add inst week09

docs/Instruction/week08.md

@@ -137,7 +137,7 @@ Ref. [last year](http://academany.fabcloud.io/fabacademy/2021/labs/kannai/site/g
     Easier procedure to burn bootloader into USB-D11C-serial board  
     [USB-D11C-serial (Arduino IDE + Xiao)](./tips/FA2022_usbserial_ArduinoIDE_Xiao.md)
 
-### ToDO
+### ToDo
 
 ### Read/browse one of the data sheets
 

docs/Instruction/week09.md

 # 9. Molding and casting
 
-This week I worked on defining my final project idea and started to getting used to the documentation process.
+## Preparation for next week
+> **Output Devices**  
+> *group assignment:*  
+> measure the power consumption of an output device  
+> *individual assignment:*  
+> add an output device to a microcontroller board you've designed,  
+> and program it to do something
 
-## Research
+### for final project
+[finalproject_function](https://fabacademy.org/2022/labs/kannai/students/yukiya-yamane/projects/final-project/#function)
 
-"Lorem ipsum dolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor incididunt ut labore et dolore magna aliqua. Ut enim ad minim veniam, quis nostrud exercitation ullamco laboris nisi ut aliquip ex ea commodo consequat. Duis aute irure dolor in reprehenderit in voluptate velit esse cillum dolore eu fugiat nulla pariatur. Excepteur sint occaecat cupidatat non proident, sunt in culpa qui officia deserunt mollit anim id est laborum."
+> - LED illumination of the back cover depending on the air quality  
+>   
+> When the Air Quality is good (CO2 is low, temperature is comfortable…), the light turns green..
+>   
+> When the Air Quality is bad (CO2 is high, temperature is too hot or cold…), the light turns red..
 
-> "Lorem ipsum dolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor incididunt ut labore et dolore magna aliqua. Ut enim ad minim veniam, quis nostrud exercitation ullamco laboris nisi ut aliquip ex ea commodo consequat. Duis aute irure dolor in reprehenderit in voluptate velit esse cillum dolore eu fugiat nulla pariatur. Excepteur sint occaecat cupidatat non proident, sunt in culpa qui officia deserunt mollit anim id est laborum."
+#### Color LED
+[kannai_inventry](https://docs.google.com/spreadsheets/d/16No34EYWp9jkpQH5ESc-zzDbUVTjdCI8g1H436G6a8c/edit#gid=426488364)
 
-## Useful links
+##### RGB LED
 
-- [Jekyll](http://jekyll.org)
-- [Google](http://google.com)
-- [Markdown](https://en.wikipedia.org/wiki/Markdown)
+![](./images/week09/rgb_led.png){width=200}
+![](./images/week09/rgb_led_sch.png){width=300}
 
-## Code Example
+##### NeoPixel(WS2812)
 
-Use the three backticks to separate code.
+[![](./images/week09/WS2812.png){width=200}](https://akizukidenshi.com/catalog/g/gI-07915/)
+![](./images/week09/WS2812_sch.png){width=200}  
+C1 104 = 100nF = 0.1uF
+Ref. [https://www.newark.com/uf-nf-pf-capacitor-conversion-table](https://www.newark.com/uf-nf-pf-capacitor-conversion-table) 
+![](./images/week09/neopixel.png){width=200}  
 
-```
-// the setup function runs once when you press reset or power the board
-void setup() {
-  // initialize digital pin LED_BUILTIN as an output.
-  pinMode(LED_BUILTIN, OUTPUT);
-}
-
-// the loop function runs over and over again forever
-void loop() {
-  digitalWrite(LED_BUILTIN, HIGH);   // turn the LED on (HIGH is the voltage level)
-  delay(1000);                       // wait for a second
-  digitalWrite(LED_BUILTIN, LOW);    // turn the LED off by making the voltage LOW
-  delay(1000);                       // wait for a second
-}
-```
 
-## Gallery
+##### neon (EL wire)
+
+  - EL: Electroluminescence
+  - Ref. [How to make EL-wire blink?(Arduino)](https://kavasmlikon.wordpress.com/2011/11/21/how-to-make-el-wire-blink/)
+
+[![](./images/week09/EL_wire.png){width=300}](www.amazon.co.jp/dp/B09M8NP2YF)
+
+#### EL sheet
+
+ - Ref. [monotaro](https://www.monotaro.com/g/01140022/)
+
+#### Lumisheet RGB
+
+ - Ref. [Lumisheet RGB](http://conquest93.com/surface-emitting.html)
+
+### for Machine Building
+
+#### Stepper motor
+
+ - Moter driver
+
+#### Servo motor
+
+
+#### DC motor
+
+### Preparation
+
+none
+
+
+## Group Assignment
+
+>  review the safety data sheets for each of your molding and casting materials,  
+>  then make and compare test casts with each of them  
+>  extra credit: try other molding and casting processes
+
+
+### Materials
+
+- machinable wax, modeling wax
+    - [Ferris File-A-Wax : blue](https://www.freemanwax.com/products/jewelry-carving-waxes/matt-wax-blocks-tablets/blue-matt-wax-blocks-tablets)
+    - [SDS](http://academany.fabcloud.io/fabacademy/2021/labs/kannai/site/instruction/local_session/images/sds-mattblue.pdf)
+
+- Silicone rubber
+    - Mold Star 31T 0.9KG Trial Kit
+    - [Smooth-on SDS](https://www.smooth-on.com/products/mold-star-trade-31t/)
+    - [SDS_JP](http://academany.fabcloud.io/fabacademy/2021/labs/kannai/site/instruction/images/sds/Mold%20Star%2019T%2C%2020T%20%2C%2031T%20%20%E3%82%B7%E3%83%AA%E3%83%BC%E3%82%BA_TI.pdf)
+    - Mix ratio by Volume: 1A:1B
+    - Mix ratio by Weight: 1A:1B
+    - pot life: 5 min
+    - cure time: 23 min
+    - color: Translucent
+    - [Share Hardness](https://www.smooth-on.com/page/durometer-shore-hardness-scale/): 30A
 
