http://wiki.makespace.org/api.php?action=feedcontributions&user=Perfectphase&feedformat=atomMakespace - User contributions [en]2024-03-29T05:28:15ZUser contributionsMediaWiki 1.22.6http://wiki.makespace.org/Equipment/CNC_RouterEquipment/CNC Router2016-01-04T01:43:23Z<p>Perfectphase: /* Spindle Motor Inverter */</p>
<hr />
<div>{{RedTool}}<br />
<br />
== CNC ROUTER IS DECOMMISSIONED ==<br />
<br />
Pending revision and/or replacement, the CNC router is now decommissioned. Usage is restricted to people operating with full knowledge that steps can be missed and the height can get wrong, resulting in head crashes. Be careful, wear safety goggles. No new training pending replacement or upgrade.<br />
<br />
[[Equipment|Equipment]] / CNC Router<br />
<br />
[[File:WP_20130509_005.jpg|thumb|460px|right|CNC Router]]<br />
<br />
<br />
== Summary ==<br />
<br />
A CNC router is a computer controlled shaping machine. These are related to the hand held router. Instead of hand held routing, the tool paths can be controlled via computer numerical control. It is a computer-controlled machine for cutting various hard materials, such as wood, composites, aluminum, steel, plastics, and foams. It is one of many kinds of tools that have CNC variants. A CNC router is very similar in concept to a CNC milling machine. The CNC router is controlled by a computer. Coordinates are uploaded into the machine controller from a separate CAD program<br />
<br />
* Capacity: 1200 x 1200 x 120mm<br />
* Rate (X,Y): 6000mm/min (Max) 5000mm/min (Working)<br />
* Rate (Z): 30mm/sec<br />
* Spindle Speed: 4500 to 24000rpm<br />
* Mechanical Precision: 0.01mm<br />
* Spindle Power: 1.5KW Variable Speed, Water-cooled<br />
* Blade Diameter: min 3.175mm, max 12.7mm <br />
* Order Format: HPGL, G code, u00, mmg, plt <br />
* Control System: DSP with USB connection <br />
<br />
Here are some examples we've made on the CNC router (please add a photo of yours any time you do a job!) <br />
<br />
<gallery><br />
File:WP_20130509_004.jpg<br />
File:WP_20130624_017.jpg<br />
File:WP_20130625_001.jpg<br />
</gallery><br />
<br />
= Using the CNC Router =<br />
== Owners ==<br />
<br />
The Owners are those who have volunteered to be in charge of the equipment, organising maintenance, training others to use it, and generally being a point of contact. The current Owners of the CNC Router are:<br />
<br />
* [[User:perfectphase|Stephen Woolhead]]<br />
* Mark Mellors<br />
* Dave Ansell<br />
* David Bebb<br />
* Simon Stirley<br />
* Jason White<br />
* Rick Lupton<br />
* Robin Sterling<br />
* Shareef Jalloq<br />
* Hidde-Jan Lemstra<br />
<br />
<br />
-- Further Contacts --<br />
<br />
* Chris Abri <!--chris.abri1985@gmail.com--><br />
<br />
If you have any questions, problems or concerns around the CNC router, please use the mailing list thread:<br />
* [https://groups.google.com/d/topic/cammakespace/rkchD7VqM2c/discussion Log : CNC Router]<br />
<br />
== Training ==<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>YOU CAN ONLY USE THE CNC ROUTER IF YOU HAVE BEEN TRAINED</b><br><br />
and have been added to the [[Equipment/CNC_Router/Training#Trained_Users|Trained Users]] list by one of the Owners<br />
</div><br />
<br />
To get trained on the CNC router and be added to the qualified user list, you will need to arrange for a training session with one of the Owners. <br />
<br />
If you'd like to arrange training, please see:<br />
* [[Equipment/CNC_Router/Training|CNC Router Training]]<br />
<br />
== Health and Safety ==<br />
<br />
The CNC Router is a potentially dangerous piece of equipment which must only be operated by members who have received appropriate training and who take due care. The top things to always remember when using the CNC Router are:<br />
* '''ONLY USE THE CNC ROUTER IF YOU ARE ON THE LIST OF TRAINED USERS'''<br />
* '''NEVER LEAVE THE CNC ROUTER RUNNING UNATTENDED'''<br />
<br />
As a trained user, you should be very aware of the following risks and how to deal with them:<br />
<br />
'''FIRE''' - Cutting with the wrong settings could result in the material igniting.<br />
<br />
'''TRAPPING''' - Stand clear of the machine while in motion.<br />
<br />
'''DUST''' - Ensure extraction system is working.<br />
<br />
'''NOISE''' - Ensure that you wear the correct PPE when working with the machine for prolonged periods.<br />
<br />
Full Risk assessment[[File:CNC_Router.pdf ]]<br />
<br />
== CNC Glossary ==<br />
<br />
As with most new ventures into another profession or hobby, there is the need to learn a “new language” and its common abbreviations. We have introduced some of these in the description of the workflow process above. Here we’ll look at some in more detail. These are listed in alphabetical order.<br />
<br />
=== 2D/2.5D/3D Toolpaths ===<br />
<br />
Depending on the information source, the definitions of 2D, 2.5D and 3D can be quite vague and appear to overlap.<br />
<br />
'''2D''' is simple horizontal cuts at a constant Z depth. For example, you cut out letter or a plaque shape to hang on the wall by moving the tool down to a specific depth and tracing the shape of the part you are cutting in 2D.<br />
<br />
'''2.5D''' would be a little more complex than 2D as while the tool is cutting, the Z depth would be changing instead of staying constant. Typically this still uses 2D vector data to define the path but the way the tool moves in relation to the 2D data and its form will determine the shape that is cut. The most common example of 2.5D is VCarving. Although this cuts 2D vector shapes, the V-shaped tool “rides” on the edges of the vectors, so as it gets wider it cuts deeper and as the vector get closer together it will lift up in Z.<br />
<br />
'''3D'''' These are toolpaths that like 2.5D toolpaths can move simultaneously in all 3 (X, Y and Z) axes however the shape they cut is described by following a 3D computer model and not vectors. They are typically cut with a Ball-Nose (round ended) tool. The tool will go back and forth across the 3D model following the contours of the part similar to an old fashioned copying or digitizing machine. The smoothness of the finished part depends on the Stepover setting in the toolpath as that determines how many times the tool will pass over the model. The size of the tool is also important as the software will only let it cut the detail that the end of the tool can fit into as it traces over the virtual surface. Examples of 3D toolpaths are 3D Rouging and 3D Finishing<br />
<br />
=== 3-axis===<br />
<br />
A 3-axis CNC machine is one that can move a router bit in the 3 primary directions, X, Y and Z. The image below show 3 views of a typical CNC setup and how the axes are referenced from each viewing direction.<br />
<br />
=== CAD ===<br />
<br />
CAD has been used as an abbreviation for both “Computer Aided Design” and “Computer Aided Drafting”. Now it has become a generic term in its own right that refers to a software program that can be used to create a 2D or 3D design.<br />
<br />
=== CAM ===<br />
<br />
When you discuss designing and preparing projects for your CNC machine, the follow-on side of CAD is CAM, which stands for ‘Computer Aided Manufacturing’ or ‘Computer Aided Machining’. This is the part of the process where the geometry developed during the CAD design process are now used to create the instructions that will move your CNC machine to ‘manufacture’ or machine the part.<br />
<br />
=== Collet ===<br />
<br />
The collet assembly is the component on a router or spindle that holds the router bit securely and consists of a precision collet and a collet nut. The collet is precisely sized to hold the router bit shank and the collet nut applies a compressive, friction fit as it is properly tightened onto the router or spindle shaft. It is very important to keep the collets clean and well maintained and depending on use, they must be periodically replaced.<br />
<br />
=== Gantry ===<br />
<br />
The gantry is the part of a CNC machine that typically has one of the horizontal axes running along it and also moves along the other horizontal axis to create the X and Y movement for the tool. The Z axis is also typically mounted on the gantry.<br />
<br />
=== G-Code === <br />
<br />
This is a generic term for the code which is sent to the machine with the instructions telling it how to move. Or, to put it in our context, the file that is saved from the software using the Post Processor to format it for the CNC machine. In reality it’s a particular type of data that a lot of CNC’s use a variant of – so G-code is not necessarily interchangeable to different machines. The name comes from the fact that many of the codes within in start with a G. For example G01 specifies a Feed Rate move and G00 specifies a Rapid move etc.<br />
<br />
=== Pass ===<br />
<br />
When you have a toolpath that is too deep, too wide or a combination of both for the router bit to remove all the material at one time, the toolpath is broken up into multiple ‘Passes’ with each pass removing a part of the material.<br />
<br />
When the toolpath is too deep, a Pass Depth (see entry below) value for the bit will be set and used to indicate the maximum Z depth the tool should cut on each Pass. The amount of material a tool can remove will be determined by the tooltype, size, material being cut and many other parameters. Tooling manufacturers typically offer recommendations for these values.<br />
<br />
=== Post Processor ===<br />
<br />
There are hundreds of different brands and models of CNC machines currently in use. When it comes to controlling them, many have a lot in common, but there can and will be differences. So, if you look at this as each machine speaks a slightly different language, there has to be a way for a single CAD/CAM program to speak to each machine and this is accomplished by using an “interpreter” called a Post Processor, also sometimes simply referred to as ‘pp’ or ‘post’.<br />
<br />
For example, you design a project to cut an exact size circle out of a piece of material and calculate a toolpath to do that. When you actually save that toolpath so it can be used at your CNC machine, the correct Post Processor will ensure the instructions for cutting that circle are prepared correctly so your CNC machine can read and understand them and accurately cut the circle as you intended.<br />
<br />
=== Router Bed or Machine Bed === <br />
<br />
The ‘bed’ identifies the part of a CNC machine where the material being machined is placed and held securely in position. For best results, the bed needs to be flat and sturdy. In most designs the bed is stationary; however there are exceptions to this where the bed moves to provide either the X or Y axis movement.<br />
<br />
=== Sacrifice Sheet / Spoilboard === <br />
<br />
The spoilboard is normally a sacrificial sheet of material placed on top of the machine bed and is intended to be replaced as necessary. It protects the machine bed and allows frequent surfacing which will help to keep a truly flat surface to mount material and help maintain accuracy. This allows the stock material to be screwed down to it and the parts drilled and cut all the way through the material thickness.<br />
<br />
=== Stepover ===<br />
<br />
The Stepover setting found for most router bits allows you to control horizontal movement when machining areas wider than the router bit. Physically, stepover is the distance the center of the bit moves horizontally for each pass.<br />
<br />
The Stepover is shown in the programs as both a physical distance (0.025” or 0.5mm for example) and as a percentage of bit diameter (6%, 8%, 50%, etc.). You can enter either value and the software will automatically calculate the other one for you. Typically most users refer to Stepover by its percentage value as it is a simple whole number and can easily be translated to other tool sizes for a particular task, for example when finishing setting the Stepover to be 10% of the ballnose tools diameter normally creates a reasonably finish surface.<br />
<br />
=== Toolpath ===<br />
<br />
A toolpath is the path created during the CAM part of your project design and represents the instructions your CNC machine will use to make the router bit move to duplicate what you have designed. In the software it is typically displayed as a set of lines which show a virtual picture of the path the tool tip will move along when the toolpath is run on the machine.<br />
<br />
=== Vector ===<br />
<br />
Vector is the word used to describe a 2D line, arc or curve. A vector can be used to describe almost any 2D shape.<br />
<br />
== Instructions ==<br />
<br />
[http://wiki.makespace.org/File:MPC6610_CNC_Router_Manual_v1.0-En.pdf Router Manual]<br />
<br />
[[Equipment/CNC_Router/Hand_Controller|Hand Controller Look-up Guide]]<br />
<br />
===Setting the Z Origin Using the Z0 Sensor===<br />
''A tool that has an extremely narrow tip may break when it touches the tool sensor depending on which tool is to be used.''<br />
<br />
1. Secure the workpiece on the bed, and place the Z0 sensor at the place where you want to set the Z origin on the workpiece. Face the surface of the Z0 sensor without the magnet facing upward.<br />
<br />
[[image:Mill_z0.PNG]]<br />
<br />
2. Use the handset to move the tool to the position above the sensor.<br />
<br />
3. On the handset press OK + 8(Z-0). The tool slowly descend until it contacts the sensor. When the tool rises and stops, the setting operation is complete. <br />
<br />
Note: It is important the tool is electrically conductive from tip to shaft, and the sensor is clean. Failure to check will cause damage to the tool and sensor.<br />
<br />
4. Remove the sensor from the workpiece to a location where it will not interfere with future cutting operations.<br />
<br />
==Software==<br />
<br />
The standard software is Vectric's line of CAM software:<br />
<br />
===VCarvePro===<br />
<br />
[[image:Vcarvepro.png]]<br />
<br />
VCarve Pro provides a powerful but intuitive software solution for 2D design and calculation of 2D and 2.5D toolpaths for cutting parts on a CNC Router. <br />
<br />
The software can import 2D designs from other programs but also includes a full set of drawing and editing tools with advanced layout options such as True-Shape Nesting. The toolpath options cover all typical 2D routing operations such as Profiling, Pocketing, Auto-Inlays and Drilling as well as 2.5D strategies such as V-Carving, Prism carving, Fluting and even a decorative Texturing strategy. Each toolpath includes appropriate options to customize the settings and provide a high level of control for different types of operation. In addition all toolpaths can be previewed to show just how the part will look when it is actually cut, this allows instant feedback to allow toolpaths to be further optimized. <br />
<br />
'''Details''': http://www.vectric.com/products/vcarve-pro.htm<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/vcarve-pro<br />
<br />
===Cut3D===<br />
<br />
[[image:Vectric-cut3d.jpg|266px]]<br />
<br />
Cut3D is a dedicated toolpath engine for CNC machining 3D models that have been designed using a 3D CAD or Graphics design product such as AutoCAD, Rhino3D, 3D Studio etc. or scanned using a laser or touch probe device. Cut3D's exceptionally easy to use interface leads you step-by-step through the process of loading a model, setting the size, interactively placing tabs to hold the job in place, calculating single, double or four sided roughing and finishing toolpaths, previewing the results and finally saving the CNC code to run on your machine.<br />
<br />
3D Models that are too large / thick to machine because of gantry height, cutter length or limited material thickness can be 'Sliced' into separate pieces. Each slice can then be machined and the complete job assembled. <br />
<br />
'''Details''': http://www.vectric.com/products/cut3d.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/cut3d<br />
<br />
===PhotoVCarve===<br />
<br />
[[image:Vectric-photovcarve.gif|266px]]<br />
<br />
PhotoVCarve creates lines of grooves that vary in width and depth to represent the detail in a photograph or image. The quality of the finished result is very dependant upon a high level of contrast between the material surface and the machined grooves. This information is very important to remember when cutting designs using the PhotoVCarve software. <br />
<br />
PhotoVCarve machines dark areas in a photograph with wide groove and the lighter areas to have narrower ones. The software automatically calculates the toolpaths based on the cutter selected and maximum depth of groove required. <br />
<br />
'''Details''': http://www.vectric.com/products/photovcarve.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/photovcarve<br />
<br />
== Tooling ==<br />
<br />
=== Router Bits ===<br />
<br />
Router bits (or cutters) are the most common type of cutter, they have two or more vertical cutting edges. These are good general purpose cutters that can be found in most DIY shops. They are the same type that you would use in a manual hand held router.<br />
<br />
<gallery><br />
File:WP_20130813_025.jpg<br />
File:WP_20130813_025.jpg<br />
File:WP_20130814_002.jpg<br />
File:WP_20130814_003.jpg<br />
</gallery><br />
<br />
It is important to notice that the cutters are on the edge of the body only, they do not extend to the centre of the cutter. This means the cutter CAN NOT BE USED AS A DRILL. An holes that are made by these sorts of cutters must be made by ramping the cutter to the correct depth in a sloping or spiral motion.<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>NEVER USE ROUTER BITS THAT HAVE BEARINGS.</b> These types of cutters are designed for manual routers where you can feel the feed back of the bearing in contact with the material being cut. A CNC device has no such feedback and will press the bearing into the material has hard as it can until something gives, i.e. the cutter breaks or much worse the spindle breaks. People found using these types of cutters on the CNC router will be BANNED! Just use the version without the bearing.<br />
<br />
<gallery><br />
File:WP_20130813_018.jpg<br />
</gallery><br />
<br />
The cutting edges should always be the lowest part of the cutter.<br />
</div><br />
<br />
=== End mills ===<br />
<br />
'''Up Cut and Down Cut'''<br />
<br />
Router end mills have two variants, up cut (left) and down cut (right); there is a third type, compression, but they are quite rare.<br />
<br />
<gallery><br />
File:WP_20130813_015.jpg<br />
</gallery><br />
<br />
Most cutters are up cut, which have the cutting service on the top of the flutes and as they rotate lift the chips up and away from the material being cut.<br />
<br />
Down cut cutters have the cutting edge on the bottom of the flutes and push chips down towards the material being cut. This has the advantage of pressing the material being cut into the bed of the machine; this is especially useful for thin plastics. The other advantage is the top surface shows far less breakout and splintering, this is a big advantage for materials like laminates.<br />
<br />
On image on the left has been cut with an up-cut end mill and the image on the right a down-cut.<br />
<br />
<gallery><br />
File:WP_20130813_005.jpg<br />
File:WP_20130813_007.jpg<br />
</gallery><br />
<br />
NOTE: There is a very big disadvantage to down cut end mills, and that is that they do not clear there chips effectively in blind holes. This means they need larger ramping moves to get to the correct cutting depth and if used in pockets without enough clearance, the friction can lead to burning or melting of the material being cut.<br />
<br />
Another down side to down-cut cutters, is that when cutting pockets, the bottom surface will not be as clean as that made with an up-cut cutter, which will do a far better job of clearing the waste chips that rub between the cutter and the material with a down-cut.<br />
<br />
== Stock Tooling ==<br />
<br />
In order to keep a small stock of cutters for general use, the CNC Router needs to have a means of generating money. Because there is no material provided for use with the CNC Router there is no way to bring in any funds for such things. Therefore, we ask that if you use one of the communal cutters please put 50p into the CNC Router Honesty Box. This will go towards funding for replenishing stock and also for the replacement of the sacrificial bed once it gets worn out. Please email the list if a communal cutter is broken or missing, so that they can replace it with one from stock. <br />
