week07.md

# 7. Computer controlled machining

# Group Assignment

## Instruction

group assignment

- do your lab's safety training
- test runout, alignment, fixturing, speeds, feeds, materials, and toolpaths for your machine

individual assignment

- [Here](https://fabacademy.org/2022/labs/kannai/students/yukiya-yamane/assignments/week08/)

## What I week this week

- Learn how to use machine safely and test runout, alignment, fixturing, speeds, feeds, materials, and toolpaths for your machine → in this page
- Ideate and design something big →[Individual Page](https://fabacademy.org/2022/labs/kannai/students/yukiya-yamane/assignments/week07/)
- Milling by CNC machine →[Individual Page](https://fabacademy.org/2022/labs/kannai/students/yukiya-yamane/assignments/week07/)
- Varnish and assemble →[Individual Page](https://fabacademy.org/2022/labs/kannai/students/yukiya-yamane/assignments/week07/)

## CNC Router and software I used

- CNC router : [ZN1325](http://www.mesin-cnc.com/?product=mesin-cnc-router-model-1325)
- Tool path maker : Vectric Cut2D Pro
- G-code sender :Mach3

## Safety Instructions

Safety was especially important for this week. Through the Wednesday class, I learned the risk and danger of CNC router. Tamiya-san gave me the lecture of how to use the CNC router.

    ![Untitled](../images/week07/safe.png)

## **CNC workflow**

### Setup CNC machine

- Launch Cut2D and create new file
- seting up about material parameter

    ![materialsetup](../images/week07/materialsetup.png)

- make toopath : set drilling position and cutting depth for fixing board

    ![cut2d_drilling.jpeg](../images/week07/cut2d_drilling.jpeg)

- Save these data as .tap file
- Launch Mach3 and load .tap file

    ![mach3.jpeg](../images/week07/mach3.jpeg)


### CNC machine setting and milling

- set the position of material (wooden plate) on the bed of CNC before fixing
- set x-y-z origin at the corner of the material ( or any other appropriate position ), and set x0/y0/z0 in Mach3
- fix the material on the bed by screwing

    ![screwing.jpg](../images/week07/screwing.jpg)


CNC machine is ready.

### Test

On my computer

- make 2D/3D CAD file :  Fusion 360
- the content of test will be described later

    ![testfusion](../images/week07/testfusion.png)

- Export file as .ai /.dxf
    - if choose .ai, save as “Illustrator CS”
    - Check ”Create pdf compatible file” in save setting

- load .ai file in Cut2D
- setting the tool (mill) information and “tabs” to support the material. selecting outside or inside is important

    ![cut2d_path.jpeg](../images/week07/cut2d_path.jpeg)

- edit Tool (depth, stepover, speed, feedrate)

    ![setting_excerpt.jpg](../images/week07/setting_excerpt.jpg)

- press “calcurate”
- set z-origin about 20 mm above the material surface, then, perform “air path” to check the tool path on CNC.
- set z-origin on the material surface ( by using paper to check the contact between tool tip and the material)
- wear the protective glassed and soundproof headphone
- start milling ( be prepared to push the stop button, in case of emergency )
- during the milling, check the wooden chips and the noise, then control the parameters such as feed rate, spindle speed, etc.
- after the milling completed, clean the material surface

    ![test.jpeg](../images/week07/test.jpeg)

- cut the “tabs”, pick up the parts.
- remove the material and sacrifice plate, then clean the CNC and room.

## Milling Test

- scaling milled board and compare real scale with designed scale

    ![test_scaling.jpg](../images/week07/test_scaling.jpg)

- check
    - runout : turned out 6mm in the test which is equal to the thread diameter
    - alignment : adjust positioning of end mill on the board and calibrate it
    - fixturing : fixed board by screwing
    - speeds : no problem to cut the material in 6500 rpm
    - feeds :  no problem to cut the material in 840 mm/min
    - materials : plywood
    - toolpaths : setting as mentioned above

## Tab and Pocket Test

- check whether pocket and dogbone can work or not
- Prepare a sample of the pockets I will use in my design
- load it to cut2D
- select only the inside hole and set these parameters. be carefull for selecting “machine vector : inside”

    ![test1.jpeg](../images/week07/test1.jpeg)

- export to .tap file and load it in Mach3
- milling the board to make holes
- After milling holes, choose only outside of the parts and set up parameters. In this time, select “Outside” in machine vectors

    ![test2.jpeg](../images/week07/test2.jpeg)

- milling the board

- milling completely

    ![pocket_test.jpeg](../images/week07/pocket_test.jpeg)

- inspect the hole to be cut clearly and completely

    ![pocket.jpeg](../images/week07/pocket.jpeg)

- detach tabs from the parts
- test to assemble tab with pocket

    ![assemble.gif](../images/week07/assemble.gif)

- got to assemble perfect

    ![assemble test.jpg](../images/week07/assemble_test.jpg)

## Making something big

→[Individual Assignment](https://fabacademy.org/2022/labs/kannai/students/yukiya-yamane/assignments/week08/)

## What I learn in this week
->  [Individual Assignment](https://fabacademy.org/2022/labs/kannai/students/yukiya-yamane/assignments/week08/)