-![](../images/sample-photo.jpg)
+![](./images/week09/durometerchart.png)
+
+- Urethanes resin
+    - Smooth-Cast 320 0.86KG Trial kit
+    - [Smooth-on SDS](https://www.smooth-on.com/products/smooth-cast-320/)
+    - [SDS](http://academany.fabcloud.io/fabacademy/2021/labs/kannai/site/instruction/images/sds/Smooth-Cast_320%2C_321%2C_322.pdf)
+    - Mix ratio by Volume: 1A:1B
+    - Mix ratio by Weight: 100A:90B
+    - pot life: 3 min
+    - cure time: 10 min
+    - color: Off white
+    - Share Hardness: 70D
+
+- So-strong
+    - Color Tints for Urethane
+    - [Smooth-on SDS](https://www.smooth-on.com/products/so-strong/)
+    -  0.01% to 3% of total system weight
+- Metal
+    - Bismuth Based Alloy Ingot
+        - [低融点合金地金（ # 138・共晶）・Pb/Cdフリー200g](https://www.zairyo-ya.com/products/236.html)
+        - 138 C
+        - [SDS_JP](http://academany.fabcloud.io/fabacademy/2021/labs/kannai/site/instruction/images/sds/LM138%E3%83%BBSDS.pdf)
+    - [Tin](https://www.zairyo-ya.com/products/ZASN03001.html)
+        - 231.9 C
+
+### Safety
+- ventilation
+    - open windows, fans...
+- protection
+    - glass
+    - groves
+- disposal
+    - finish chemicals reaction before dispose  -> heat
+    - dispose cups and Stir bars directly into bin
+    - change groves
+        - **do not touch any uncovered place, chair, desk...**
+
+## Individual assignment:
+
+>  design a mold around the stock and tooling that you'll be using,  
+> mill it (rough cut + three-axis finish cut),  
+> and use it to cast parts  
+> extra credit: use more then two mold parts  
+
+### Sizes  
+
+!!! Attention
+    1. Check all material and tool sizes in whole process
+    2. 3D model should be arranged with these sizes
+    3. start milling
+
+- Machinable wax
+    - size: 152mm x 92mm x 39mm (real size is smaller)
+- Machines
+    - Genmitsu PROVerXL
+        - work area: 400mm × 300mm × 110mm
+    - MDX-15
+        - work area: 152.4mm × 101.6mm × 60.5mm
+- Endmill
+    - 0.1250” DIA 4FL SE LONG AlTiN 1/8
+        - Tool_dia: 1/8” =3.175mm
+        - OverAll Length: 2-1/4”(2.25”) =57.15mm
+        - **Rough cut**
+    - 0.0625” DIA 2FL SE AlTiN 1/16
+        - Tool_dia: 1/16” =1.5875mm
+        - OverAll Length: 1-1/2”(1.5”) =38.1mm
+        - **Finish cut**
+
+### Design restriction from these sizes
+
+- XY size -> real wax size
+   - Final Part size < (real wax size - wax_wallx2 - mold_wallx2)
+   - distance between bumps (凸 and 凸) > 1.58mm(1/16”) > 0.79mm(1/32”)
+   - width of dent 凹: tool size > 1.58mm(1/16”) > 0.79mm(1/32”)
+- Z depth
+   - tool: 1/16_endmill_lemgth=38.1mm -in_collet_lenght=10mm = 28mm
+   - machine: genmitsu_z=110mm - Wax_height_39mm = 71mm > tool_length
+   - machine: MDX-15_z=60.5mm - Wax_height_39mm = 21.5mm
+       - 2 sides mold: 21.5mm each = 43mm_max
+       - 1 side mold: 21.5mm_max
+  - prevention of hitting collet
+      - Ref. [last year](http://academany.fabcloud.io/fabacademy/2021/labs/kannai/site/instruction/local_session/week11/)
+        - [tilt image](http://academany.fabcloud.io/fabacademy/2021/labs/kannai/site/instruction/images/tilt_simple_image.png)
+        - [tilt degree calculation](http://academany.fabcloud.io/fabacademy/2021/labs/kannai/site/instruction/images/tilt_degree_image.png)
+
+### Design for casting
+
+- Registration (for alignment)
+    - ref. [How to Make Molds](https://www.instructables.com/How-to-make-molds/)
+    - [Registration Key](https://content.instructables.com/FGW/SY6T/HXLD7MNO/FGWSY6THXLD7MNO.jpg?auto=webp&fit=bounds&frame=1&height=1024&width=1024)
+    - nest (recommend)
+- sprue -> lower position
+- runner
+- air vent -> higher position
+- parting line  -> edge/surface -> deburring
+
+### Process
+  - 1 side molding/ 2 sides molding or more
+  - negative/positive
+      - 3D modeling process
+          - [sample](https://a360.co/3mwu8mo)
+          - design final part (positive)
+          - design molds to make final part (negative)
+          - design wax to make molds (positive)
+      - casting process
+          - pour liquid silicone rubber into wax to cast molds (negative)
+          - pour liquid resin into molds to cast final part (positive)
+
+### ToDo
+
+#### Design
+
+- Fusion360
+    - Final_part
+        - model **including smooth tilted or curved surfaces instead of "steps" towards axis Z**
+    - Silicon_mold
+        - model Silicon_block
+        - combine > cut
+            - Silicone_block - final part = Silicon_mold
+    - Wax
+        - model Wax_block
+        - combine > cut
+            - Wax_block - Silicone_mold
+    - add
+        - Sprue
+        - Air vent
+        - Registration key
+
+#### Milling
+
+- genmitsu ProVerXL
+    - Tips: [Wax milling with mods and Genmitsu PROVerXL4030](./tips/wax_milling_mods.md)
+    - rough cut
+    - finish cut
+        - Stepover
+
+```
+// mill 3D stl -> mill raster 3D node
+
+var w = evt.data.width
+var xmin = evt.data.xmin
+var xmax = evt.data.xmax
+var diameter = evt.data.diameter
+var stepover = evt.data.stepover
+var mmunits = evt.data.mmunits
+var step = Math.floor(stepover*diameter*w/(mmunits*(xmax-xmin)))
+```
 