<br />
There will likely be 1 or two of each of the following cutters available for use, however please do not count on this being the case:<br />
<br />
* 2.5mm square cutter - single flute<br />
* 1/8" square cutter - single flute<br />
* 1/8" ball cutter - 2 flute<br />
<br />
* 6mm square cutter - 2 flute<br />
* 6mm ball cutter - 2 flute<br />
<br />
* engraver 0.2 30deg 1/8" 30mm length (8 of)<br />
* engraver 0.8 30deg 1/8" 30mm length (2 of)<br />
<br />
* 22mm 2 flute straight <br />
* 90deg x 32mm VBit<br />
<br />
<br />
Some Suppliers are listed below:<br />
<br />
== Feeds & Speeds ==<br />
<br />
What are feeds and speeds? Why are they important?<br />
<br />
[http://www.youtube.com/watch?v=ip2jm_6aUyk&feature=c4-overview&list=UUivA7_KLKWo43tFcCkFvydw Milling machine tutorial - cutter selection, speeds and feeds]<br />
<br />
[http://en.wikipedia.org/wiki/Speeds_and_feeds Wikipedia - Speeds and feeds]<br />
<br />
The phrase speeds and feeds (or feeds and speeds) refers to two separate velocities in machine tool practice, cutting speed and feed rate. They are often considered as a pair because of their combined effect on the cutting process. Each, however, can also be considered and analyzed in its own right.<br />
<br />
Cutting speed (also called surface speed or simply speed) is the speed difference (relative velocity) between the cutting tool and the surface of the workpiece it is operating on. It is expressed in units of distance along the workpiece surface per unit of time, typically surface feet per minute (sfm) or meters per minute (m/min). Feed rate (also often styled as a solid compound, feedrate, or called simply feed) is the relative velocity at which the cutter is advanced along the workpiece; its vector is perpendicular to the vector of cutting speed. Feed rate units depend on the motion of the tool and workpiece; when the workpiece rotates (e.g., in turning and boring), the units are almost always distance per spindle revolution (inches per revolution [in/rev or ipr] or millimeters per revolution [mm/rev]). When the workpiece does not rotate (e.g., in milling), the units are typically distance per time (inches per minute [in/min or ipm] or millimeters per minute [mm/min]), although distance per revolution or per cutter tooth are also sometimes used.<br />
<br />
===Spindle speed quick reference===<br />
<br />
{| class="wikitable"<br />
!|<br />
!|400Hz <br />
!|350Hz <br />
!|300Hz <br />
!|250Hz <br />
!|200Hz <br />
!|150Hz <br />
|-<br />
!|RPM<br />
|24000 <br />
|21000 <br />
|18000 <br />
|15000 <br />
|12000 <br />
|9000 <br />
|-<br />
|}<br />
<br />
===Feed rate quick reference===<br />
<br />
{| class="wikitable" <br />
!|100% <br />
!|75% <br />
!|66% <br />
!|50% <br />
!|33% <br />
!|25% <br />
|-<br />
!|6000<br />
|4500<br />
|3960<br />
|3000<br />
|1980<br />
|1500<br />
|-<br />
!|5000<br />
|3750<br />
|3300<br />
|2500<br />
|1650<br />
|1250<br />
|-<br />
!|4000<br />
|3000<br />
|2640<br />
|2000<br />
|1320<br />
|1000<br />
|-<br />
!|3000 <br />
|2250 <br />
|1980 <br />
|1500 <br />
|990 <br />
|750 <br />
|-<br />
!|2500 <br />
|1875 <br />
|1650 <br />
|1250 <br />
|825 <br />
|625 <br />
|-<br />
!|2000 <br />
|1500 <br />
|1320 <br />
|1000 <br />
|660 <br />
|500 <br />
|-<br />
!|1500 <br />
|1125 <br />
|990 <br />
|750 <br />
|495 <br />
|375 <br />
|-<br />
!|1000 <br />
|750 <br />
|660 <br />
|500 <br />
|330 <br />
|250 <br />
|-<br />
!|500 <br />
|375 <br />
|330 <br />
|250 <br />
|165 <br />
|125 <br />
|-<br />
|}<br />
<br />
=== Sample feed rates ===<br />
<br />
For working out feeds and speeds, recommend http://www.cnccookbook.com/CCGWizard.<br />
<br />
The feeds and speeds below have been tested on our machine. The 3mm cutters were single flute carbide. 2 flute HSS cutters may require different settings to avoid breakages.<br />
<br />
{| class="wikitable"<br />
!|MDF<br />
!|1mm deep <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep <br />
|-<br />
!|3mm &Oslash;<br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|-<br />
!|6mm &Oslash; <br />
|3000/24Krpm<br />
|3000/15Krpm <br />
|2000/13Krpm <br />
|1500/11Krpm <br />
|-<br />
!|22mm &Oslash; <br />
|3000/5000rpm <br />
|N/A <br />
|N/A<br />
|N/A<br />
|-<br />
|}<br />
<br />
{| class="wikitable"<br />
!|Plywood<br />
!|1mm deep <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep<br />
|-<br />
!|3mm &Oslash; <br />
|2000/24Krpm <br />
|2000/24Krpm<br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|-<br />
!|6mm &Oslash;<br />
|3000/15Krpm<br />
|3000/15Krpm <br />
|1500/15Krpm <br />
|1000/11Krpm <br />
|-<br />
!|22mm &Oslash; <br />
|3000/5Krpm <br />
|N/A <br />
|N/A<br />
|N/A<br />
|-<br />
|}<br />
<br />
<br />
Polycarbonate:<br />
300Hz 1600mm/min<br />
<br />
Foamed PVC (foamex):<br />
6mm diameter, 10mm deep pass depth, spindle 400Hz (24krpm), feed 9000mm/min.<br />
<br />
3mm diameter, 3mm deep pass depth, 400Hz (24krpm), 9000mm/min.<br />
<br />
Polyurethane foam:<br />
<br />
6mm diameter, full depth pass (30mm+), 400Hz (24krpm), 9000mm/min.<br />
<br />
3mm diameter, 6mm deep pass depth, 400Hz (24krpm), 9000mm/min.<br />
<br />
Acetal (Delrin):<br />
<br />
6mm Cutter, 2mm deep pass depth, spindle 150 - 180Hz, feed 3000mm/min.<br />
<br />
1/8th or 3mm cutter, 1.5 - 2mm deep pass depth, spindle 130 - 160Hz, feed 2-3000mm/min.<br />
<br />
== Tips & Tricks ==<br />
<br />
= Maintenance =<br />
<br />
The maintenance of the CNC Router is carried out by the Owners, with some basic maintenance being carried out by Users on every job.<br />
<br />
== Maintenance Schedule ==<br />
Every job<br />
* Vacuum cutting dust from bed and around machine<br />
* Sand down high points created on sacrificial bed by cutting/screwing<br />
<br />
As required, by users<br />
* Empty extraction bin <br />
* check for blockages in manifold box where extraction pipes meet<br />
<br />
Monthly<br />
* Inspect extraction hoses for splits/ wear<br />
* Clean guide rails (Don't oil them, it makes dust stick)<br />
* Check level, condition and flow of cooling water and replace as necessary<br />
* Inspect sacrificial bed, re-skim or replace as required<br />
* Inspect cable from pendent to router<br />
* Inspect ER11 collet nut for wear<br />
* Inspect auto levelling probe wire<br />
* check collet set for wear/damage<br />
* Check USB socket on pendent and USB memory stick for splits/damage<br />
<br />
Annual<br />
* Check nuts on lead screws for excessive backlash and adjust if required<br />
* Inspect all covers/structure for signs of damage, cracks etc<br />
* Check tightness (or even presence) of screws holding covers in place<br />
* Check CNC electronics (and PC) cabinets for dust build up and vacuum out if required<br />
* Check feet/supports are all taking load and that the structure is level/flat<br />
* Check motor cables aren't wearing/cracking<br />
<br />
== Maintenance Log ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
3/7/13: Lower spindle clamp bolts replaced with longer stainless ones, holes through tapped as original ones had stripped.<br />
23/12/15: complete maintenance checklist completed. controller cable slightly frayed at machine end, collet nut could do with being replaced. otherwise, everything fine.<br />
<br />
== Maintenance Shopping List ==<br />
<br />
* Cutters<br />
* Sacrificial Bed (1.2m x 1.2m 12mm MDF)<br />
* ER11 collet nut<br />
* controller cable<br />
<br />
= Becoming an Owner/Trainer =<br />
<br />
Becoming an '''Owner''' of a piece of Makespace equipment means that you will be responsible for the maintenance, upkeep and H&S of that equipment. You will also be responsible for running inductions and keeping the information banks (Wiki/Forum/Google Groups) maintained.<br />
<br />
A '''Trainer''' is responsible for running inductions only but will be required to understand how the machine works in order to pass on the relevant skills. A trainer will not be required to maintain the machine but would be expected to keep an eye on its status and report any issues if they develop (as would be expected of any user).<br />
<br />
== Steps to becoming an Owner or Trainer ==<br />
<br />
* Step 1: Contact a current Owner who will talk you through the various responsibilities. [http://wiki.makespace.org/Equipment/CNC_Router#Owners Owners] or Forum: [http://makespace.org/forum/viewtopic.php?f=20&t=89 here]<br />
* Step 2: Sign up to a 'Train the Trainer Training' session on Meetup. It is likely one will need to be set up specially in order for you to sign up but the owner you spoke to should take care of this.<br />
* Step 3: Complete the training to the satisfaction of the Owner/s running the sessions.<br />
* Step 4: Have your name added to the Trainers list and set up your first solo induction session.<br />
* Step 5: Once you are a Trainer you are eligible to become an Owner of the CNC Router. To become an Owner will simply require one further meeting with one of the current owners. This will simply be to walk through the requirements and techniques of maintaining the machine along with any other responsibilites. If the other owners are happy, you can add your name to the [http://wiki.makespace.org/Equipment/CNC_Router#Owners Owners] list.<br />
<br />
== Train the Trainer Training ==<br />
<br />
The first session will be fairly informal, with a look to getting more familiar with the machine and how it operates. We will walk through the Induction cheat-sheet (located on the Wiki) and discuss methods of giving attendees the information they need to use the CNC Router safely.<br />
<br />
The follow up sessions will be arranged during the first session. The second session will include a brief look at the software, Meetup and a full dry-run induction. The third session will be an observed induction where you will be left to train 2 people (with input if necessary). Once complete you will be free to arrange as many induction sessions as you are happy to do. Although you wont be an owner of the CNC Router, if you would like to become one at this point please ask.<br />
<br />
= Further Information =<br />
<br />
== Hardware ==<br />
<br />
=== Controller ===<br />
[[File:MPC6610 CNC Router Manual v1.0-En.pdf]]<br />
<br />
<gallery><br />
File:CNC_Router_controller_1.jpg<br />
File:CNC_Router_controller_2.jpg<br />
File:WP 20151230 18 00 14 Pro.jpg<br />
</gallery><br />
<br />
=== Z-Axis Stepper Driver ===<br />
<br />
[[File:M542-05m.pdf]]<br />
<br />
=== X and Y Axis Stepper Driver === <br />
<br />
[[File:MA860Hm.pdf]]<br />
<br />
Default switch settings<br />
* 1 - On<br />
* 2 - Off<br />
* 3 - On<br />
* 4 - Off<br />
* 5 - Off<br />
* 6 - Off<br />
* 7 - On<br />
* 8 - On<br />
<br />
=== Y Axis Stepper motor ===<br />
<br />
86BYGH450A-06 (NEMA34 Hybid Stepper Motor, MAX torque: 495 oz-in)<br />
<br />
* Insulation Resistant - 500V DC 100MΩ Min<br />
* Insulation Strength - 50Hz 1Minute 500V Min<br />
* Ambient Temperature - -20~+50 degree<br />
* Temperature Rise - 80 Max.<br />
* Radial Play - 0.02mm Max.<br />
* End Play - 0.1-0.3mm<br />
* Model: 85BYGH450A-06<br />
* Motor dimension: 85*85*75mm<br />
* Current/phase: 4.0A<br />
* Voltage/phase: 2.0V<br />
* Inductance/phase: 2.3+/-20%mH<br />
* Resistance/phase: 0.5+/-10%ohm<br />
* Holding torque: 3.5 N. M<br />
* Shaft diameter: 13 mm<br />
* Shaft length: 31.50mm<br />
* Leading wires: 4 leading wires<br />
<br />
=== Spindle Motor Inverter ===<br />
YTB-S2 Series Yatai frequency converter 220v single phase 1.5Kw<br />
<br />
== Installation ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
<gallery><br />
File:Photo_1.JPG<br />
File:WP_20130509_005.jpg<br />
</gallery><br />
<br />
== Purchase ==<br />
Full Purchase, Delivery and Installation (£?????)<br />
<br />
== Notes ==<br />
<br />
http://www.shopbottools.com/mProducts/prSstandard.htm</div>Perfectphasehttp://wiki.makespace.org/Equipment/CNC_RouterEquipment/CNC Router2016-01-04T01:42:01Z<p>Perfectphase: /* Z-Axis Stepper Driver */</p>
<hr />
<div>{{RedTool}}<br />
<br />
== CNC ROUTER IS DECOMMISSIONED ==<br />
<br />
Pending revision and/or replacement, the CNC router is now decommissioned. Usage is restricted to people operating with full knowledge that steps can be missed and the height can get wrong, resulting in head crashes. Be careful, wear safety goggles. No new training pending replacement or upgrade.<br />
<br />
[[Equipment|Equipment]] / CNC Router<br />
<br />
[[File:WP_20130509_005.jpg|thumb|460px|right|CNC Router]]<br />
<br />
<br />
== Summary ==<br />
<br />
A CNC router is a computer controlled shaping machine. These are related to the hand held router. Instead of hand held routing, the tool paths can be controlled via computer numerical control. It is a computer-controlled machine for cutting various hard materials, such as wood, composites, aluminum, steel, plastics, and foams. It is one of many kinds of tools that have CNC variants. A CNC router is very similar in concept to a CNC milling machine. The CNC router is controlled by a computer. Coordinates are uploaded into the machine controller from a separate CAD program<br />
<br />
* Capacity: 1200 x 1200 x 120mm<br />
* Rate (X,Y): 6000mm/min (Max) 5000mm/min (Working)<br />
* Rate (Z): 30mm/sec<br />
* Spindle Speed: 4500 to 24000rpm<br />
* Mechanical Precision: 0.01mm<br />
* Spindle Power: 1.5KW Variable Speed, Water-cooled<br />
* Blade Diameter: min 3.175mm, max 12.7mm <br />
* Order Format: HPGL, G code, u00, mmg, plt <br />
* Control System: DSP with USB connection <br />
<br />
Here are some examples we've made on the CNC router (please add a photo of yours any time you do a job!) <br />
<br />
<gallery><br />
File:WP_20130509_004.jpg<br />
File:WP_20130624_017.jpg<br />
File:WP_20130625_001.jpg<br />
</gallery><br />
<br />
= Using the CNC Router =<br />
== Owners ==<br />
<br />
The Owners are those who have volunteered to be in charge of the equipment, organising maintenance, training others to use it, and generally being a point of contact. The current Owners of the CNC Router are:<br />
<br />
* [[User:perfectphase|Stephen Woolhead]]<br />
* Mark Mellors<br />
* Dave Ansell<br />
* David Bebb<br />
* Simon Stirley<br />
* Jason White<br />
* Rick Lupton<br />
* Robin Sterling<br />
* Shareef Jalloq<br />
* Hidde-Jan Lemstra<br />
<br />
<br />
-- Further Contacts --<br />
<br />
* Chris Abri <!--chris.abri1985@gmail.com--><br />
<br />
If you have any questions, problems or concerns around the CNC router, please use the mailing list thread:<br />
* [https://groups.google.com/d/topic/cammakespace/rkchD7VqM2c/discussion Log : CNC Router]<br />
<br />
== Training ==<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>YOU CAN ONLY USE THE CNC ROUTER IF YOU HAVE BEEN TRAINED</b><br><br />
and have been added to the [[Equipment/CNC_Router/Training#Trained_Users|Trained Users]] list by one of the Owners<br />
</div><br />
<br />
To get trained on the CNC router and be added to the qualified user list, you will need to arrange for a training session with one of the Owners. <br />
<br />
If you'd like to arrange training, please see:<br />
* [[Equipment/CNC_Router/Training|CNC Router Training]]<br />
<br />
== Health and Safety ==<br />
<br />
The CNC Router is a potentially dangerous piece of equipment which must only be operated by members who have received appropriate training and who take due care. The top things to always remember when using the CNC Router are:<br />
* '''ONLY USE THE CNC ROUTER IF YOU ARE ON THE LIST OF TRAINED USERS'''<br />
* '''NEVER LEAVE THE CNC ROUTER RUNNING UNATTENDED'''<br />
<br />
As a trained user, you should be very aware of the following risks and how to deal with them:<br />
<br />
'''FIRE''' - Cutting with the wrong settings could result in the material igniting.<br />
<br />
'''TRAPPING''' - Stand clear of the machine while in motion.<br />
<br />
'''DUST''' - Ensure extraction system is working.<br />
<br />
'''NOISE''' - Ensure that you wear the correct PPE when working with the machine for prolonged periods.<br />
<br />
Full Risk assessment[[File:CNC_Router.pdf ]]<br />
<br />
== CNC Glossary ==<br />
<br />
As with most new ventures into another profession or hobby, there is the need to learn a “new language” and its common abbreviations. We have introduced some of these in the description of the workflow process above. Here we’ll look at some in more detail. These are listed in alphabetical order.<br />
<br />
=== 2D/2.5D/3D Toolpaths ===<br />
<br />
Depending on the information source, the definitions of 2D, 2.5D and 3D can be quite vague and appear to overlap.<br />
<br />
'''2D''' is simple horizontal cuts at a constant Z depth. For example, you cut out letter or a plaque shape to hang on the wall by moving the tool down to a specific depth and tracing the shape of the part you are cutting in 2D.<br />
<br />
'''2.5D''' would be a little more complex than 2D as while the tool is cutting, the Z depth would be changing instead of staying constant. Typically this still uses 2D vector data to define the path but the way the tool moves in relation to the 2D data and its form will determine the shape that is cut. The most common example of 2.5D is VCarving. Although this cuts 2D vector shapes, the V-shaped tool “rides” on the edges of the vectors, so as it gets wider it cuts deeper and as the vector get closer together it will lift up in Z.<br />
<br />
'''3D'''' These are toolpaths that like 2.5D toolpaths can move simultaneously in all 3 (X, Y and Z) axes however the shape they cut is described by following a 3D computer model and not vectors. They are typically cut with a Ball-Nose (round ended) tool. The tool will go back and forth across the 3D model following the contours of the part similar to an old fashioned copying or digitizing machine. The smoothness of the finished part depends on the Stepover setting in the toolpath as that determines how many times the tool will pass over the model. The size of the tool is also important as the software will only let it cut the detail that the end of the tool can fit into as it traces over the virtual surface. Examples of 3D toolpaths are 3D Rouging and 3D Finishing<br />
<br />
=== 3-axis===<br />
<br />
A 3-axis CNC machine is one that can move a router bit in the 3 primary directions, X, Y and Z. The image below show 3 views of a typical CNC setup and how the axes are referenced from each viewing direction.<br />
<br />
=== CAD ===<br />
<br />
CAD has been used as an abbreviation for both “Computer Aided Design” and “Computer Aided Drafting”. Now it has become a generic term in its own right that refers to a software program that can be used to create a 2D or 3D design.<br />
<br />
=== CAM ===<br />
<br />
When you discuss designing and preparing projects for your CNC machine, the follow-on side of CAD is CAM, which stands for ‘Computer Aided Manufacturing’ or ‘Computer Aided Machining’. This is the part of the process where the geometry developed during the CAD design process are now used to create the instructions that will move your CNC machine to ‘manufacture’ or machine the part.<br />
<br />
=== Collet ===<br />
<br />
The collet assembly is the component on a router or spindle that holds the router bit securely and consists of a precision collet and a collet nut. The collet is precisely sized to hold the router bit shank and the collet nut applies a compressive, friction fit as it is properly tightened onto the router or spindle shaft. It is very important to keep the collets clean and well maintained and depending on use, they must be periodically replaced.<br />
<br />
=== Gantry ===<br />
<br />
The gantry is the part of a CNC machine that typically has one of the horizontal axes running along it and also moves along the other horizontal axis to create the X and Y movement for the tool. The Z axis is also typically mounted on the gantry.<br />
<br />
=== G-Code === <br />
<br />
