
+
+1. Load the design into [mods](http://modsproject.org/) and load the custom program for the Roland SRM-20 that you can
+   find in the Barcelona Lab.
+    1. You can
+       find [the customized programs for milling and cutting](https://fabacademy.org/2022/labs/barcelona/students/eduard-almasque/assignments/04-electronics-production/week04-creating-basic-boards/#automating-these-almost-perfect-programs)
+       in Edu's documentation
 2. You will use the milling program to mill the traces, and the cutting program to cut out the outline of your board.
-   1. Load the custom program into mods by:
-      1. Right-clicking on an empty space, and chosing "Programs > Open program from file"
-      2. Load the milling program you downloaded
-   2. Load the traces file that has the design of your board (PNG or SVG)
+    1. Load the custom program into mods by:
+        1. Right-clicking on an empty space, and choosing "Programs > Open program from file"
+        2. Load the milling program you downloaded
+        3. This program has been customized for the Barcelona Lab machines, so you don't have to customize any other
+           settings.
+        4. If you cannot use this custom program, you will have to customize the settings manually.
+           See [custom settings section](#manually-configuring-settings) for a detailed breakdown.
+    2. Load the traces file that has the design of your board (PNG or SVG)
+    3. Click "Calculate" and the \*.RML file will be downloaded
+        1. You will use this file to mill your traces when you are on the Roland machine
+    4. Repeat the process with the cutting programme, and the outline file
+        1. This will give you the RML file to do the outline.
 
+### Launching the milling programs
 
-## Our lab equipment
+3. Book time in the Roland SRM-20 machine.
+    1. lol. no one ever does it!
+4. Go to the computer lab, and launch the _V-Panel for SRM-20_ app. This application is used to send milling jobs to the
+   Roland SRM-20 machine.
+5. Get a new blank board.
+    1. Stick it to the bed with double-sided tape.
+    2. Make sure you cover the entire surface to avoid it moving out of place.
+6. Load the 1/64th inch. milling bit (for tracing) into the machine
+    1. Remember to hold it in place with your finger while you tighten it, to make sure it doesn't fall off and break
+       while you are tightening it.
+7. Configure the 0,0 for X and Y axis
+    1. Close the safety cover
+    2. Use the VPanel app to move the milling bit to the starting coordinates for X and Y only.
+    3. Click on the "X/Y" button under the "Set origin point" in order to configure those to 0,0
+8. Configure the 0 for the Z axis
+    1. ⚠️This is the dangerous (expensive) step, if you do it wrong/carelessly
+    2. You need to move the milling bit close to the board, without it touching.
+    3. You will need to carefully unscrew the bit and lower it gently by hand until it rests on top of the board.
+    4. Once it is resting on top of the board, tighten it again, while still holding it in place to avoid it going
+       up/down.
+    5. Click on the "Z" button under the "Set origin point"
+9. Validate your settings (Optional)
+    1. You can lift the spindle up a few mm
+    2. Turn on the spindle. Wait until it reaches 10k rpm.
+    3. Lower it very slowly until it reaches Z = 0 and see if it's touching the board and milling a tiny dot into it.
+    4. If it's not milling properly, you Z is set too high, and you should readjust.
+10. You have successfully calibrated your equipment. 👯‍♂️👯‍♀️🎉
+11. You are not ready to load the RML file into the application.
+    1. Click the "Cut" button.
+    2. Delete any pending tasks that might be on the list.
+    3. Click on "Add" to load your file
+    4. ⚠ Mill the job!
+        1. Click on Output to launch the milling job
+12. Other tips:
+    1. You can always pause the job to check out what it looks like, and resume later.
+    2. You can cancel the job to fully stop the operation. This will not let you resume and you will have to restart the
+       job from the beginning.
+
+### Launching the cutting programs
+
+Repeat the steps above, but load the 1/32 inch. into the spindle instead of the 1/64 inch one ⚠️IMPORTANT: You will need
+to recalibrate the Z axis only!
+
+### Manually Configuring Settings
+
+#### Milling settings
+
+1. Make sure that your file has a **DPI of 1000**
+2. Under _PCB Defaults_ module;
+    1. Set offset number to **4**
+    2. Set speed to **3mm/s**
+    3. ![](week04-our-first-board/set-pcb-defaults.jpg)
+3. Under _Roland SRM-20 Absolute Coordinate_ module:
+    1. Set speed to 3mm/s
+    2. Origin to **0,0,0**
+    3. Jog height to **10mm**
+    4. Set Z coordinate for home to **20mm**
+    5. ![](week04-our-first-board/roland-coordinate-settings.jpg)
+4. Under the _mill-raster 2D_ module:
+    1. Check if the offset number is **4**
+    2. Check that direction is set to **Climb**
+    3. ![](week04-our-first-board/read-png.jpg)
+5. Connect a line between the _Absolute Coordinates_ module (the _output_ node) to the "Save File" module.
+6. Click on _Calculate_ and the RML will automatically be downloaded by your browser
+
+#### Cutting settings
+
+Cutting the outline uses the same settings except for these small tweaks
 
+2. Under _PCB Defaults_ module;
+    1. Set offset number to **1**
+    2. Set speed to **1.5mm/s**
+3. Under _Mill Raster 2D_ module:
+    1. Set Max depth: set 1.75mm
+
+![](week04-our-first-board/mill-raster.jpg)
+
+## Our lab equipment
 
 ### Roland SRM-20
 
+Our barcelona lab has a couple Roland SRM-20 milling machines.
+
+![](week04-our-first-board/srm20_png.png)
+
+### Testing our machine tolerances
+
+![](week04-our-first-board/linetest.png)
+
+During week 3, we had to test and find out what are the tolerances for our equipment, so we could make important design
+decisions when milling and designing new boards.
+
+![](week04-our-first-board/milling-tolerances.jpg)
+
+To find out, we printed out a test board and this is the result.
+
+#### Conclusions:
+
+**Physical Constraints**: When cutting from the outside, anything under 0.007mm will be scraped off and will not have any copper material left.
 
+**Mods Logic**: When cutting from the inside, anything under 0.014mm will not be cut, as the milling bit is too wide, and Mods will not
+allow it to get milled.
 
-### Authors:
+### Documented by:
 
 - [Dhanu](https://fabacademy.org/2022/labs/barcelona/students/dhanushree-prakash/)
 - [Adai](https://fabacademy.org/2022/labs/barcelona/students/adai-surinac/)