-## Video
+#### Casting Silicone mold
 
-### From Vimeo
+- Silicone rubber: Mold Star 31T
+    - weight 1A:1B
+    - Mix
+        - pot life
+    - Cure
+        - cure time -> longer in low temperature
+        - 2 sides molds -> cure completely otherwise stick together
 
-<iframe src="https://player.vimeo.com/video/10048961" width="640" height="480" frameborder="0" webkitallowfullscreen mozallowfullscreen allowfullscreen></iframe>
-<p><a href="https://vimeo.com/10048961">Sound Waves</a> from <a href="https://vimeo.com/radarboy">George Gally (Radarboy)</a> on <a href="https://vimeo.com">Vimeo</a>.</p>
+#### Casting material
 
-### From Youtube
+- Urethane resin
+    - Weight 100A:90B
+    - Mix
+        - pot life
+    - Cure
+        - cure time -> longer in low temperature
+- Metal
+    - talk
+    - Mold Star 31T: heat resistant up to 232°C
+        - Bismuth Based Alloy (138 C)
+        - Tin (231.9 C)
+- Silicone rubber
+    - release agent
+- Food
+    - Silicone rubber is not food safety -> do not eat  
 
-<iframe width="560" height="315" src="https://www.youtube.com/embed/jjNgJFemlC4" frameborder="0" allow="autoplay; encrypted-media" allowfullscreen></iframe>
+### Assessment
 
-## 3D Models
+[Assessment](https://fabacademy.org/2022/nueval/moulding_and_casting.html)
 
-<div class="sketchfab-embed-wrapper"><iframe width="640" height="480" src="https://sketchfab.com/models/658c8f8a2f3042c3ad7bdedd83f1c915/embed" frameborder="0" allow="autoplay; fullscreen; vr" mozallowfullscreen="true" webkitallowfullscreen="true"></iframe>
+FAQ  
 
-<p style="font-size: 13px; font-weight: normal; margin: 5px; color: #4A4A4A;">
-    <a href="https://sketchfab.com/models/658c8f8a2f3042c3ad7bdedd83f1c915?utm_medium=embed&utm_source=website&utm_campaign=share-popup" target="_blank" style="font-weight: bold; color: #1CAAD9;">Dita&#39;s Gown</a>
-    by <a href="https://sketchfab.com/francisbitontistudio?utm_medium=embed&utm_source=website&utm_campaign=share-popup" target="_blank" style="font-weight: bold; color: #1CAAD9;">Francis Bitonti Studio</a>
-    on <a href="https://sketchfab.com?utm_medium=embed&utm_source=website&utm_campaign=share-popup" target="_blank" style="font-weight: bold; color: #1CAAD9;">Sketchfab</a>
-</p>
-</div>
+> **What does 3-axis milling mean?**  
+> Answer: You should have smooth tilted or curved surfaces instead of  
+> "steps" towards axis Z.