This is a generic term for the code which is sent to the machine with the instructions telling it how to move. Or, to put it in our context, the file that is saved from the software using the Post Processor to format it for the CNC machine. In reality it’s a particular type of data that a lot of CNC’s use a variant of – so G-code is not necessarily interchangeable to different machines. The name comes from the fact that many of the codes within in start with a G. For example G01 specifies a Feed Rate move and G00 specifies a Rapid move etc.<br />
<br />
=== Pass ===<br />
<br />
When you have a toolpath that is too deep, too wide or a combination of both for the router bit to remove all the material at one time, the toolpath is broken up into multiple ‘Passes’ with each pass removing a part of the material.<br />
<br />
When the toolpath is too deep, a Pass Depth (see entry below) value for the bit will be set and used to indicate the maximum Z depth the tool should cut on each Pass. The amount of material a tool can remove will be determined by the tooltype, size, material being cut and many other parameters. Tooling manufacturers typically offer recommendations for these values.<br />
<br />
=== Post Processor ===<br />
<br />
There are hundreds of different brands and models of CNC machines currently in use. When it comes to controlling them, many have a lot in common, but there can and will be differences. So, if you look at this as each machine speaks a slightly different language, there has to be a way for a single CAD/CAM program to speak to each machine and this is accomplished by using an “interpreter” called a Post Processor, also sometimes simply referred to as ‘pp’ or ‘post’.<br />
<br />
For example, you design a project to cut an exact size circle out of a piece of material and calculate a toolpath to do that. When you actually save that toolpath so it can be used at your CNC machine, the correct Post Processor will ensure the instructions for cutting that circle are prepared correctly so your CNC machine can read and understand them and accurately cut the circle as you intended.<br />
<br />
=== Router Bed or Machine Bed === <br />
<br />
The ‘bed’ identifies the part of a CNC machine where the material being machined is placed and held securely in position. For best results, the bed needs to be flat and sturdy. In most designs the bed is stationary; however there are exceptions to this where the bed moves to provide either the X or Y axis movement.<br />
<br />
=== Sacrifice Sheet / Spoilboard === <br />
<br />
The spoilboard is normally a sacrificial sheet of material placed on top of the machine bed and is intended to be replaced as necessary. It protects the machine bed and allows frequent surfacing which will help to keep a truly flat surface to mount material and help maintain accuracy. This allows the stock material to be screwed down to it and the parts drilled and cut all the way through the material thickness.<br />
<br />
=== Stepover ===<br />
<br />
The Stepover setting found for most router bits allows you to control horizontal movement when machining areas wider than the router bit. Physically, stepover is the distance the center of the bit moves horizontally for each pass.<br />
<br />
The Stepover is shown in the programs as both a physical distance (0.025” or 0.5mm for example) and as a percentage of bit diameter (6%, 8%, 50%, etc.). You can enter either value and the software will automatically calculate the other one for you. Typically most users refer to Stepover by its percentage value as it is a simple whole number and can easily be translated to other tool sizes for a particular task, for example when finishing setting the Stepover to be 10% of the ballnose tools diameter normally creates a reasonably finish surface.<br />
<br />
=== Toolpath ===<br />
<br />
A toolpath is the path created during the CAM part of your project design and represents the instructions your CNC machine will use to make the router bit move to duplicate what you have designed. In the software it is typically displayed as a set of lines which show a virtual picture of the path the tool tip will move along when the toolpath is run on the machine.<br />
<br />
=== Vector ===<br />
<br />
Vector is the word used to describe a 2D line, arc or curve. A vector can be used to describe almost any 2D shape.<br />
<br />
== Instructions ==<br />
<br />
[http://wiki.makespace.org/File:MPC6610_CNC_Router_Manual_v1.0-En.pdf Router Manual]<br />
<br />
[[Equipment/CNC_Router/Hand_Controller|Hand Controller Look-up Guide]]<br />
<br />
===Setting the Z Origin Using the Z0 Sensor===<br />
''A tool that has an extremely narrow tip may break when it touches the tool sensor depending on which tool is to be used.''<br />
<br />
1. Secure the workpiece on the bed, and place the Z0 sensor at the place where you want to set the Z origin on the workpiece. Face the surface of the Z0 sensor without the magnet facing upward.<br />
<br />
[[image:Mill_z0.PNG]]<br />
<br />
2. Use the handset to move the tool to the position above the sensor.<br />
<br />
3. On the handset press OK + 8(Z-0). The tool slowly descend until it contacts the sensor. When the tool rises and stops, the setting operation is complete. <br />
<br />
Note: It is important the tool is electrically conductive from tip to shaft, and the sensor is clean. Failure to check will cause damage to the tool and sensor.<br />
<br />
4. Remove the sensor from the workpiece to a location where it will not interfere with future cutting operations.<br />
<br />
==Software==<br />
<br />
The standard software is Vectric's line of CAM software:<br />
<br />
===VCarvePro===<br />
<br />
[[image:Vcarvepro.png]]<br />
<br />
VCarve Pro provides a powerful but intuitive software solution for 2D design and calculation of 2D and 2.5D toolpaths for cutting parts on a CNC Router. <br />
<br />
The software can import 2D designs from other programs but also includes a full set of drawing and editing tools with advanced layout options such as True-Shape Nesting. The toolpath options cover all typical 2D routing operations such as Profiling, Pocketing, Auto-Inlays and Drilling as well as 2.5D strategies such as V-Carving, Prism carving, Fluting and even a decorative Texturing strategy. Each toolpath includes appropriate options to customize the settings and provide a high level of control for different types of operation. In addition all toolpaths can be previewed to show just how the part will look when it is actually cut, this allows instant feedback to allow toolpaths to be further optimized. <br />
<br />
'''Details''': http://www.vectric.com/products/vcarve-pro.htm<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/vcarve-pro<br />
<br />
===Cut3D===<br />
<br />
[[image:Vectric-cut3d.jpg|266px]]<br />
<br />
Cut3D is a dedicated toolpath engine for CNC machining 3D models that have been designed using a 3D CAD or Graphics design product such as AutoCAD, Rhino3D, 3D Studio etc. or scanned using a laser or touch probe device. Cut3D's exceptionally easy to use interface leads you step-by-step through the process of loading a model, setting the size, interactively placing tabs to hold the job in place, calculating single, double or four sided roughing and finishing toolpaths, previewing the results and finally saving the CNC code to run on your machine.<br />
<br />
3D Models that are too large / thick to machine because of gantry height, cutter length or limited material thickness can be 'Sliced' into separate pieces. Each slice can then be machined and the complete job assembled. <br />
<br />
'''Details''': http://www.vectric.com/products/cut3d.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/cut3d<br />
<br />
===PhotoVCarve===<br />
<br />
[[image:Vectric-photovcarve.gif|266px]]<br />
<br />
PhotoVCarve creates lines of grooves that vary in width and depth to represent the detail in a photograph or image. The quality of the finished result is very dependant upon a high level of contrast between the material surface and the machined grooves. This information is very important to remember when cutting designs using the PhotoVCarve software. <br />
<br />
PhotoVCarve machines dark areas in a photograph with wide groove and the lighter areas to have narrower ones. The software automatically calculates the toolpaths based on the cutter selected and maximum depth of groove required. <br />
<br />
'''Details''': http://www.vectric.com/products/photovcarve.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/photovcarve<br />
<br />
== Tooling ==<br />
<br />
=== Router Bits ===<br />
<br />
Router bits (or cutters) are the most common type of cutter, they have two or more vertical cutting edges. These are good general purpose cutters that can be found in most DIY shops. They are the same type that you would use in a manual hand held router.<br />
<br />
<gallery><br />
File:WP_20130813_025.jpg<br />
File:WP_20130813_025.jpg<br />
File:WP_20130814_002.jpg<br />
File:WP_20130814_003.jpg<br />
</gallery><br />
<br />
It is important to notice that the cutters are on the edge of the body only, they do not extend to the centre of the cutter. This means the cutter CAN NOT BE USED AS A DRILL. An holes that are made by these sorts of cutters must be made by ramping the cutter to the correct depth in a sloping or spiral motion.<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>NEVER USE ROUTER BITS THAT HAVE BEARINGS.</b> These types of cutters are designed for manual routers where you can feel the feed back of the bearing in contact with the material being cut. A CNC device has no such feedback and will press the bearing into the material has hard as it can until something gives, i.e. the cutter breaks or much worse the spindle breaks. People found using these types of cutters on the CNC router will be BANNED! Just use the version without the bearing.<br />
<br />
<gallery><br />
File:WP_20130813_018.jpg<br />
</gallery><br />
<br />
The cutting edges should always be the lowest part of the cutter.<br />
</div><br />
<br />
=== End mills ===<br />
<br />
'''Up Cut and Down Cut'''<br />
<br />
Router end mills have two variants, up cut (left) and down cut (right); there is a third type, compression, but they are quite rare.<br />
<br />
<gallery><br />
File:WP_20130813_015.jpg<br />
</gallery><br />
<br />
Most cutters are up cut, which have the cutting service on the top of the flutes and as they rotate lift the chips up and away from the material being cut.<br />
<br />
Down cut cutters have the cutting edge on the bottom of the flutes and push chips down towards the material being cut. This has the advantage of pressing the material being cut into the bed of the machine; this is especially useful for thin plastics. The other advantage is the top surface shows far less breakout and splintering, this is a big advantage for materials like laminates.<br />
<br />
On image on the left has been cut with an up-cut end mill and the image on the right a down-cut.<br />
<br />
<gallery><br />
File:WP_20130813_005.jpg<br />
File:WP_20130813_007.jpg<br />
</gallery><br />
<br />
NOTE: There is a very big disadvantage to down cut end mills, and that is that they do not clear there chips effectively in blind holes. This means they need larger ramping moves to get to the correct cutting depth and if used in pockets without enough clearance, the friction can lead to burning or melting of the material being cut.<br />
<br />
Another down side to down-cut cutters, is that when cutting pockets, the bottom surface will not be as clean as that made with an up-cut cutter, which will do a far better job of clearing the waste chips that rub between the cutter and the material with a down-cut.<br />
<br />
== Stock Tooling ==<br />
<br />
In order to keep a small stock of cutters for general use, the CNC Router needs to have a means of generating money. Because there is no material provided for use with the CNC Router there is no way to bring in any funds for such things. Therefore, we ask that if you use one of the communal cutters please put 50p into the CNC Router Honesty Box. This will go towards funding for replenishing stock and also for the replacement of the sacrificial bed once it gets worn out. Please email the list if a communal cutter is broken or missing, so that they can replace it with one from stock. <br />
<br />
There will likely be 1 or two of each of the following cutters available for use, however please do not count on this being the case:<br />
<br />
* 2.5mm square cutter - single flute<br />
* 1/8" square cutter - single flute<br />
* 1/8" ball cutter - 2 flute<br />
<br />
* 6mm square cutter - 2 flute<br />
* 6mm ball cutter - 2 flute<br />
<br />
* engraver 0.2 30deg 1/8" 30mm length (8 of)<br />
* engraver 0.8 30deg 1/8" 30mm length (2 of)<br />
<br />
* 22mm 2 flute straight <br />
* 90deg x 32mm VBit<br />
<br />
<br />
Some Suppliers are listed below:<br />
<br />
== Feeds & Speeds ==<br />
<br />
What are feeds and speeds? Why are they important?<br />
<br />
[http://www.youtube.com/watch?v=ip2jm_6aUyk&feature=c4-overview&list=UUivA7_KLKWo43tFcCkFvydw Milling machine tutorial - cutter selection, speeds and feeds]<br />
<br />
[http://en.wikipedia.org/wiki/Speeds_and_feeds Wikipedia - Speeds and feeds]<br />
<br />
The phrase speeds and feeds (or feeds and speeds) refers to two separate velocities in machine tool practice, cutting speed and feed rate. They are often considered as a pair because of their combined effect on the cutting process. Each, however, can also be considered and analyzed in its own right.<br />
<br />
Cutting speed (also called surface speed or simply speed) is the speed difference (relative velocity) between the cutting tool and the surface of the workpiece it is operating on. It is expressed in units of distance along the workpiece surface per unit of time, typically surface feet per minute (sfm) or meters per minute (m/min). Feed rate (also often styled as a solid compound, feedrate, or called simply feed) is the relative velocity at which the cutter is advanced along the workpiece; its vector is perpendicular to the vector of cutting speed. Feed rate units depend on the motion of the tool and workpiece; when the workpiece rotates (e.g., in turning and boring), the units are almost always distance per spindle revolution (inches per revolution [in/rev or ipr] or millimeters per revolution [mm/rev]). When the workpiece does not rotate (e.g., in milling), the units are typically distance per time (inches per minute [in/min or ipm] or millimeters per minute [mm/min]), although distance per revolution or per cutter tooth are also sometimes used.<br />
<br />
===Spindle speed quick reference===<br />
<br />
{| class="wikitable"<br />
!|<br />
!|400Hz <br />
!|350Hz <br />
!|300Hz <br />
!|250Hz <br />
!|200Hz <br />
!|150Hz <br />
|-<br />
!|RPM<br />
|24000 <br />
|21000 <br />
|18000 <br />
|15000 <br />
|12000 <br />
|9000 <br />
|-<br />
|}<br />
<br />
===Feed rate quick reference===<br />
<br />
{| class="wikitable" <br />
!|100% <br />
!|75% <br />
!|66% <br />
!|50% <br />
!|33% <br />
!|25% <br />
|-<br />
!|6000<br />
|4500<br />
|3960<br />
|3000<br />
|1980<br />
|1500<br />
|-<br />
!|5000<br />
|3750<br />
|3300<br />
|2500<br />
|1650<br />
|1250<br />
|-<br />
!|4000<br />
|3000<br />
|2640<br />
|2000<br />
|1320<br />
|1000<br />
|-<br />
!|3000 <br />
|2250 <br />
|1980 <br />
|1500 <br />
|990 <br />
|750 <br />
|-<br />
!|2500 <br />
|1875 <br />
|1650 <br />
|1250 <br />
|825 <br />
|625 <br />
|-<br />
!|2000 <br />
|1500 <br />
|1320 <br />
|1000 <br />
|660 <br />
|500 <br />
|-<br />
!|1500 <br />
|1125 <br />
|990 <br />
|750 <br />
|495 <br />
|375 <br />
|-<br />
!|1000 <br />
|750 <br />
|660 <br />
|500 <br />
|330 <br />
|250 <br />
|-<br />
!|500 <br />
|375 <br />
|330 <br />
|250 <br />
|165 <br />
|125 <br />
|-<br />
|}<br />
<br />
=== Sample feed rates ===<br />
<br />
For working out feeds and speeds, recommend http://www.cnccookbook.com/CCGWizard.<br />
<br />
The feeds and speeds below have been tested on our machine. The 3mm cutters were single flute carbide. 2 flute HSS cutters may require different settings to avoid breakages.<br />
<br />
{| class="wikitable"<br />
!|MDF<br />
!|1mm deep <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep <br />
|-<br />
!|3mm &Oslash;<br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|-<br />
!|6mm &Oslash; <br />
|3000/24Krpm<br />
|3000/15Krpm <br />
|2000/13Krpm <br />
|1500/11Krpm <br />
|-<br />
!|22mm &Oslash; <br />
|3000/5000rpm <br />
|N/A <br />
|N/A<br />
|N/A<br />
|-<br />
|}<br />
<br />
{| class="wikitable"<br />
!|Plywood<br />
!|1mm deep <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep<br />
|-<br />
!|3mm &Oslash; <br />
|2000/24Krpm <br />
|2000/24Krpm<br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|-<br />
!|6mm &Oslash;<br />
|3000/15Krpm<br />
|3000/15Krpm <br />
|1500/15Krpm <br />
|1000/11Krpm <br />
|-<br />
!|22mm &Oslash; <br />
|3000/5Krpm <br />
|N/A <br />
|N/A<br />
|N/A<br />
|-<br />
|}<br />
<br />
<br />
Polycarbonate:<br />
300Hz 1600mm/min<br />
<br />
Foamed PVC (foamex):<br />
6mm diameter, 10mm deep pass depth, spindle 400Hz (24krpm), feed 9000mm/min.<br />
<br />
3mm diameter, 3mm deep pass depth, 400Hz (24krpm), 9000mm/min.<br />
<br />
Polyurethane foam:<br />
<br />
6mm diameter, full depth pass (30mm+), 400Hz (24krpm), 9000mm/min.<br />
<br />
3mm diameter, 6mm deep pass depth, 400Hz (24krpm), 9000mm/min.<br />
<br />
Acetal (Delrin):<br />
<br />
6mm Cutter, 2mm deep pass depth, spindle 150 - 180Hz, feed 3000mm/min.<br />
<br />
1/8th or 3mm cutter, 1.5 - 2mm deep pass depth, spindle 130 - 160Hz, feed 2-3000mm/min.<br />
<br />
== Tips & Tricks ==<br />
<br />
= Maintenance =<br />
<br />
The maintenance of the CNC Router is carried out by the Owners, with some basic maintenance being carried out by Users on every job.<br />
<br />
== Maintenance Schedule ==<br />
Every job<br />
* Vacuum cutting dust from bed and around machine<br />
* Sand down high points created on sacrificial bed by cutting/screwing<br />
<br />
As required, by users<br />
* Empty extraction bin <br />
* check for blockages in manifold box where extraction pipes meet<br />
<br />
Monthly<br />
* Inspect extraction hoses for splits/ wear<br />
* Clean guide rails (Don't oil them, it makes dust stick)<br />
* Check level, condition and flow of cooling water and replace as necessary<br />
* Inspect sacrificial bed, re-skim or replace as required<br />
* Inspect cable from pendent to router<br />
* Inspect ER11 collet nut for wear<br />
* Inspect auto levelling probe wire<br />
* check collet set for wear/damage<br />
* Check USB socket on pendent and USB memory stick for splits/damage<br />
<br />
Annual<br />
* Check nuts on lead screws for excessive backlash and adjust if required<br />
* Inspect all covers/structure for signs of damage, cracks etc<br />
* Check tightness (or even presence) of screws holding covers in place<br />
* Check CNC electronics (and PC) cabinets for dust build up and vacuum out if required<br />
* Check feet/supports are all taking load and that the structure is level/flat<br />
* Check motor cables aren't wearing/cracking<br />
<br />
== Maintenance Log ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
3/7/13: Lower spindle clamp bolts replaced with longer stainless ones, holes through tapped as original ones had stripped.<br />
23/12/15: complete maintenance checklist completed. controller cable slightly frayed at machine end, collet nut could do with being replaced. otherwise, everything fine.<br />
<br />
== Maintenance Shopping List ==<br />
<br />
* Cutters<br />
* Sacrificial Bed (1.2m x 1.2m 12mm MDF)<br />
* ER11 collet nut<br />
* controller cable<br />
<br />
= Becoming an Owner/Trainer =<br />
<br />
Becoming an '''Owner''' of a piece of Makespace equipment means that you will be responsible for the maintenance, upkeep and H&S of that equipment. You will also be responsible for running inductions and keeping the information banks (Wiki/Forum/Google Groups) maintained.<br />
<br />
A '''Trainer''' is responsible for running inductions only but will be required to understand how the machine works in order to pass on the relevant skills. A trainer will not be required to maintain the machine but would be expected to keep an eye on its status and report any issues if they develop (as would be expected of any user).<br />
<br />
== Steps to becoming an Owner or Trainer ==<br />
<br />
* Step 1: Contact a current Owner who will talk you through the various responsibilities. [http://wiki.makespace.org/Equipment/CNC_Router#Owners Owners] or Forum: [http://makespace.org/forum/viewtopic.php?f=20&t=89 here]<br />
* Step 2: Sign up to a 'Train the Trainer Training' session on Meetup. It is likely one will need to be set up specially in order for you to sign up but the owner you spoke to should take care of this.<br />
* Step 3: Complete the training to the satisfaction of the Owner/s running the sessions.<br />
* Step 4: Have your name added to the Trainers list and set up your first solo induction session.<br />
* Step 5: Once you are a Trainer you are eligible to become an Owner of the CNC Router. To become an Owner will simply require one further meeting with one of the current owners. This will simply be to walk through the requirements and techniques of maintaining the machine along with any other responsibilites. If the other owners are happy, you can add your name to the [http://wiki.makespace.org/Equipment/CNC_Router#Owners Owners] list.<br />
<br />
== Train the Trainer Training ==<br />
<br />
The first session will be fairly informal, with a look to getting more familiar with the machine and how it operates. We will walk through the Induction cheat-sheet (located on the Wiki) and discuss methods of giving attendees the information they need to use the CNC Router safely.<br />
<br />
The follow up sessions will be arranged during the first session. The second session will include a brief look at the software, Meetup and a full dry-run induction. The third session will be an observed induction where you will be left to train 2 people (with input if necessary). Once complete you will be free to arrange as many induction sessions as you are happy to do. Although you wont be an owner of the CNC Router, if you would like to become one at this point please ask.<br />
<br />
= Further Information =<br />
<br />
== Hardware ==<br />
<br />
=== Controller ===<br />
[[File:MPC6610 CNC Router Manual v1.0-En.pdf]]<br />
<br />
<gallery><br />
File:CNC_Router_controller_1.jpg<br />
File:CNC_Router_controller_2.jpg<br />
File:WP 20151230 18 00 14 Pro.jpg<br />
</gallery><br />
<br />
=== Z-Axis Stepper Driver ===<br />
<br />
[[File:M542-05m.pdf]]<br />
<br />
=== X and Y Axis Stepper Driver === <br />
<br />
[[File:MA860Hm.pdf]]<br />
<br />
Default switch settings<br />
* 1 - On<br />
* 2 - Off<br />
* 3 - On<br />
* 4 - Off<br />
* 5 - Off<br />
* 6 - Off<br />
* 7 - On<br />
* 8 - On<br />
<br />
=== Y Axis Stepper motor ===<br />
<br />
86BYGH450A-06 (NEMA34 Hybid Stepper Motor, MAX torque: 495 oz-in)<br />
<br />
* Insulation Resistant - 500V DC 100MΩ Min<br />
* Insulation Strength - 50Hz 1Minute 500V Min<br />
* Ambient Temperature - -20~+50 degree<br />
* Temperature Rise - 80 Max.<br />
* Radial Play - 0.02mm Max.<br />
* End Play - 0.1-0.3mm<br />
* Model: 85BYGH450A-06<br />
* Motor dimension: 85*85*75mm<br />
* Current/phase: 4.0A<br />
* Voltage/phase: 2.0V<br />
* Inductance/phase: 2.3+/-20%mH<br />
* Resistance/phase: 0.5+/-10%ohm<br />
* Holding torque: 3.5 N. M<br />
* Shaft diameter: 13 mm<br />
* Shaft length: 31.50mm<br />
* Leading wires: 4 leading wires<br />
<br />
=== Spindle Motor Inverter ===<br />
YTB-S2 Series Yatai frequency converter 220v single phase<br />
<br />
== Installation ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
<gallery><br />
File:Photo_1.JPG<br />
File:WP_20130509_005.jpg<br />
</gallery><br />
<br />
== Purchase ==<br />
Full Purchase, Delivery and Installation (£?????)<br />
<br />
== Notes ==<br />
<br />
http://www.shopbottools.com/mProducts/prSstandard.htm</div>Perfectphasehttp://wiki.makespace.org/Equipment/CNC_RouterEquipment/CNC Router2016-01-04T01:41:50Z<p>Perfectphase: /* Further Information */</p>
<hr />
<div>{{RedTool}}<br />
<br />
== CNC ROUTER IS DECOMMISSIONED ==<br />
<br />
Pending revision and/or replacement, the CNC router is now decommissioned. Usage is restricted to people operating with full knowledge that steps can be missed and the height can get wrong, resulting in head crashes. Be careful, wear safety goggles. No new training pending replacement or upgrade.<br />
<br />
[[Equipment|Equipment]] / CNC Router<br />
<br />
[[File:WP_20130509_005.jpg|thumb|460px|right|CNC Router]]<br />
<br />
<br />
== Summary ==<br />
<br />
A CNC router is a computer controlled shaping machine. These are related to the hand held router. Instead of hand held routing, the tool paths can be controlled via computer numerical control. It is a computer-controlled machine for cutting various hard materials, such as wood, composites, aluminum, steel, plastics, and foams. It is one of many kinds of tools that have CNC variants. A CNC router is very similar in concept to a CNC milling machine. The CNC router is controlled by a computer. Coordinates are uploaded into the machine controller from a separate CAD program<br />
<br />
* Capacity: 1200 x 1200 x 120mm<br />
* Rate (X,Y): 6000mm/min (Max) 5000mm/min (Working)<br />
* Rate (Z): 30mm/sec<br />
* Spindle Speed: 4500 to 24000rpm<br />
* Mechanical Precision: 0.01mm<br />
* Spindle Power: 1.5KW Variable Speed, Water-cooled<br />
* Blade Diameter: min 3.175mm, max 12.7mm <br />
* Order Format: HPGL, G code, u00, mmg, plt <br />
* Control System: DSP with USB connection <br />
<br />
Here are some examples we've made on the CNC router (please add a photo of yours any time you do a job!) <br />
<br />
<gallery><br />
File:WP_20130509_004.jpg<br />
File:WP_20130624_017.jpg<br />
File:WP_20130625_001.jpg<br />
</gallery><br />
<br />
= Using the CNC Router =<br />
== Owners ==<br />
<br />
The Owners are those who have volunteered to be in charge of the equipment, organising maintenance, training others to use it, and generally being a point of contact. The current Owners of the CNC Router are:<br />
<br />
* [[User:perfectphase|Stephen Woolhead]]<br />
* Mark Mellors<br />
* Dave Ansell<br />
* David Bebb<br />
* Simon Stirley<br />
* Jason White<br />
* Rick Lupton<br />
* Robin Sterling<br />
* Shareef Jalloq<br />
* Hidde-Jan Lemstra<br />
<br />
<br />
-- Further Contacts --<br />
<br />
* Chris Abri <!--chris.abri1985@gmail.com--><br />
<br />
If you have any questions, problems or concerns around the CNC router, please use the mailing list thread:<br />
* [https://groups.google.com/d/topic/cammakespace/rkchD7VqM2c/discussion Log : CNC Router]<br />
<br />
== Training ==<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>YOU CAN ONLY USE THE CNC ROUTER IF YOU HAVE BEEN TRAINED</b><br><br />
and have been added to the [[Equipment/CNC_Router/Training#Trained_Users|Trained Users]] list by one of the Owners<br />
</div><br />
<br />
To get trained on the CNC router and be added to the qualified user list, you will need to arrange for a training session with one of the Owners. <br />
<br />
If you'd like to arrange training, please see:<br />
* [[Equipment/CNC_Router/Training|CNC Router Training]]<br />
<br />
== Health and Safety ==<br />
<br />
The CNC Router is a potentially dangerous piece of equipment which must only be operated by members who have received appropriate training and who take due care. The top things to always remember when using the CNC Router are:<br />
* '''ONLY USE THE CNC ROUTER IF YOU ARE ON THE LIST OF TRAINED USERS'''<br />
* '''NEVER LEAVE THE CNC ROUTER RUNNING UNATTENDED'''<br />
<br />
As a trained user, you should be very aware of the following risks and how to deal with them:<br />
<br />
'''FIRE''' - Cutting with the wrong settings could result in the material igniting.<br />
<br />
'''TRAPPING''' - Stand clear of the machine while in motion.<br />
<br />
'''DUST''' - Ensure extraction system is working.<br />
<br />
'''NOISE''' - Ensure that you wear the correct PPE when working with the machine for prolonged periods.<br />
<br />
Full Risk assessment[[File:CNC_Router.pdf ]]<br />
<br />
== CNC Glossary ==<br />
<br />
As with most new ventures into another profession or hobby, there is the need to learn a “new language” and its common abbreviations. We have introduced some of these in the description of the workflow process above. Here we’ll look at some in more detail. These are listed in alphabetical order.<br />
<br />
=== 2D/2.5D/3D Toolpaths ===<br />
<br />
Depending on the information source, the definitions of 2D, 2.5D and 3D can be quite vague and appear to overlap.<br />
<br />
'''2D''' is simple horizontal cuts at a constant Z depth. For example, you cut out letter or a plaque shape to hang on the wall by moving the tool down to a specific depth and tracing the shape of the part you are cutting in 2D.<br />
<br />
'''2.5D''' would be a little more complex than 2D as while the tool is cutting, the Z depth would be changing instead of staying constant. Typically this still uses 2D vector data to define the path but the way the tool moves in relation to the 2D data and its form will determine the shape that is cut. The most common example of 2.5D is VCarving. Although this cuts 2D vector shapes, the V-shaped tool “rides” on the edges of the vectors, so as it gets wider it cuts deeper and as the vector get closer together it will lift up in Z.<br />
<br />
'''3D'''' These are toolpaths that like 2.5D toolpaths can move simultaneously in all 3 (X, Y and Z) axes however the shape they cut is described by following a 3D computer model and not vectors. They are typically cut with a Ball-Nose (round ended) tool. The tool will go back and forth across the 3D model following the contours of the part similar to an old fashioned copying or digitizing machine. The smoothness of the finished part depends on the Stepover setting in the toolpath as that determines how many times the tool will pass over the model. The size of the tool is also important as the software will only let it cut the detail that the end of the tool can fit into as it traces over the virtual surface. Examples of 3D toolpaths are 3D Rouging and 3D Finishing<br />
<br />
=== 3-axis===<br />
<br />
A 3-axis CNC machine is one that can move a router bit in the 3 primary directions, X, Y and Z. The image below show 3 views of a typical CNC setup and how the axes are referenced from each viewing direction.<br />
<br />
=== CAD ===<br />
<br />
CAD has been used as an abbreviation for both “Computer Aided Design” and “Computer Aided Drafting”. Now it has become a generic term in its own right that refers to a software program that can be used to create a 2D or 3D design.<br />
<br />
=== CAM ===<br />
<br />
When you discuss designing and preparing projects for your CNC machine, the follow-on side of CAD is CAM, which stands for ‘Computer Aided Manufacturing’ or ‘Computer Aided Machining’. This is the part of the process where the geometry developed during the CAD design process are now used to create the instructions that will move your CNC machine to ‘manufacture’ or machine the part.<br />
<br />
=== Collet ===<br />
<br />
The collet assembly is the component on a router or spindle that holds the router bit securely and consists of a precision collet and a collet nut. The collet is precisely sized to hold the router bit shank and the collet nut applies a compressive, friction fit as it is properly tightened onto the router or spindle shaft. It is very important to keep the collets clean and well maintained and depending on use, they must be periodically replaced.<br />
<br />
=== Gantry ===<br />
<br />
The gantry is the part of a CNC machine that typically has one of the horizontal axes running along it and also moves along the other horizontal axis to create the X and Y movement for the tool. The Z axis is also typically mounted on the gantry.<br />
<br />
=== G-Code === <br />
<br />
This is a generic term for the code which is sent to the machine with the instructions telling it how to move. Or, to put it in our context, the file that is saved from the software using the Post Processor to format it for the CNC machine. In reality it’s a particular type of data that a lot of CNC’s use a variant of – so G-code is not necessarily interchangeable to different machines. The name comes from the fact that many of the codes within in start with a G. For example G01 specifies a Feed Rate move and G00 specifies a Rapid move etc.<br />
<br />
=== Pass ===<br />
<br />
When you have a toolpath that is too deep, too wide or a combination of both for the router bit to remove all the material at one time, the toolpath is broken up into multiple ‘Passes’ with each pass removing a part of the material.<br />
<br />
When the toolpath is too deep, a Pass Depth (see entry below) value for the bit will be set and used to indicate the maximum Z depth the tool should cut on each Pass. The amount of material a tool can remove will be determined by the tooltype, size, material being cut and many other parameters. Tooling manufacturers typically offer recommendations for these values.<br />
<br />
=== Post Processor ===<br />
<br />
There are hundreds of different brands and models of CNC machines currently in use. When it comes to controlling them, many have a lot in common, but there can and will be differences. So, if you look at this as each machine speaks a slightly different language, there has to be a way for a single CAD/CAM program to speak to each machine and this is accomplished by using an “interpreter” called a Post Processor, also sometimes simply referred to as ‘pp’ or ‘post’.<br />
<br />
For example, you design a project to cut an exact size circle out of a piece of material and calculate a toolpath to do that. When you actually save that toolpath so it can be used at your CNC machine, the correct Post Processor will ensure the instructions for cutting that circle are prepared correctly so your CNC machine can read and understand them and accurately cut the circle as you intended.<br />
<br />
=== Router Bed or Machine Bed === <br />
<br />
The ‘bed’ identifies the part of a CNC machine where the material being machined is placed and held securely in position. For best results, the bed needs to be flat and sturdy. In most designs the bed is stationary; however there are exceptions to this where the bed moves to provide either the X or Y axis movement.<br />
<br />
=== Sacrifice Sheet / Spoilboard === <br />
<br />
The spoilboard is normally a sacrificial sheet of material placed on top of the machine bed and is intended to be replaced as necessary. It protects the machine bed and allows frequent surfacing which will help to keep a truly flat surface to mount material and help maintain accuracy. This allows the stock material to be screwed down to it and the parts drilled and cut all the way through the material thickness.<br />
<br />
=== Stepover ===<br />
<br />
The Stepover setting found for most router bits allows you to control horizontal movement when machining areas wider than the router bit. Physically, stepover is the distance the center of the bit moves horizontally for each pass.<br />
<br />
The Stepover is shown in the programs as both a physical distance (0.025” or 0.5mm for example) and as a percentage of bit diameter (6%, 8%, 50%, etc.). You can enter either value and the software will automatically calculate the other one for you. Typically most users refer to Stepover by its percentage value as it is a simple whole number and can easily be translated to other tool sizes for a particular task, for example when finishing setting the Stepover to be 10% of the ballnose tools diameter normally creates a reasonably finish surface.<br />
<br />
=== Toolpath ===<br />
<br />
A toolpath is the path created during the CAM part of your project design and represents the instructions your CNC machine will use to make the router bit move to duplicate what you have designed. In the software it is typically displayed as a set of lines which show a virtual picture of the path the tool tip will move along when the toolpath is run on the machine.<br />
<br />
=== Vector ===<br />
<br />
Vector is the word used to describe a 2D line, arc or curve. A vector can be used to describe almost any 2D shape.<br />
<br />
== Instructions ==<br />
<br />
[http://wiki.makespace.org/File:MPC6610_CNC_Router_Manual_v1.0-En.pdf Router Manual]<br />
<br />
[[Equipment/CNC_Router/Hand_Controller|Hand Controller Look-up Guide]]<br />
<br />
===Setting the Z Origin Using the Z0 Sensor===<br />
''A tool that has an extremely narrow tip may break when it touches the tool sensor depending on which tool is to be used.''<br />
<br />
1. Secure the workpiece on the bed, and place the Z0 sensor at the place where you want to set the Z origin on the workpiece. Face the surface of the Z0 sensor without the magnet facing upward.<br />
<br />
[[image:Mill_z0.PNG]]<br />
<br />
2. Use the handset to move the tool to the position above the sensor.<br />
<br />
3. On the handset press OK + 8(Z-0). The tool slowly descend until it contacts the sensor. When the tool rises and stops, the setting operation is complete. <br />
<br />
Note: It is important the tool is electrically conductive from tip to shaft, and the sensor is clean. Failure to check will cause damage to the tool and sensor.<br />
<br />
4. Remove the sensor from the workpiece to a location where it will not interfere with future cutting operations.<br />
<br />
==Software==<br />
<br />
The standard software is Vectric's line of CAM software:<br />
<br />
===VCarvePro===<br />
<br />
[[image:Vcarvepro.png]]<br />
<br />
VCarve Pro provides a powerful but intuitive software solution for 2D design and calculation of 2D and 2.5D toolpaths for cutting parts on a CNC Router. <br />
<br />
The software can import 2D designs from other programs but also includes a full set of drawing and editing tools with advanced layout options such as True-Shape Nesting. The toolpath options cover all typical 2D routing operations such as Profiling, Pocketing, Auto-Inlays and Drilling as well as 2.5D strategies such as V-Carving, Prism carving, Fluting and even a decorative Texturing strategy. Each toolpath includes appropriate options to customize the settings and provide a high level of control for different types of operation. In addition all toolpaths can be previewed to show just how the part will look when it is actually cut, this allows instant feedback to allow toolpaths to be further optimized. <br />
<br />
'''Details''': http://www.vectric.com/products/vcarve-pro.htm<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/vcarve-pro<br />
<br />
===Cut3D===<br />
<br />
[[image:Vectric-cut3d.jpg|266px]]<br />
<br />
Cut3D is a dedicated toolpath engine for CNC machining 3D models that have been designed using a 3D CAD or Graphics design product such as AutoCAD, Rhino3D, 3D Studio etc. or scanned using a laser or touch probe device. Cut3D's exceptionally easy to use interface leads you step-by-step through the process of loading a model, setting the size, interactively placing tabs to hold the job in place, calculating single, double or four sided roughing and finishing toolpaths, previewing the results and finally saving the CNC code to run on your machine.<br />
<br />
3D Models that are too large / thick to machine because of gantry height, cutter length or limited material thickness can be 'Sliced' into separate pieces. Each slice can then be machined and the complete job assembled. <br />
<br />
'''Details''': http://www.vectric.com/products/cut3d.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/cut3d<br />
<br />
===PhotoVCarve===<br />
<br />
[[image:Vectric-photovcarve.gif|266px]]<br />
<br />
PhotoVCarve creates lines of grooves that vary in width and depth to represent the detail in a photograph or image. The quality of the finished result is very dependant upon a high level of contrast between the material surface and the machined grooves. This information is very important to remember when cutting designs using the PhotoVCarve software. <br />
<br />
PhotoVCarve machines dark areas in a photograph with wide groove and the lighter areas to have narrower ones. The software automatically calculates the toolpaths based on the cutter selected and maximum depth of groove required. <br />
<br />
'''Details''': http://www.vectric.com/products/photovcarve.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/photovcarve<br />
<br />
== Tooling ==<br />
<br />
=== Router Bits ===<br />
<br />
Router bits (or cutters) are the most common type of cutter, they have two or more vertical cutting edges. These are good general purpose cutters that can be found in most DIY shops. They are the same type that you would use in a manual hand held router.<br />
<br />
<gallery><br />
File:WP_20130813_025.jpg<br />
File:WP_20130813_025.jpg<br />
File:WP_20130814_002.jpg<br />
File:WP_20130814_003.jpg<br />
</gallery><br />
<br />
It is important to notice that the cutters are on the edge of the body only, they do not extend to the centre of the cutter. This means the cutter CAN NOT BE USED AS A DRILL. An holes that are made by these sorts of cutters must be made by ramping the cutter to the correct depth in a sloping or spiral motion.<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>NEVER USE ROUTER BITS THAT HAVE BEARINGS.</b> These types of cutters are designed for manual routers where you can feel the feed back of the bearing in contact with the material being cut. A CNC device has no such feedback and will press the bearing into the material has hard as it can until something gives, i.e. the cutter breaks or much worse the spindle breaks. People found using these types of cutters on the CNC router will be BANNED! Just use the version without the bearing.<br />
<br />
<gallery><br />
File:WP_20130813_018.jpg<br />
</gallery><br />
<br />
The cutting edges should always be the lowest part of the cutter.<br />
</div><br />
<br />
=== End mills ===<br />
<br />
'''Up Cut and Down Cut'''<br />
<br />
Router end mills have two variants, up cut (left) and down cut (right); there is a third type, compression, but they are quite rare.<br />
<br />
<gallery><br />
File:WP_20130813_015.jpg<br />
</gallery><br />
<br />
Most cutters are up cut, which have the cutting service on the top of the flutes and as they rotate lift the chips up and away from the material being cut.<br />
<br />
Down cut cutters have the cutting edge on the bottom of the flutes and push chips down towards the material being cut. This has the advantage of pressing the material being cut into the bed of the machine; this is especially useful for thin plastics. The other advantage is the top surface shows far less breakout and splintering, this is a big advantage for materials like laminates.<br />
<br />
On image on the left has been cut with an up-cut end mill and the image on the right a down-cut.<br />
<br />
<gallery><br />
File:WP_20130813_005.jpg<br />
File:WP_20130813_007.jpg<br />
</gallery><br />
<br />
NOTE: There is a very big disadvantage to down cut end mills, and that is that they do not clear there chips effectively in blind holes. This means they need larger ramping moves to get to the correct cutting depth and if used in pockets without enough clearance, the friction can lead to burning or melting of the material being cut.<br />
<br />
Another down side to down-cut cutters, is that when cutting pockets, the bottom surface will not be as clean as that made with an up-cut cutter, which will do a far better job of clearing the waste chips that rub between the cutter and the material with a down-cut.<br />
<br />
== Stock Tooling ==<br />
<br />
In order to keep a small stock of cutters for general use, the CNC Router needs to have a means of generating money. Because there is no material provided for use with the CNC Router there is no way to bring in any funds for such things. Therefore, we ask that if you use one of the communal cutters please put 50p into the CNC Router Honesty Box. This will go towards funding for replenishing stock and also for the replacement of the sacrificial bed once it gets worn out. Please email the list if a communal cutter is broken or missing, so that they can replace it with one from stock. <br />
<br />
There will likely be 1 or two of each of the following cutters available for use, however please do not count on this being the case:<br />
<br />
* 2.5mm square cutter - single flute<br />
* 1/8" square cutter - single flute<br />
* 1/8" ball cutter - 2 flute<br />
<br />
* 6mm square cutter - 2 flute<br />
* 6mm ball cutter - 2 flute<br />
<br />
* engraver 0.2 30deg 1/8" 30mm length (8 of)<br />
* engraver 0.8 30deg 1/8" 30mm length (2 of)<br />
<br />
* 22mm 2 flute straight <br />
* 90deg x 32mm VBit<br />
<br />
<br />
Some Suppliers are listed below:<br />
<br />
== Feeds & Speeds ==<br />
<br />
What are feeds and speeds? Why are they important?<br />
<br />
[http://www.youtube.com/watch?v=ip2jm_6aUyk&feature=c4-overview&list=UUivA7_KLKWo43tFcCkFvydw Milling machine tutorial - cutter selection, speeds and feeds]<br />
<br />
[http://en.wikipedia.org/wiki/Speeds_and_feeds Wikipedia - Speeds and feeds]<br />
<br />
The phrase speeds and feeds (or feeds and speeds) refers to two separate velocities in machine tool practice, cutting speed and feed rate. They are often considered as a pair because of their combined effect on the cutting process. Each, however, can also be considered and analyzed in its own right.<br />
<br />
Cutting speed (also called surface speed or simply speed) is the speed difference (relative velocity) between the cutting tool and the surface of the workpiece it is operating on. It is expressed in units of distance along the workpiece surface per unit of time, typically surface feet per minute (sfm) or meters per minute (m/min). Feed rate (also often styled as a solid compound, feedrate, or called simply feed) is the relative velocity at which the cutter is advanced along the workpiece; its vector is perpendicular to the vector of cutting speed. Feed rate units depend on the motion of the tool and workpiece; when the workpiece rotates (e.g., in turning and boring), the units are almost always distance per spindle revolution (inches per revolution [in/rev or ipr] or millimeters per revolution [mm/rev]). When the workpiece does not rotate (e.g., in milling), the units are typically distance per time (inches per minute [in/min or ipm] or millimeters per minute [mm/min]), although distance per revolution or per cutter tooth are also sometimes used.<br />
<br />
===Spindle speed quick reference===<br />
<br />
{| class="wikitable"<br />
!|<br />
!|400Hz <br />
!|350Hz <br />
!|300Hz <br />
!|250Hz <br />
!|200Hz <br />
!|150Hz <br />
|-<br />
!|RPM<br />
|24000 <br />
|21000 <br />
|18000 <br />
|15000 <br />
|12000 <br />
|9000 <br />
|-<br />
|}<br />
<br />
===Feed rate quick reference===<br />
<br />
{| class="wikitable" <br />
!|100% <br />
!|75% <br />
!|66% <br />
!|50% <br />
!|33% <br />
!|25% <br />
|-<br />
!|6000<br />
|4500<br />
|3960<br />
|3000<br />
|1980<br />
|1500<br />
|-<br />
!|5000<br />
|3750<br />
|3300<br />
|2500<br />
|1650<br />
|1250<br />
|-<br />
!|4000<br />
|3000<br />
|2640<br />
|2000<br />
|1320<br />
|1000<br />
|-<br />
!|3000 <br />
|2250 <br />
|1980 <br />
|1500 <br />
|990 <br />
|750 <br />
|-<br />
!|2500 <br />
|1875 <br />
|1650 <br />
|1250 <br />
|825 <br />
|625 <br />
|-<br />
!|2000 <br />
|1500 <br />
|1320 <br />
|1000 <br />
|660 <br />
|500 <br />
|-<br />
!|1500 <br />
|1125 <br />
|990 <br />
|750 <br />
|495 <br />
|375 <br />
|-<br />
!|1000 <br />
|750 <br />
|660 <br />
|500 <br />
|330 <br />
|250 <br />
|-<br />
!|500 <br />
|375 <br />
|330 <br />
|250 <br />
|165 <br />
|125 <br />
|-<br />
|}<br />
<br />
=== Sample feed rates ===<br />
<br />
For working out feeds and speeds, recommend http://www.cnccookbook.com/CCGWizard.<br />
<br />
The feeds and speeds below have been tested on our machine. The 3mm cutters were single flute carbide. 2 flute HSS cutters may require different settings to avoid breakages.<br />
<br />
{| class="wikitable"<br />
!|MDF<br />
!|1mm deep <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep <br />
|-<br />
!|3mm &Oslash;<br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|-<br />
!|6mm &Oslash; <br />
|3000/24Krpm<br />
|3000/15Krpm <br />
|2000/13Krpm <br />
|1500/11Krpm <br />
|-<br />
!|22mm &Oslash; <br />
|3000/5000rpm <br />
|N/A <br />
|N/A<br />
|N/A<br />
|-<br />
|}<br />
<br />
{| class="wikitable"<br />
!|Plywood<br />
!|1mm deep <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep<br />
|-<br />
!|3mm &Oslash; <br />
|2000/24Krpm <br />
|2000/24Krpm<br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|-<br />
!|6mm &Oslash;<br />
|3000/15Krpm<br />
|3000/15Krpm <br />
|1500/15Krpm <br />
|1000/11Krpm <br />
|-<br />
!|22mm &Oslash; <br />
|3000/5Krpm <br />
|N/A <br />
|N/A<br />
|N/A<br />
|-<br />
|}<br />
<br />
<br />
Polycarbonate:<br />
300Hz 1600mm/min<br />
<br />
Foamed PVC (foamex):<br />
6mm diameter, 10mm deep pass depth, spindle 400Hz (24krpm), feed 9000mm/min.<br />
<br />
3mm diameter, 3mm deep pass depth, 400Hz (24krpm), 9000mm/min.<br />
<br />
Polyurethane foam:<br />
<br />
6mm diameter, full depth pass (30mm+), 400Hz (24krpm), 9000mm/min.<br />
<br />
3mm diameter, 6mm deep pass depth, 400Hz (24krpm), 9000mm/min.<br />
<br />
Acetal (Delrin):<br />
<br />
6mm Cutter, 2mm deep pass depth, spindle 150 - 180Hz, feed 3000mm/min.<br />
<br />
1/8th or 3mm cutter, 1.5 - 2mm deep pass depth, spindle 130 - 160Hz, feed 2-3000mm/min.<br />
<br />
== Tips & Tricks ==<br />
<br />
= Maintenance =<br />
<br />
The maintenance of the CNC Router is carried out by the Owners, with some basic maintenance being carried out by Users on every job.<br />
<br />
== Maintenance Schedule ==<br />
Every job<br />
* Vacuum cutting dust from bed and around machine<br />
* Sand down high points created on sacrificial bed by cutting/screwing<br />
<br />
As required, by users<br />
* Empty extraction bin <br />
* check for blockages in manifold box where extraction pipes meet<br />
<br />
Monthly<br />
* Inspect extraction hoses for splits/ wear<br />
* Clean guide rails (Don't oil them, it makes dust stick)<br />
* Check level, condition and flow of cooling water and replace as necessary<br />
* Inspect sacrificial bed, re-skim or replace as required<br />
* Inspect cable from pendent to router<br />
* Inspect ER11 collet nut for wear<br />
* Inspect auto levelling probe wire<br />
* check collet set for wear/damage<br />
* Check USB socket on pendent and USB memory stick for splits/damage<br />
<br />
Annual<br />
* Check nuts on lead screws for excessive backlash and adjust if required<br />
* Inspect all covers/structure for signs of damage, cracks etc<br />
* Check tightness (or even presence) of screws holding covers in place<br />
* Check CNC electronics (and PC) cabinets for dust build up and vacuum out if required<br />
* Check feet/supports are all taking load and that the structure is level/flat<br />
* Check motor cables aren't wearing/cracking<br />
<br />
== Maintenance Log ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
3/7/13: Lower spindle clamp bolts replaced with longer stainless ones, holes through tapped as original ones had stripped.<br />
23/12/15: complete maintenance checklist completed. controller cable slightly frayed at machine end, collet nut could do with being replaced. otherwise, everything fine.<br />
<br />
== Maintenance Shopping List ==<br />
<br />
* Cutters<br />
* Sacrificial Bed (1.2m x 1.2m 12mm MDF)<br />
* ER11 collet nut<br />
* controller cable<br />
<br />
= Becoming an Owner/Trainer =<br />
<br />
Becoming an '''Owner''' of a piece of Makespace equipment means that you will be responsible for the maintenance, upkeep and H&S of that equipment. You will also be responsible for running inductions and keeping the information banks (Wiki/Forum/Google Groups) maintained.<br />
<br />
A '''Trainer''' is responsible for running inductions only but will be required to understand how the machine works in order to pass on the relevant skills. A trainer will not be required to maintain the machine but would be expected to keep an eye on its status and report any issues if they develop (as would be expected of any user).<br />
<br />
== Steps to becoming an Owner or Trainer ==<br />
<br />
* Step 1: Contact a current Owner who will talk you through the various responsibilities. [http://wiki.makespace.org/Equipment/CNC_Router#Owners Owners] or Forum: [http://makespace.org/forum/viewtopic.php?f=20&t=89 here]<br />
* Step 2: Sign up to a 'Train the Trainer Training' session on Meetup. It is likely one will need to be set up specially in order for you to sign up but the owner you spoke to should take care of this.<br />
* Step 3: Complete the training to the satisfaction of the Owner/s running the sessions.<br />
* Step 4: Have your name added to the Trainers list and set up your first solo induction session.<br />
* Step 5: Once you are a Trainer you are eligible to become an Owner of the CNC Router. To become an Owner will simply require one further meeting with one of the current owners. This will simply be to walk through the requirements and techniques of maintaining the machine along with any other responsibilites. If the other owners are happy, you can add your name to the [http://wiki.makespace.org/Equipment/CNC_Router#Owners Owners] list.<br />
<br />
== Train the Trainer Training ==<br />
<br />
The first session will be fairly informal, with a look to getting more familiar with the machine and how it operates. We will walk through the Induction cheat-sheet (located on the Wiki) and discuss methods of giving attendees the information they need to use the CNC Router safely.<br />
<br />
The follow up sessions will be arranged during the first session. The second session will include a brief look at the software, Meetup and a full dry-run induction. The third session will be an observed induction where you will be left to train 2 people (with input if necessary). Once complete you will be free to arrange as many induction sessions as you are happy to do. Although you wont be an owner of the CNC Router, if you would like to become one at this point please ask.<br />
<br />
= Further Information =<br />
<br />
== Hardware ==<br />
<br />
=== Controller ===<br />
[[File:MPC6610 CNC Router Manual v1.0-En.pdf]]<br />
<br />
<gallery><br />
File:CNC_Router_controller_1.jpg<br />
File:CNC_Router_controller_2.jpg<br />
File:WP 20151230 18 00 14 Pro.jpg<br />
</gallery><br />
<br />
=== Z-Axis Stepper Driver ===<br />
<br />
[[File:M542-05m.pdf]]<br />
<br />
<br />
=== X and Y Axis Stepper Driver === <br />
<br />
[[File:MA860Hm.pdf]]<br />
<br />
Default switch settings<br />
* 1 - On<br />
* 2 - Off<br />
* 3 - On<br />
* 4 - Off<br />
* 5 - Off<br />
* 6 - Off<br />
* 7 - On<br />
* 8 - On<br />
<br />
=== Y Axis Stepper motor ===<br />
<br />
86BYGH450A-06 (NEMA34 Hybid Stepper Motor, MAX torque: 495 oz-in)<br />
<br />
* Insulation Resistant - 500V DC 100MΩ Min<br />
* Insulation Strength - 50Hz 1Minute 500V Min<br />
* Ambient Temperature - -20~+50 degree<br />
* Temperature Rise - 80 Max.<br />
* Radial Play - 0.02mm Max.<br />
* End Play - 0.1-0.3mm<br />
* Model: 85BYGH450A-06<br />
* Motor dimension: 85*85*75mm<br />
* Current/phase: 4.0A<br />
* Voltage/phase: 2.0V<br />
* Inductance/phase: 2.3+/-20%mH<br />
* Resistance/phase: 0.5+/-10%ohm<br />
* Holding torque: 3.5 N. M<br />
* Shaft diameter: 13 mm<br />
* Shaft length: 31.50mm<br />
* Leading wires: 4 leading wires<br />
<br />
=== Spindle Motor Inverter ===<br />
YTB-S2 Series Yatai frequency converter 220v single phase<br />
<br />
== Installation ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
<gallery><br />
File:Photo_1.JPG<br />
File:WP_20130509_005.jpg<br />
</gallery><br />
<br />
== Purchase ==<br />
Full Purchase, Delivery and Installation (£?????)<br />
<br />
== Notes ==<br />
<br />
http://www.shopbottools.com/mProducts/prSstandard.htm</div>Perfectphasehttp://wiki.makespace.org/File:17d845d5-ab07-4c6a-9f36-f8686db17998.jpgFile:17d845d5-ab07-4c6a-9f36-f8686db17998.jpg2016-01-04T01:41:40Z<p>Perfectphase: </p>
<hr />
<div></div>Perfectphasehttp://wiki.makespace.org/Equipment/CNC_RouterEquipment/CNC Router2016-01-04T01:33:50Z<p>Perfectphase: /* Further Information */</p>
<hr />
<div>{{RedTool}}<br />
<br />
== CNC ROUTER IS DECOMMISSIONED ==<br />
<br />
Pending revision and/or replacement, the CNC router is now decommissioned. Usage is restricted to people operating with full knowledge that steps can be missed and the height can get wrong, resulting in head crashes. Be careful, wear safety goggles. No new training pending replacement or upgrade.<br />
<br />
[[Equipment|Equipment]] / CNC Router<br />
<br />
[[File:WP_20130509_005.jpg|thumb|460px|right|CNC Router]]<br />
<br />
<br />
== Summary ==<br />
<br />
A CNC router is a computer controlled shaping machine. These are related to the hand held router. Instead of hand held routing, the tool paths can be controlled via computer numerical control. It is a computer-controlled machine for cutting various hard materials, such as wood, composites, aluminum, steel, plastics, and foams. It is one of many kinds of tools that have CNC variants. A CNC router is very similar in concept to a CNC milling machine. The CNC router is controlled by a computer. Coordinates are uploaded into the machine controller from a separate CAD program<br />
<br />
* Capacity: 1200 x 1200 x 120mm<br />
* Rate (X,Y): 6000mm/min (Max) 5000mm/min (Working)<br />
* Rate (Z): 30mm/sec<br />
* Spindle Speed: 4500 to 24000rpm<br />
* Mechanical Precision: 0.01mm<br />
* Spindle Power: 1.5KW Variable Speed, Water-cooled<br />
* Blade Diameter: min 3.175mm, max 12.7mm <br />
* Order Format: HPGL, G code, u00, mmg, plt <br />
* Control System: DSP with USB connection <br />
<br />
Here are some examples we've made on the CNC router (please add a photo of yours any time you do a job!) <br />
<br />
<gallery><br />
File:WP_20130509_004.jpg<br />
File:WP_20130624_017.jpg<br />
File:WP_20130625_001.jpg<br />
</gallery><br />
<br />
= Using the CNC Router =<br />
== Owners ==<br />
<br />
The Owners are those who have volunteered to be in charge of the equipment, organising maintenance, training others to use it, and generally being a point of contact. The current Owners of the CNC Router are:<br />
<br />
* [[User:perfectphase|Stephen Woolhead]]<br />
* Mark Mellors<br />
* Dave Ansell<br />
* David Bebb<br />
* Simon Stirley<br />
* Jason White<br />
* Rick Lupton<br />
* Robin Sterling<br />
* Shareef Jalloq<br />
* Hidde-Jan Lemstra<br />
<br />
<br />
-- Further Contacts --<br />
<br />
* Chris Abri <!--chris.abri1985@gmail.com--><br />
<br />
If you have any questions, problems or concerns around the CNC router, please use the mailing list thread:<br />
* [https://groups.google.com/d/topic/cammakespace/rkchD7VqM2c/discussion Log : CNC Router]<br />
<br />
== Training ==<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>YOU CAN ONLY USE THE CNC ROUTER IF YOU HAVE BEEN TRAINED</b><br><br />
and have been added to the [[Equipment/CNC_Router/Training#Trained_Users|Trained Users]] list by one of the Owners<br />
</div><br />
<br />
To get trained on the CNC router and be added to the qualified user list, you will need to arrange for a training session with one of the Owners. <br />
<br />
If you'd like to arrange training, please see:<br />
* [[Equipment/CNC_Router/Training|CNC Router Training]]<br />
<br />
== Health and Safety ==<br />
<br />
The CNC Router is a potentially dangerous piece of equipment which must only be operated by members who have received appropriate training and who take due care. The top things to always remember when using the CNC Router are:<br />
* '''ONLY USE THE CNC ROUTER IF YOU ARE ON THE LIST OF TRAINED USERS'''<br />
* '''NEVER LEAVE THE CNC ROUTER RUNNING UNATTENDED'''<br />
<br />
As a trained user, you should be very aware of the following risks and how to deal with them:<br />
<br />
'''FIRE''' - Cutting with the wrong settings could result in the material igniting.<br />
<br />
'''TRAPPING''' - Stand clear of the machine while in motion.<br />
<br />
'''DUST''' - Ensure extraction system is working.<br />
<br />
'''NOISE''' - Ensure that you wear the correct PPE when working with the machine for prolonged periods.<br />
<br />
Full Risk assessment[[File:CNC_Router.pdf ]]<br />
<br />
== CNC Glossary ==<br />
<br />
As with most new ventures into another profession or hobby, there is the need to learn a “new language” and its common abbreviations. We have introduced some of these in the description of the workflow process above. Here we’ll look at some in more detail. These are listed in alphabetical order.<br />
<br />
=== 2D/2.5D/3D Toolpaths ===<br />
<br />
Depending on the information source, the definitions of 2D, 2.5D and 3D can be quite vague and appear to overlap.<br />
<br />
'''2D''' is simple horizontal cuts at a constant Z depth. For example, you cut out letter or a plaque shape to hang on the wall by moving the tool down to a specific depth and tracing the shape of the part you are cutting in 2D.<br />
<br />
'''2.5D''' would be a little more complex than 2D as while the tool is cutting, the Z depth would be changing instead of staying constant. Typically this still uses 2D vector data to define the path but the way the tool moves in relation to the 2D data and its form will determine the shape that is cut. The most common example of 2.5D is VCarving. Although this cuts 2D vector shapes, the V-shaped tool “rides” on the edges of the vectors, so as it gets wider it cuts deeper and as the vector get closer together it will lift up in Z.<br />
<br />
'''3D'''' These are toolpaths that like 2.5D toolpaths can move simultaneously in all 3 (X, Y and Z) axes however the shape they cut is described by following a 3D computer model and not vectors. They are typically cut with a Ball-Nose (round ended) tool. The tool will go back and forth across the 3D model following the contours of the part similar to an old fashioned copying or digitizing machine. The smoothness of the finished part depends on the Stepover setting in the toolpath as that determines how many times the tool will pass over the model. The size of the tool is also important as the software will only let it cut the detail that the end of the tool can fit into as it traces over the virtual surface. Examples of 3D toolpaths are 3D Rouging and 3D Finishing<br />
<br />
=== 3-axis===<br />
<br />
A 3-axis CNC machine is one that can move a router bit in the 3 primary directions, X, Y and Z. The image below show 3 views of a typical CNC setup and how the axes are referenced from each viewing direction.<br />
<br />
=== CAD ===<br />
<br />
CAD has been used as an abbreviation for both “Computer Aided Design” and “Computer Aided Drafting”. Now it has become a generic term in its own right that refers to a software program that can be used to create a 2D or 3D design.<br />
<br />
=== CAM ===<br />
<br />
When you discuss designing and preparing projects for your CNC machine, the follow-on side of CAD is CAM, which stands for ‘Computer Aided Manufacturing’ or ‘Computer Aided Machining’. This is the part of the process where the geometry developed during the CAD design process are now used to create the instructions that will move your CNC machine to ‘manufacture’ or machine the part.<br />
<br />
=== Collet ===<br />
<br />
The collet assembly is the component on a router or spindle that holds the router bit securely and consists of a precision collet and a collet nut. The collet is precisely sized to hold the router bit shank and the collet nut applies a compressive, friction fit as it is properly tightened onto the router or spindle shaft. It is very important to keep the collets clean and well maintained and depending on use, they must be periodically replaced.<br />
<br />
=== Gantry ===<br />
<br />
The gantry is the part of a CNC machine that typically has one of the horizontal axes running along it and also moves along the other horizontal axis to create the X and Y movement for the tool. The Z axis is also typically mounted on the gantry.<br />
<br />
=== G-Code === <br />
<br />
This is a generic term for the code which is sent to the machine with the instructions telling it how to move. Or, to put it in our context, the file that is saved from the software using the Post Processor to format it for the CNC machine. In reality it’s a particular type of data that a lot of CNC’s use a variant of – so G-code is not necessarily interchangeable to different machines. The name comes from the fact that many of the codes within in start with a G. For example G01 specifies a Feed Rate move and G00 specifies a Rapid move etc.<br />
<br />
=== Pass ===<br />
<br />
When you have a toolpath that is too deep, too wide or a combination of both for the router bit to remove all the material at one time, the toolpath is broken up into multiple ‘Passes’ with each pass removing a part of the material.<br />
<br />
When the toolpath is too deep, a Pass Depth (see entry below) value for the bit will be set and used to indicate the maximum Z depth the tool should cut on each Pass. The amount of material a tool can remove will be determined by the tooltype, size, material being cut and many other parameters. Tooling manufacturers typically offer recommendations for these values.<br />
<br />
=== Post Processor ===<br />
<br />
There are hundreds of different brands and models of CNC machines currently in use. When it comes to controlling them, many have a lot in common, but there can and will be differences. So, if you look at this as each machine speaks a slightly different language, there has to be a way for a single CAD/CAM program to speak to each machine and this is accomplished by using an “interpreter” called a Post Processor, also sometimes simply referred to as ‘pp’ or ‘post’.<br />
<br />
For example, you design a project to cut an exact size circle out of a piece of material and calculate a toolpath to do that. When you actually save that toolpath so it can be used at your CNC machine, the correct Post Processor will ensure the instructions for cutting that circle are prepared correctly so your CNC machine can read and understand them and accurately cut the circle as you intended.<br />
<br />
=== Router Bed or Machine Bed === <br />
<br />
The ‘bed’ identifies the part of a CNC machine where the material being machined is placed and held securely in position. For best results, the bed needs to be flat and sturdy. In most designs the bed is stationary; however there are exceptions to this where the bed moves to provide either the X or Y axis movement.<br />
<br />
=== Sacrifice Sheet / Spoilboard === <br />
<br />
The spoilboard is normally a sacrificial sheet of material placed on top of the machine bed and is intended to be replaced as necessary. It protects the machine bed and allows frequent surfacing which will help to keep a truly flat surface to mount material and help maintain accuracy. This allows the stock material to be screwed down to it and the parts drilled and cut all the way through the material thickness.<br />
<br />
=== Stepover ===<br />
<br />
The Stepover setting found for most router bits allows you to control horizontal movement when machining areas wider than the router bit. Physically, stepover is the distance the center of the bit moves horizontally for each pass.<br />
<br />
The Stepover is shown in the programs as both a physical distance (0.025” or 0.5mm for example) and as a percentage of bit diameter (6%, 8%, 50%, etc.). You can enter either value and the software will automatically calculate the other one for you. Typically most users refer to Stepover by its percentage value as it is a simple whole number and can easily be translated to other tool sizes for a particular task, for example when finishing setting the Stepover to be 10% of the ballnose tools diameter normally creates a reasonably finish surface.<br />
<br />
=== Toolpath ===<br />
<br />
A toolpath is the path created during the CAM part of your project design and represents the instructions your CNC machine will use to make the router bit move to duplicate what you have designed. In the software it is typically displayed as a set of lines which show a virtual picture of the path the tool tip will move along when the toolpath is run on the machine.<br />
<br />
=== Vector ===<br />
<br />
Vector is the word used to describe a 2D line, arc or curve. A vector can be used to describe almost any 2D shape.<br />
<br />
== Instructions ==<br />
<br />
[http://wiki.makespace.org/File:MPC6610_CNC_Router_Manual_v1.0-En.pdf Router Manual]<br />
<br />
[[Equipment/CNC_Router/Hand_Controller|Hand Controller Look-up Guide]]<br />
<br />
===Setting the Z Origin Using the Z0 Sensor===<br />
''A tool that has an extremely narrow tip may break when it touches the tool sensor depending on which tool is to be used.''<br />
<br />
1. Secure the workpiece on the bed, and place the Z0 sensor at the place where you want to set the Z origin on the workpiece. Face the surface of the Z0 sensor without the magnet facing upward.<br />
<br />
[[image:Mill_z0.PNG]]<br />
<br />
2. Use the handset to move the tool to the position above the sensor.<br />
<br />
3. On the handset press OK + 8(Z-0). The tool slowly descend until it contacts the sensor. When the tool rises and stops, the setting operation is complete. <br />
<br />
Note: It is important the tool is electrically conductive from tip to shaft, and the sensor is clean. Failure to check will cause damage to the tool and sensor.<br />
<br />
4. Remove the sensor from the workpiece to a location where it will not interfere with future cutting operations.<br />
<br />
==Software==<br />
<br />
The standard software is Vectric's line of CAM software:<br />
<br />
===VCarvePro===<br />
<br />
[[image:Vcarvepro.png]]<br />
<br />
VCarve Pro provides a powerful but intuitive software solution for 2D design and calculation of 2D and 2.5D toolpaths for cutting parts on a CNC Router. <br />
<br />
The software can import 2D designs from other programs but also includes a full set of drawing and editing tools with advanced layout options such as True-Shape Nesting. The toolpath options cover all typical 2D routing operations such as Profiling, Pocketing, Auto-Inlays and Drilling as well as 2.5D strategies such as V-Carving, Prism carving, Fluting and even a decorative Texturing strategy. Each toolpath includes appropriate options to customize the settings and provide a high level of control for different types of operation. In addition all toolpaths can be previewed to show just how the part will look when it is actually cut, this allows instant feedback to allow toolpaths to be further optimized. <br />
<br />
'''Details''': http://www.vectric.com/products/vcarve-pro.htm<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/vcarve-pro<br />
<br />
===Cut3D===<br />
<br />
[[image:Vectric-cut3d.jpg|266px]]<br />
<br />
Cut3D is a dedicated toolpath engine for CNC machining 3D models that have been designed using a 3D CAD or Graphics design product such as AutoCAD, Rhino3D, 3D Studio etc. or scanned using a laser or touch probe device. Cut3D's exceptionally easy to use interface leads you step-by-step through the process of loading a model, setting the size, interactively placing tabs to hold the job in place, calculating single, double or four sided roughing and finishing toolpaths, previewing the results and finally saving the CNC code to run on your machine.<br />
<br />
3D Models that are too large / thick to machine because of gantry height, cutter length or limited material thickness can be 'Sliced' into separate pieces. Each slice can then be machined and the complete job assembled. <br />
<br />
'''Details''': http://www.vectric.com/products/cut3d.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/cut3d<br />
<br />
===PhotoVCarve===<br />
<br />
[[image:Vectric-photovcarve.gif|266px]]<br />
<br />
PhotoVCarve creates lines of grooves that vary in width and depth to represent the detail in a photograph or image. The quality of the finished result is very dependant upon a high level of contrast between the material surface and the machined grooves. This information is very important to remember when cutting designs using the PhotoVCarve software. <br />
<br />
PhotoVCarve machines dark areas in a photograph with wide groove and the lighter areas to have narrower ones. The software automatically calculates the toolpaths based on the cutter selected and maximum depth of groove required. <br />
<br />
'''Details''': http://www.vectric.com/products/photovcarve.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/photovcarve<br />
<br />
== Tooling ==<br />
<br />
=== Router Bits ===<br />
<br />
Router bits (or cutters) are the most common type of cutter, they have two or more vertical cutting edges. These are good general purpose cutters that can be found in most DIY shops. They are the same type that you would use in a manual hand held router.<br />
<br />
<gallery><br />
File:WP_20130813_025.jpg<br />
File:WP_20130813_025.jpg<br />
File:WP_20130814_002.jpg<br />
File:WP_20130814_003.jpg<br />
</gallery><br />
<br />
It is important to notice that the cutters are on the edge of the body only, they do not extend to the centre of the cutter. This means the cutter CAN NOT BE USED AS A DRILL. An holes that are made by these sorts of cutters must be made by ramping the cutter to the correct depth in a sloping or spiral motion.<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>NEVER USE ROUTER BITS THAT HAVE BEARINGS.</b> These types of cutters are designed for manual routers where you can feel the feed back of the bearing in contact with the material being cut. A CNC device has no such feedback and will press the bearing into the material has hard as it can until something gives, i.e. the cutter breaks or much worse the spindle breaks. People found using these types of cutters on the CNC router will be BANNED! Just use the version without the bearing.<br />
<br />
<gallery><br />
File:WP_20130813_018.jpg<br />
</gallery><br />
<br />
The cutting edges should always be the lowest part of the cutter.<br />
</div><br />
<br />
=== End mills ===<br />
<br />
'''Up Cut and Down Cut'''<br />
<br />
Router end mills have two variants, up cut (left) and down cut (right); there is a third type, compression, but they are quite rare.<br />
<br />
<gallery><br />
File:WP_20130813_015.jpg<br />
</gallery><br />
<br />
Most cutters are up cut, which have the cutting service on the top of the flutes and as they rotate lift the chips up and away from the material being cut.<br />
<br />
Down cut cutters have the cutting edge on the bottom of the flutes and push chips down towards the material being cut. This has the advantage of pressing the material being cut into the bed of the machine; this is especially useful for thin plastics. The other advantage is the top surface shows far less breakout and splintering, this is a big advantage for materials like laminates.<br />
<br />
On image on the left has been cut with an up-cut end mill and the image on the right a down-cut.<br />
<br />
<gallery><br />
File:WP_20130813_005.jpg<br />
File:WP_20130813_007.jpg<br />
</gallery><br />
<br />
NOTE: There is a very big disadvantage to down cut end mills, and that is that they do not clear there chips effectively in blind holes. This means they need larger ramping moves to get to the correct cutting depth and if used in pockets without enough clearance, the friction can lead to burning or melting of the material being cut.<br />
<br />
Another down side to down-cut cutters, is that when cutting pockets, the bottom surface will not be as clean as that made with an up-cut cutter, which will do a far better job of clearing the waste chips that rub between the cutter and the material with a down-cut.<br />
<br />
== Stock Tooling ==<br />
<br />
In order to keep a small stock of cutters for general use, the CNC Router needs to have a means of generating money. Because there is no material provided for use with the CNC Router there is no way to bring in any funds for such things. Therefore, we ask that if you use one of the communal cutters please put 50p into the CNC Router Honesty Box. This will go towards funding for replenishing stock and also for the replacement of the sacrificial bed once it gets worn out. Please email the list if a communal cutter is broken or missing, so that they can replace it with one from stock. <br />
<br />
There will likely be 1 or two of each of the following cutters available for use, however please do not count on this being the case:<br />
<br />
* 2.5mm square cutter - single flute<br />
* 1/8" square cutter - single flute<br />
* 1/8" ball cutter - 2 flute<br />
<br />
* 6mm square cutter - 2 flute<br />
* 6mm ball cutter - 2 flute<br />
<br />
* engraver 0.2 30deg 1/8" 30mm length (8 of)<br />
* engraver 0.8 30deg 1/8" 30mm length (2 of)<br />
<br />
* 22mm 2 flute straight <br />
* 90deg x 32mm VBit<br />
<br />
<br />
Some Suppliers are listed below:<br />
<br />
== Feeds & Speeds ==<br />
<br />
What are feeds and speeds? Why are they important?<br />
<br />
[http://www.youtube.com/watch?v=ip2jm_6aUyk&feature=c4-overview&list=UUivA7_KLKWo43tFcCkFvydw Milling machine tutorial - cutter selection, speeds and feeds]<br />
<br />
[http://en.wikipedia.org/wiki/Speeds_and_feeds Wikipedia - Speeds and feeds]<br />
<br />
The phrase speeds and feeds (or feeds and speeds) refers to two separate velocities in machine tool practice, cutting speed and feed rate. They are often considered as a pair because of their combined effect on the cutting process. Each, however, can also be considered and analyzed in its own right.<br />
<br />
Cutting speed (also called surface speed or simply speed) is the speed difference (relative velocity) between the cutting tool and the surface of the workpiece it is operating on. It is expressed in units of distance along the workpiece surface per unit of time, typically surface feet per minute (sfm) or meters per minute (m/min). Feed rate (also often styled as a solid compound, feedrate, or called simply feed) is the relative velocity at which the cutter is advanced along the workpiece; its vector is perpendicular to the vector of cutting speed. Feed rate units depend on the motion of the tool and workpiece; when the workpiece rotates (e.g., in turning and boring), the units are almost always distance per spindle revolution (inches per revolution [in/rev or ipr] or millimeters per revolution [mm/rev]). When the workpiece does not rotate (e.g., in milling), the units are typically distance per time (inches per minute [in/min or ipm] or millimeters per minute [mm/min]), although distance per revolution or per cutter tooth are also sometimes used.<br />
<br />
===Spindle speed quick reference===<br />
<br />
{| class="wikitable"<br />
!|<br />
!|400Hz <br />
!|350Hz <br />
!|300Hz <br />
!|250Hz <br />
!|200Hz <br />
!|150Hz <br />
|-<br />
!|RPM<br />
|24000 <br />
|21000 <br />
|18000 <br />
|15000 <br />
|12000 <br />
|9000 <br />
|-<br />
|}<br />
<br />
===Feed rate quick reference===<br />
<br />
{| class="wikitable" <br />
!|100% <br />
!|75% <br />
!|66% <br />
!|50% <br />
!|33% <br />
!|25% <br />
|-<br />
!|6000<br />
|4500<br />
|3960<br />
|3000<br />
|1980<br />
|1500<br />
|-<br />
!|5000<br />
|3750<br />
|3300<br />
|2500<br />
|1650<br />
|1250<br />
|-<br />
!|4000<br />
|3000<br />
|2640<br />
|2000<br />
|1320<br />
|1000<br />
|-<br />
!|3000 <br />
|2250 <br />
|1980 <br />
|1500 <br />
|990 <br />
|750 <br />
|-<br />
!|2500 <br />
|1875 <br />
|1650 <br />
|1250 <br />
|825 <br />
|625 <br />
|-<br />
!|2000 <br />
|1500 <br />
|1320 <br />
|1000 <br />
|660 <br />
|500 <br />
|-<br />
!|1500 <br />
|1125 <br />
|990 <br />
|750 <br />
|495 <br />
|375 <br />
|-<br />
!|1000 <br />
|750 <br />
|660 <br />
|500 <br />
|330 <br />
|250 <br />
|-<br />
!|500 <br />
|375 <br />
|330 <br />
|250 <br />
|165 <br />
|125 <br />
|-<br />
|}<br />
<br />
=== Sample feed rates ===<br />
<br />
For working out feeds and speeds, recommend http://www.cnccookbook.com/CCGWizard.<br />
<br />
The feeds and speeds below have been tested on our machine. The 3mm cutters were single flute carbide. 2 flute HSS cutters may require different settings to avoid breakages.<br />
<br />
{| class="wikitable"<br />
!|MDF<br />
!|1mm deep <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep <br />
|-<br />
!|3mm &Oslash;<br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|-<br />
!|6mm &Oslash; <br />
|3000/24Krpm<br />
|3000/15Krpm <br />
|2000/13Krpm <br />
|1500/11Krpm <br />
|-<br />
!|22mm &Oslash; <br />
|3000/5000rpm <br />
|N/A <br />
|N/A<br />
|N/A<br />
|-<br />
|}<br />
<br />
{| class="wikitable"<br />
!|Plywood<br />
!|1mm deep <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep<br />
|-<br />
!|3mm &Oslash; <br />
|2000/24Krpm <br />
|2000/24Krpm<br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|-<br />
!|6mm &Oslash;<br />
|3000/15Krpm<br />
|3000/15Krpm <br />
|1500/15Krpm <br />
|1000/11Krpm <br />
|-<br />
!|22mm &Oslash; <br />
|3000/5Krpm <br />
|N/A <br />
|N/A<br />
|N/A<br />
|-<br />
|}<br />
<br />
<br />
Polycarbonate:<br />
300Hz 1600mm/min<br />
<br />
Foamed PVC (foamex):<br />
6mm diameter, 10mm deep pass depth, spindle 400Hz (24krpm), feed 9000mm/min.<br />
<br />
3mm diameter, 3mm deep pass depth, 400Hz (24krpm), 9000mm/min.<br />
<br />
Polyurethane foam:<br />
<br />
6mm diameter, full depth pass (30mm+), 400Hz (24krpm), 9000mm/min.<br />
<br />
3mm diameter, 6mm deep pass depth, 400Hz (24krpm), 9000mm/min.<br />
<br />
Acetal (Delrin):<br />
<br />
6mm Cutter, 2mm deep pass depth, spindle 150 - 180Hz, feed 3000mm/min.<br />
<br />
1/8th or 3mm cutter, 1.5 - 2mm deep pass depth, spindle 130 - 160Hz, feed 2-3000mm/min.<br />
<br />
== Tips & Tricks ==<br />
<br />
= Maintenance =<br />
<br />
The maintenance of the CNC Router is carried out by the Owners, with some basic maintenance being carried out by Users on every job.<br />
<br />
== Maintenance Schedule ==<br />
Every job<br />
* Vacuum cutting dust from bed and around machine<br />
* Sand down high points created on sacrificial bed by cutting/screwing<br />
<br />
As required, by users<br />
* Empty extraction bin <br />
* check for blockages in manifold box where extraction pipes meet<br />
<br />
Monthly<br />
* Inspect extraction hoses for splits/ wear<br />
* Clean guide rails (Don't oil them, it makes dust stick)<br />
* Check level, condition and flow of cooling water and replace as necessary<br />
* Inspect sacrificial bed, re-skim or replace as required<br />
* Inspect cable from pendent to router<br />
* Inspect ER11 collet nut for wear<br />
* Inspect auto levelling probe wire<br />
* check collet set for wear/damage<br />
* Check USB socket on pendent and USB memory stick for splits/damage<br />
<br />
Annual<br />
* Check nuts on lead screws for excessive backlash and adjust if required<br />
* Inspect all covers/structure for signs of damage, cracks etc<br />
* Check tightness (or even presence) of screws holding covers in place<br />
* Check CNC electronics (and PC) cabinets for dust build up and vacuum out if required<br />
* Check feet/supports are all taking load and that the structure is level/flat<br />
* Check motor cables aren't wearing/cracking<br />
<br />
== Maintenance Log ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
3/7/13: Lower spindle clamp bolts replaced with longer stainless ones, holes through tapped as original ones had stripped.<br />
23/12/15: complete maintenance checklist completed. controller cable slightly frayed at machine end, collet nut could do with being replaced. otherwise, everything fine.<br />
<br />
== Maintenance Shopping List ==<br />
<br />
* Cutters<br />
* Sacrificial Bed (1.2m x 1.2m 12mm MDF)<br />
* ER11 collet nut<br />
* controller cable<br />
<br />
= Becoming an Owner/Trainer =<br />
<br />
Becoming an '''Owner''' of a piece of Makespace equipment means that you will be responsible for the maintenance, upkeep and H&S of that equipment. You will also be responsible for running inductions and keeping the information banks (Wiki/Forum/Google Groups) maintained.<br />
<br />
A '''Trainer''' is responsible for running inductions only but will be required to understand how the machine works in order to pass on the relevant skills. A trainer will not be required to maintain the machine but would be expected to keep an eye on its status and report any issues if they develop (as would be expected of any user).<br />
<br />
== Steps to becoming an Owner or Trainer ==<br />
<br />
* Step 1: Contact a current Owner who will talk you through the various responsibilities. [http://wiki.makespace.org/Equipment/CNC_Router#Owners Owners] or Forum: [http://makespace.org/forum/viewtopic.php?f=20&t=89 here]<br />
* Step 2: Sign up to a 'Train the Trainer Training' session on Meetup. It is likely one will need to be set up specially in order for you to sign up but the owner you spoke to should take care of this.<br />
* Step 3: Complete the training to the satisfaction of the Owner/s running the sessions.<br />
* Step 4: Have your name added to the Trainers list and set up your first solo induction session.<br />
* Step 5: Once you are a Trainer you are eligible to become an Owner of the CNC Router. To become an Owner will simply require one further meeting with one of the current owners. This will simply be to walk through the requirements and techniques of maintaining the machine along with any other responsibilites. If the other owners are happy, you can add your name to the [http://wiki.makespace.org/Equipment/CNC_Router#Owners Owners] list.<br />
<br />
== Train the Trainer Training ==<br />
<br />
The first session will be fairly informal, with a look to getting more familiar with the machine and how it operates. We will walk through the Induction cheat-sheet (located on the Wiki) and discuss methods of giving attendees the information they need to use the CNC Router safely.<br />
<br />
The follow up sessions will be arranged during the first session. The second session will include a brief look at the software, Meetup and a full dry-run induction. The third session will be an observed induction where you will be left to train 2 people (with input if necessary). Once complete you will be free to arrange as many induction sessions as you are happy to do. Although you wont be an owner of the CNC Router, if you would like to become one at this point please ask.<br />
<br />
= Further Information =<br />
<br />
== Hardware ==<br />
<br />
=== Controller ===<br />
[[File:MPC6610 CNC Router Manual v1.0-En.pdf]]<br />
<br />
<gallery><br />
File:CNC_Router_controller_1.jpg<br />
File:CNC_Router_controller_2.jpg<br />
File:WP 20151230 18 00 14 Pro.jpg<br />
</gallery><br />
<br />
=== Z-Axis Stepper Driver ===<br />
<br />
[[File:M542-05m.pdf]]<br />
<br />
<br />
=== X and Y Axis Stepper Driver === <br />
<br />
[[File:MA860Hm.pdf]]<br />
<br />
Default switch settings<br />
* 1 - On<br />
* 2 - Off<br />
* 3 - On<br />
* 4 - Off<br />
* 5 - Off<br />
* 6 - Off<br />
* 7 - On<br />
* 8 - On<br />
<br />
=== Y Axis Stepper motor ===<br />
<br />
86BYGH450A-06 (NEMA34 Hybid Stepper Motor, MAX torque: 495 oz-in)<br />
<br />
* Insulation Resistant - 500V DC 100MΩ Min<br />
* Insulation Strength - 50Hz 1Minute 500V Min<br />
* Ambient Temperature - -20~+50 degree<br />
* Temperature Rise - 80 Max.<br />
* Radial Play - 0.02mm Max.<br />
* End Play - 0.1-0.3mm<br />
* Model: 85BYGH450A-06<br />
* Motor dimension: 85*85*75mm<br />
* Current/phase: 4.0A<br />
* Voltage/phase: 2.0V<br />
* Inductance/phase: 2.3+/-20%mH<br />
* Resistance/phase: 0.5+/-10%ohm<br />
* Holding torque: 3.5 N. M<br />
* Shaft diameter: 13 mm<br />
* Shaft length: 31.50mm<br />
* Leading wires: 4 leading wires<br />
<br />
== Installation ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
<gallery><br />
File:Photo_1.JPG<br />
File:WP_20130509_005.jpg<br />
</gallery><br />
<br />
== Purchase ==<br />
Full Purchase, Delivery and Installation (£?????)<br />
<br />
== Notes ==<br />
<br />
http://www.shopbottools.com/mProducts/prSstandard.htm</div>Perfectphasehttp://wiki.makespace.org/Equipment/CNC_RouterEquipment/CNC Router2016-01-04T01:28:43Z<p>Perfectphase: /* Hardware */</p>
<hr />
<div>{{RedTool}}<br />
<br />
== CNC ROUTER IS DECOMMISSIONED ==<br />
<br />
Pending revision and/or replacement, the CNC router is now decommissioned. Usage is restricted to people operating with full knowledge that steps can be missed and the height can get wrong, resulting in head crashes. Be careful, wear safety goggles. No new training pending replacement or upgrade.<br />
<br />
[[Equipment|Equipment]] / CNC Router<br />
<br />
[[File:WP_20130509_005.jpg|thumb|460px|right|CNC Router]]<br />
<br />
<br />
== Summary ==<br />
<br />
A CNC router is a computer controlled shaping machine. These are related to the hand held router. Instead of hand held routing, the tool paths can be controlled via computer numerical control. It is a computer-controlled machine for cutting various hard materials, such as wood, composites, aluminum, steel, plastics, and foams. It is one of many kinds of tools that have CNC variants. A CNC router is very similar in concept to a CNC milling machine. The CNC router is controlled by a computer. Coordinates are uploaded into the machine controller from a separate CAD program<br />
<br />
* Capacity: 1200 x 1200 x 120mm<br />
* Rate (X,Y): 6000mm/min (Max) 5000mm/min (Working)<br />
* Rate (Z): 30mm/sec<br />
* Spindle Speed: 4500 to 24000rpm<br />
* Mechanical Precision: 0.01mm<br />
* Spindle Power: 1.5KW Variable Speed, Water-cooled<br />
* Blade Diameter: min 3.175mm, max 12.7mm <br />
* Order Format: HPGL, G code, u00, mmg, plt <br />
* Control System: DSP with USB connection <br />
<br />
Here are some examples we've made on the CNC router (please add a photo of yours any time you do a job!) <br />
<br />
<gallery><br />
File:WP_20130509_004.jpg<br />
File:WP_20130624_017.jpg<br />
File:WP_20130625_001.jpg<br />
</gallery><br />
<br />
= Using the CNC Router =<br />
== Owners ==<br />
<br />
The Owners are those who have volunteered to be in charge of the equipment, organising maintenance, training others to use it, and generally being a point of contact. The current Owners of the CNC Router are:<br />
<br />
* [[User:perfectphase|Stephen Woolhead]]<br />
* Mark Mellors<br />
* Dave Ansell<br />
* David Bebb<br />
* Simon Stirley<br />
* Jason White<br />
* Rick Lupton<br />
* Robin Sterling<br />
* Shareef Jalloq<br />
* Hidde-Jan Lemstra<br />
<br />
<br />
-- Further Contacts --<br />
<br />
* Chris Abri <!--chris.abri1985@gmail.com--><br />
<br />
If you have any questions, problems or concerns around the CNC router, please use the mailing list thread:<br />
* [https://groups.google.com/d/topic/cammakespace/rkchD7VqM2c/discussion Log : CNC Router]<br />
<br />
== Training ==<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>YOU CAN ONLY USE THE CNC ROUTER IF YOU HAVE BEEN TRAINED</b><br><br />
and have been added to the [[Equipment/CNC_Router/Training#Trained_Users|Trained Users]] list by one of the Owners<br />
</div><br />
<br />
To get trained on the CNC router and be added to the qualified user list, you will need to arrange for a training session with one of the Owners. <br />
<br />
If you'd like to arrange training, please see:<br />
* [[Equipment/CNC_Router/Training|CNC Router Training]]<br />
<br />
== Health and Safety ==<br />
<br />
The CNC Router is a potentially dangerous piece of equipment which must only be operated by members who have received appropriate training and who take due care. The top things to always remember when using the CNC Router are:<br />
* '''ONLY USE THE CNC ROUTER IF YOU ARE ON THE LIST OF TRAINED USERS'''<br />
* '''NEVER LEAVE THE CNC ROUTER RUNNING UNATTENDED'''<br />
<br />
As a trained user, you should be very aware of the following risks and how to deal with them:<br />
<br />
'''FIRE''' - Cutting with the wrong settings could result in the material igniting.<br />
<br />
'''TRAPPING''' - Stand clear of the machine while in motion.<br />
<br />
'''DUST''' - Ensure extraction system is working.<br />
<br />
'''NOISE''' - Ensure that you wear the correct PPE when working with the machine for prolonged periods.<br />
<br />
Full Risk assessment[[File:CNC_Router.pdf ]]<br />
<br />
== CNC Glossary ==<br />
<br />
As with most new ventures into another profession or hobby, there is the need to learn a “new language” and its common abbreviations. We have introduced some of these in the description of the workflow process above. Here we’ll look at some in more detail. These are listed in alphabetical order.<br />
<br />
=== 2D/2.5D/3D Toolpaths ===<br />
<br />
Depending on the information source, the definitions of 2D, 2.5D and 3D can be quite vague and appear to overlap.<br />
<br />
'''2D''' is simple horizontal cuts at a constant Z depth. For example, you cut out letter or a plaque shape to hang on the wall by moving the tool down to a specific depth and tracing the shape of the part you are cutting in 2D.<br />
<br />
'''2.5D''' would be a little more complex than 2D as while the tool is cutting, the Z depth would be changing instead of staying constant. Typically this still uses 2D vector data to define the path but the way the tool moves in relation to the 2D data and its form will determine the shape that is cut. The most common example of 2.5D is VCarving. Although this cuts 2D vector shapes, the V-shaped tool “rides” on the edges of the vectors, so as it gets wider it cuts deeper and as the vector get closer together it will lift up in Z.<br />
<br />
'''3D'''' These are toolpaths that like 2.5D toolpaths can move simultaneously in all 3 (X, Y and Z) axes however the shape they cut is described by following a 3D computer model and not vectors. They are typically cut with a Ball-Nose (round ended) tool. The tool will go back and forth across the 3D model following the contours of the part similar to an old fashioned copying or digitizing machine. The smoothness of the finished part depends on the Stepover setting in the toolpath as that determines how many times the tool will pass over the model. The size of the tool is also important as the software will only let it cut the detail that the end of the tool can fit into as it traces over the virtual surface. Examples of 3D toolpaths are 3D Rouging and 3D Finishing<br />
<br />
=== 3-axis===<br />
<br />
A 3-axis CNC machine is one that can move a router bit in the 3 primary directions, X, Y and Z. The image below show 3 views of a typical CNC setup and how the axes are referenced from each viewing direction.<br />
<br />
=== CAD ===<br />
<br />
CAD has been used as an abbreviation for both “Computer Aided Design” and “Computer Aided Drafting”. Now it has become a generic term in its own right that refers to a software program that can be used to create a 2D or 3D design.<br />
<br />
=== CAM ===<br />
<br />
When you discuss designing and preparing projects for your CNC machine, the follow-on side of CAD is CAM, which stands for ‘Computer Aided Manufacturing’ or ‘Computer Aided Machining’. This is the part of the process where the geometry developed during the CAD design process are now used to create the instructions that will move your CNC machine to ‘manufacture’ or machine the part.<br />
<br />
=== Collet ===<br />
<br />
The collet assembly is the component on a router or spindle that holds the router bit securely and consists of a precision collet and a collet nut. The collet is precisely sized to hold the router bit shank and the collet nut applies a compressive, friction fit as it is properly tightened onto the router or spindle shaft. It is very important to keep the collets clean and well maintained and depending on use, they must be periodically replaced.<br />
<br />
=== Gantry ===<br />
<br />
The gantry is the part of a CNC machine that typically has one of the horizontal axes running along it and also moves along the other horizontal axis to create the X and Y movement for the tool. The Z axis is also typically mounted on the gantry.<br />
<br />
=== G-Code === <br />
<br />
This is a generic term for the code which is sent to the machine with the instructions telling it how to move. Or, to put it in our context, the file that is saved from the software using the Post Processor to format it for the CNC machine. In reality it’s a particular type of data that a lot of CNC’s use a variant of – so G-code is not necessarily interchangeable to different machines. The name comes from the fact that many of the codes within in start with a G. For example G01 specifies a Feed Rate move and G00 specifies a Rapid move etc.<br />
<br />
=== Pass ===<br />
<br />
When you have a toolpath that is too deep, too wide or a combination of both for the router bit to remove all the material at one time, the toolpath is broken up into multiple ‘Passes’ with each pass removing a part of the material.<br />
<br />
When the toolpath is too deep, a Pass Depth (see entry below) value for the bit will be set and used to indicate the maximum Z depth the tool should cut on each Pass. The amount of material a tool can remove will be determined by the tooltype, size, material being cut and many other parameters. Tooling manufacturers typically offer recommendations for these values.<br />
<br />
=== Post Processor ===<br />
<br />
There are hundreds of different brands and models of CNC machines currently in use. When it comes to controlling them, many have a lot in common, but there can and will be differences. So, if you look at this as each machine speaks a slightly different language, there has to be a way for a single CAD/CAM program to speak to each machine and this is accomplished by using an “interpreter” called a Post Processor, also sometimes simply referred to as ‘pp’ or ‘post’.<br />
<br />
For example, you design a project to cut an exact size circle out of a piece of material and calculate a toolpath to do that. When you actually save that toolpath so it can be used at your CNC machine, the correct Post Processor will ensure the instructions for cutting that circle are prepared correctly so your CNC machine can read and understand them and accurately cut the circle as you intended.<br />
<br />
=== Router Bed or Machine Bed === <br />
<br />
The ‘bed’ identifies the part of a CNC machine where the material being machined is placed and held securely in position. For best results, the bed needs to be flat and sturdy. In most designs the bed is stationary; however there are exceptions to this where the bed moves to provide either the X or Y axis movement.<br />
<br />
=== Sacrifice Sheet / Spoilboard === <br />
<br />
The spoilboard is normally a sacrificial sheet of material placed on top of the machine bed and is intended to be replaced as necessary. It protects the machine bed and allows frequent surfacing which will help to keep a truly flat surface to mount material and help maintain accuracy. This allows the stock material to be screwed down to it and the parts drilled and cut all the way through the material thickness.<br />
<br />
=== Stepover ===<br />
<br />
The Stepover setting found for most router bits allows you to control horizontal movement when machining areas wider than the router bit. Physically, stepover is the distance the center of the bit moves horizontally for each pass.<br />
<br />
The Stepover is shown in the programs as both a physical distance (0.025” or 0.5mm for example) and as a percentage of bit diameter (6%, 8%, 50%, etc.). You can enter either value and the software will automatically calculate the other one for you. Typically most users refer to Stepover by its percentage value as it is a simple whole number and can easily be translated to other tool sizes for a particular task, for example when finishing setting the Stepover to be 10% of the ballnose tools diameter normally creates a reasonably finish surface.<br />
<br />
=== Toolpath ===<br />
<br />
A toolpath is the path created during the CAM part of your project design and represents the instructions your CNC machine will use to make the router bit move to duplicate what you have designed. In the software it is typically displayed as a set of lines which show a virtual picture of the path the tool tip will move along when the toolpath is run on the machine.<br />
<br />
=== Vector ===<br />
<br />
Vector is the word used to describe a 2D line, arc or curve. A vector can be used to describe almost any 2D shape.<br />
<br />
== Instructions ==<br />
<br />
[http://wiki.makespace.org/File:MPC6610_CNC_Router_Manual_v1.0-En.pdf Router Manual]<br />
<br />
[[Equipment/CNC_Router/Hand_Controller|Hand Controller Look-up Guide]]<br />
<br />
===Setting the Z Origin Using the Z0 Sensor===<br />
''A tool that has an extremely narrow tip may break when it touches the tool sensor depending on which tool is to be used.''<br />
<br />
1. Secure the workpiece on the bed, and place the Z0 sensor at the place where you want to set the Z origin on the workpiece. Face the surface of the Z0 sensor without the magnet facing upward.<br />
<br />
[[image:Mill_z0.PNG]]<br />
<br />
2. Use the handset to move the tool to the position above the sensor.<br />
<br />
3. On the handset press OK + 8(Z-0). The tool slowly descend until it contacts the sensor. When the tool rises and stops, the setting operation is complete. <br />
<br />
Note: It is important the tool is electrically conductive from tip to shaft, and the sensor is clean. Failure to check will cause damage to the tool and sensor.<br />
<br />
4. Remove the sensor from the workpiece to a location where it will not interfere with future cutting operations.<br />
<br />
==Software==<br />
<br />
The standard software is Vectric's line of CAM software:<br />
<br />
===VCarvePro===<br />
<br />
[[image:Vcarvepro.png]]<br />
<br />
VCarve Pro provides a powerful but intuitive software solution for 2D design and calculation of 2D and 2.5D toolpaths for cutting parts on a CNC Router. <br />
<br />
The software can import 2D designs from other programs but also includes a full set of drawing and editing tools with advanced layout options such as True-Shape Nesting. The toolpath options cover all typical 2D routing operations such as Profiling, Pocketing, Auto-Inlays and Drilling as well as 2.5D strategies such as V-Carving, Prism carving, Fluting and even a decorative Texturing strategy. Each toolpath includes appropriate options to customize the settings and provide a high level of control for different types of operation. In addition all toolpaths can be previewed to show just how the part will look when it is actually cut, this allows instant feedback to allow toolpaths to be further optimized. <br />
<br />
'''Details''': http://www.vectric.com/products/vcarve-pro.htm<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/vcarve-pro<br />
<br />
===Cut3D===<br />
<br />
[[image:Vectric-cut3d.jpg|266px]]<br />
<br />
Cut3D is a dedicated toolpath engine for CNC machining 3D models that have been designed using a 3D CAD or Graphics design product such as AutoCAD, Rhino3D, 3D Studio etc. or scanned using a laser or touch probe device. Cut3D's exceptionally easy to use interface leads you step-by-step through the process of loading a model, setting the size, interactively placing tabs to hold the job in place, calculating single, double or four sided roughing and finishing toolpaths, previewing the results and finally saving the CNC code to run on your machine.<br />
<br />
3D Models that are too large / thick to machine because of gantry height, cutter length or limited material thickness can be 'Sliced' into separate pieces. Each slice can then be machined and the complete job assembled. <br />
<br />
'''Details''': http://www.vectric.com/products/cut3d.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/cut3d<br />
<br />
===PhotoVCarve===<br />
<br />
[[image:Vectric-photovcarve.gif|266px]]<br />
<br />
PhotoVCarve creates lines of grooves that vary in width and depth to represent the detail in a photograph or image. The quality of the finished result is very dependant upon a high level of contrast between the material surface and the machined grooves. This information is very important to remember when cutting designs using the PhotoVCarve software. <br />
<br />
PhotoVCarve machines dark areas in a photograph with wide groove and the lighter areas to have narrower ones. The software automatically calculates the toolpaths based on the cutter selected and maximum depth of groove required. <br />
<br />
'''Details''': http://www.vectric.com/products/photovcarve.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/photovcarve<br />
<br />
== Tooling ==<br />
<br />
=== Router Bits ===<br />
<br />
Router bits (or cutters) are the most common type of cutter, they have two or more vertical cutting edges. These are good general purpose cutters that can be found in most DIY shops. They are the same type that you would use in a manual hand held router.<br />
<br />
<gallery><br />
File:WP_20130813_025.jpg<br />
File:WP_20130813_025.jpg<br />
File:WP_20130814_002.jpg<br />
File:WP_20130814_003.jpg<br />
</gallery><br />
<br />
It is important to notice that the cutters are on the edge of the body only, they do not extend to the centre of the cutter. This means the cutter CAN NOT BE USED AS A DRILL. An holes that are made by these sorts of cutters must be made by ramping the cutter to the correct depth in a sloping or spiral motion.<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>NEVER USE ROUTER BITS THAT HAVE BEARINGS.</b> These types of cutters are designed for manual routers where you can feel the feed back of the bearing in contact with the material being cut. A CNC device has no such feedback and will press the bearing into the material has hard as it can until something gives, i.e. the cutter breaks or much worse the spindle breaks. People found using these types of cutters on the CNC router will be BANNED! Just use the version without the bearing.<br />
<br />
<gallery><br />
File:WP_20130813_018.jpg<br />
</gallery><br />
<br />
The cutting edges should always be the lowest part of the cutter.<br />
</div><br />
<br />
=== End mills ===<br />
<br />
'''Up Cut and Down Cut'''<br />
<br />
Router end mills have two variants, up cut (left) and down cut (right); there is a third type, compression, but they are quite rare.<br />
<br />
<gallery><br />
File:WP_20130813_015.jpg<br />
</gallery><br />
<br />
Most cutters are up cut, which have the cutting service on the top of the flutes and as they rotate lift the chips up and away from the material being cut.<br />
<br />
Down cut cutters have the cutting edge on the bottom of the flutes and push chips down towards the material being cut. This has the advantage of pressing the material being cut into the bed of the machine; this is especially useful for thin plastics. The other advantage is the top surface shows far less breakout and splintering, this is a big advantage for materials like laminates.<br />
<br />
On image on the left has been cut with an up-cut end mill and the image on the right a down-cut.<br />
<br />
<gallery><br />
File:WP_20130813_005.jpg<br />
File:WP_20130813_007.jpg<br />
</gallery><br />
<br />
NOTE: There is a very big disadvantage to down cut end mills, and that is that they do not clear there chips effectively in blind holes. This means they need larger ramping moves to get to the correct cutting depth and if used in pockets without enough clearance, the friction can lead to burning or melting of the material being cut.<br />
<br />
Another down side to down-cut cutters, is that when cutting pockets, the bottom surface will not be as clean as that made with an up-cut cutter, which will do a far better job of clearing the waste chips that rub between the cutter and the material with a down-cut.<br />
<br />
== Stock Tooling ==<br />
<br />
In order to keep a small stock of cutters for general use, the CNC Router needs to have a means of generating money. Because there is no material provided for use with the CNC Router there is no way to bring in any funds for such things. Therefore, we ask that if you use one of the communal cutters please put 50p into the CNC Router Honesty Box. This will go towards funding for replenishing stock and also for the replacement of the sacrificial bed once it gets worn out. Please email the list if a communal cutter is broken or missing, so that they can replace it with one from stock. <br />
<br />
There will likely be 1 or two of each of the following cutters available for use, however please do not count on this being the case:<br />
<br />
* 2.5mm square cutter - single flute<br />
* 1/8" square cutter - single flute<br />
* 1/8" ball cutter - 2 flute<br />
<br />
* 6mm square cutter - 2 flute<br />
* 6mm ball cutter - 2 flute<br />
<br />
* engraver 0.2 30deg 1/8" 30mm length (8 of)<br />
* engraver 0.8 30deg 1/8" 30mm length (2 of)<br />
<br />
* 22mm 2 flute straight <br />
* 90deg x 32mm VBit<br />
<br />
<br />
Some Suppliers are listed below:<br />
<br />
== Feeds & Speeds ==<br />
<br />
What are feeds and speeds? Why are they important?<br />
<br />
[http://www.youtube.com/watch?v=ip2jm_6aUyk&feature=c4-overview&list=UUivA7_KLKWo43tFcCkFvydw Milling machine tutorial - cutter selection, speeds and feeds]<br />
<br />
[http://en.wikipedia.org/wiki/Speeds_and_feeds Wikipedia - Speeds and feeds]<br />
<br />
The phrase speeds and feeds (or feeds and speeds) refers to two separate velocities in machine tool practice, cutting speed and feed rate. They are often considered as a pair because of their combined effect on the cutting process. Each, however, can also be considered and analyzed in its own right.<br />
<br />
Cutting speed (also called surface speed or simply speed) is the speed difference (relative velocity) between the cutting tool and the surface of the workpiece it is operating on. It is expressed in units of distance along the workpiece surface per unit of time, typically surface feet per minute (sfm) or meters per minute (m/min). Feed rate (also often styled as a solid compound, feedrate, or called simply feed) is the relative velocity at which the cutter is advanced along the workpiece; its vector is perpendicular to the vector of cutting speed. Feed rate units depend on the motion of the tool and workpiece; when the workpiece rotates (e.g., in turning and boring), the units are almost always distance per spindle revolution (inches per revolution [in/rev or ipr] or millimeters per revolution [mm/rev]). When the workpiece does not rotate (e.g., in milling), the units are typically distance per time (inches per minute [in/min or ipm] or millimeters per minute [mm/min]), although distance per revolution or per cutter tooth are also sometimes used.<br />
<br />
===Spindle speed quick reference===<br />
<br />
{| class="wikitable"<br />
!|<br />
!|400Hz <br />
!|350Hz <br />
!|300Hz <br />
!|250Hz <br />
!|200Hz <br />
!|150Hz <br />
|-<br />
!|RPM<br />
|24000 <br />
|21000 <br />
|18000 <br />
|15000 <br />
|12000 <br />
|9000 <br />
|-<br />
|}<br />
<br />
===Feed rate quick reference===<br />
<br />
{| class="wikitable" <br />
!|100% <br />
!|75% <br />
!|66% <br />
!|50% <br />
!|33% <br />
!|25% <br />
|-<br />
!|6000<br />
|4500<br />
|3960<br />
|3000<br />
|1980<br />
|1500<br />
|-<br />
!|5000<br />
|3750<br />
|3300<br />
|2500<br />
|1650<br />
|1250<br />
|-<br />
!|4000<br />
|3000<br />
|2640<br />
|2000<br />
|1320<br />
|1000<br />
|-<br />
!|3000 <br />
|2250 <br />
|1980 <br />
|1500 <br />
|990 <br />
|750 <br />
|-<br />
!|2500 <br />
|1875 <br />
|1650 <br />
|1250 <br />
|825 <br />
|625 <br />
|-<br />
!|2000 <br />
|1500 <br />
|1320 <br />
|1000 <br />
|660 <br />
|500 <br />
|-<br />
!|1500 <br />
|1125 <br />
|990 <br />
|750 <br />
|495 <br />
|375 <br />
|-<br />
!|1000 <br />
|750 <br />
|660 <br />
|500 <br />
|330 <br />
|250 <br />
|-<br />
!|500 <br />
|375 <br />
|330 <br />
|250 <br />
|165 <br />
|125 <br />
|-<br />
|}<br />
<br />
=== Sample feed rates ===<br />
<br />
For working out feeds and speeds, recommend http://www.cnccookbook.com/CCGWizard.<br />
<br />
The feeds and speeds below have been tested on our machine. The 3mm cutters were single flute carbide. 2 flute HSS cutters may require different settings to avoid breakages.<br />
<br />
{| class="wikitable"<br />
!|MDF<br />
!|1mm deep <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep <br />
|-<br />
!|3mm &Oslash;<br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|-<br />
!|6mm &Oslash; <br />
|3000/24Krpm<br />
|3000/15Krpm <br />
|2000/13Krpm <br />
|1500/11Krpm <br />
|-<br />
!|22mm &Oslash; <br />
|3000/5000rpm <br />
|N/A <br />
|N/A<br />
|N/A<br />
|-<br />
|}<br />
<br />
{| class="wikitable"<br />
!|Plywood<br />
!|1mm deep <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep<br />
|-<br />
!|3mm &Oslash; <br />
|2000/24Krpm <br />
|2000/24Krpm<br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|-<br />
!|6mm &Oslash;<br />
|3000/15Krpm<br />
|3000/15Krpm <br />
|1500/15Krpm <br />
|1000/11Krpm <br />
|-<br />
!|22mm &Oslash; <br />
|3000/5Krpm <br />
|N/A <br />
|N/A<br />
|N/A<br />
|-<br />
|}<br />
<br />
<br />
Polycarbonate:<br />
300Hz 1600mm/min<br />
<br />
Foamed PVC (foamex):<br />
6mm diameter, 10mm deep pass depth, spindle 400Hz (24krpm), feed 9000mm/min.<br />
<br />
3mm diameter, 3mm deep pass depth, 400Hz (24krpm), 9000mm/min.<br />
<br />
Polyurethane foam:<br />
<br />
6mm diameter, full depth pass (30mm+), 400Hz (24krpm), 9000mm/min.<br />
<br />
3mm diameter, 6mm deep pass depth, 400Hz (24krpm), 9000mm/min.<br />
<br />
Acetal (Delrin):<br />
<br />
6mm Cutter, 2mm deep pass depth, spindle 150 - 180Hz, feed 3000mm/min.<br />
<br />
1/8th or 3mm cutter, 1.5 - 2mm deep pass depth, spindle 130 - 160Hz, feed 2-3000mm/min.<br />
<br />
== Tips & Tricks ==<br />
<br />
= Maintenance =<br />
<br />
The maintenance of the CNC Router is carried out by the Owners, with some basic maintenance being carried out by Users on every job.<br />
<br />
== Maintenance Schedule ==<br />
Every job<br />
* Vacuum cutting dust from bed and around machine<br />
* Sand down high points created on sacrificial bed by cutting/screwing<br />
<br />
As required, by users<br />
* Empty extraction bin <br />
* check for blockages in manifold box where extraction pipes meet<br />
<br />
Monthly<br />
* Inspect extraction hoses for splits/ wear<br />
* Clean guide rails (Don't oil them, it makes dust stick)<br />
* Check level, condition and flow of cooling water and replace as necessary<br />
* Inspect sacrificial bed, re-skim or replace as required<br />
* Inspect cable from pendent to router<br />
* Inspect ER11 collet nut for wear<br />
* Inspect auto levelling probe wire<br />
* check collet set for wear/damage<br />
* Check USB socket on pendent and USB memory stick for splits/damage<br />
<br />
Annual<br />
* Check nuts on lead screws for excessive backlash and adjust if required<br />
* Inspect all covers/structure for signs of damage, cracks etc<br />
* Check tightness (or even presence) of screws holding covers in place<br />
* Check CNC electronics (and PC) cabinets for dust build up and vacuum out if required<br />
* Check feet/supports are all taking load and that the structure is level/flat<br />
* Check motor cables aren't wearing/cracking<br />
<br />
== Maintenance Log ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
3/7/13: Lower spindle clamp bolts replaced with longer stainless ones, holes through tapped as original ones had stripped.<br />
23/12/15: complete maintenance checklist completed. controller cable slightly frayed at machine end, collet nut could do with being replaced. otherwise, everything fine.<br />
<br />
== Maintenance Shopping List ==<br />
<br />
* Cutters<br />
* Sacrificial Bed (1.2m x 1.2m 12mm MDF)<br />
* ER11 collet nut<br />
* controller cable<br />
<br />
= Becoming an Owner/Trainer =<br />
<br />
Becoming an '''Owner''' of a piece of Makespace equipment means that you will be responsible for the maintenance, upkeep and H&S of that equipment. You will also be responsible for running inductions and keeping the information banks (Wiki/Forum/Google Groups) maintained.<br />
<br />
A '''Trainer''' is responsible for running inductions only but will be required to understand how the machine works in order to pass on the relevant skills. A trainer will not be required to maintain the machine but would be expected to keep an eye on its status and report any issues if they develop (as would be expected of any user).<br />
<br />
== Steps to becoming an Owner or Trainer ==<br />
<br />
* Step 1: Contact a current Owner who will talk you through the various responsibilities. [http://wiki.makespace.org/Equipment/CNC_Router#Owners Owners] or Forum: [http://makespace.org/forum/viewtopic.php?f=20&t=89 here]<br />
* Step 2: Sign up to a 'Train the Trainer Training' session on Meetup. It is likely one will need to be set up specially in order for you to sign up but the owner you spoke to should take care of this.<br />
* Step 3: Complete the training to the satisfaction of the Owner/s running the sessions.<br />
* Step 4: Have your name added to the Trainers list and set up your first solo induction session.<br />
* Step 5: Once you are a Trainer you are eligible to become an Owner of the CNC Router. To become an Owner will simply require one further meeting with one of the current owners. This will simply be to walk through the requirements and techniques of maintaining the machine along with any other responsibilites. If the other owners are happy, you can add your name to the [http://wiki.makespace.org/Equipment/CNC_Router#Owners Owners] list.<br />
<br />
== Train the Trainer Training ==<br />
<br />
The first session will be fairly informal, with a look to getting more familiar with the machine and how it operates. We will walk through the Induction cheat-sheet (located on the Wiki) and discuss methods of giving attendees the information they need to use the CNC Router safely.<br />
<br />
The follow up sessions will be arranged during the first session. The second session will include a brief look at the software, Meetup and a full dry-run induction. The third session will be an observed induction where you will be left to train 2 people (with input if necessary). Once complete you will be free to arrange as many induction sessions as you are happy to do. Although you wont be an owner of the CNC Router, if you would like to become one at this point please ask.<br />
<br />
= Further Information =<br />
<br />
== Hardware ==<br />
<br />
Controller: [[File:MPC6610 CNC Router Manual v1.0-En.pdf]]<br />
<br />
<gallery><br />
File:CNC_Router_controller_1.jpg<br />
File:CNC_Router_controller_2.jpg<br />
File:WP 20151230 18 00 14 Pro.jpg<br />
</gallery><br />
<br />
Z-Axis Stepper Driver: [[File:M542-05m.pdf]]<br />
<br />
X and Y Axis Stepper Driver: [[File:MA860Hm.pdf]]<br />
<br />
Y Axis Stepper motor: 86BYGH450A-06 (NEMA34 Hybid Stepper Motor, MAX torque: 495 oz-in)<br />
* Insulation Resistant - 500V DC 100MΩ Min<br />
* Insulation Strength - 50Hz 1Minute 500V Min<br />
* Ambient Temperature - -20~+50 degree<br />
* Temperature Rise - 80 Max.<br />
* Radial Play - 0.02mm Max.<br />
* End Play - 0.1-0.3mm<br />
* Model: 85BYGH450A-06<br />
* Motor dimension: 85*85*75mm<br />
* Current/phase: 4.0A<br />
* Voltage/phase: 2.0V<br />
* Inductance/phase: 2.3+/-20%mH<br />
* Resistance/phase: 0.5+/-10%ohm<br />
* Holding torque: 3.5 N. M<br />
* Shaft diameter: 13 mm<br />
* Shaft length: 31.50mm<br />
* Leading wires: 4 leading wires<br />
<br />
== Installation ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
<gallery><br />
File:Photo_1.JPG<br />
File:WP_20130509_005.jpg<br />
</gallery><br />
<br />
== Purchase ==<br />
Full Purchase, Delivery and Installation (£?????)<br />
<br />
== Notes ==<br />
<br />
http://www.shopbottools.com/mProducts/prSstandard.htm</div>Perfectphasehttp://wiki.makespace.org/File:WP_20151230_18_00_14_Pro.jpgFile:WP 20151230 18 00 14 Pro.jpg2016-01-04T01:25:41Z<p>Perfectphase: </p>
<hr />
<div></div>Perfectphasehttp://wiki.makespace.org/Equipment/CNC_RouterEquipment/CNC Router2016-01-04T01:24:51Z<p>Perfectphase: /* Further Information */</p>
<hr />
<div>{{RedTool}}<br />
<br />
== CNC ROUTER IS DECOMMISSIONED ==<br />
<br />
Pending revision and/or replacement, the CNC router is now decommissioned. Usage is restricted to people operating with full knowledge that steps can be missed and the height can get wrong, resulting in head crashes. Be careful, wear safety goggles. No new training pending replacement or upgrade.<br />
<br />
[[Equipment|Equipment]] / CNC Router<br />
<br />
[[File:WP_20130509_005.jpg|thumb|460px|right|CNC Router]]<br />
<br />
<br />
== Summary ==<br />
<br />
A CNC router is a computer controlled shaping machine. These are related to the hand held router. Instead of hand held routing, the tool paths can be controlled via computer numerical control. It is a computer-controlled machine for cutting various hard materials, such as wood, composites, aluminum, steel, plastics, and foams. It is one of many kinds of tools that have CNC variants. A CNC router is very similar in concept to a CNC milling machine. The CNC router is controlled by a computer. Coordinates are uploaded into the machine controller from a separate CAD program<br />
<br />
* Capacity: 1200 x 1200 x 120mm<br />
* Rate (X,Y): 6000mm/min (Max) 5000mm/min (Working)<br />
* Rate (Z): 30mm/sec<br />
* Spindle Speed: 4500 to 24000rpm<br />
* Mechanical Precision: 0.01mm<br />
* Spindle Power: 1.5KW Variable Speed, Water-cooled<br />
* Blade Diameter: min 3.175mm, max 12.7mm <br />
* Order Format: HPGL, G code, u00, mmg, plt <br />
* Control System: DSP with USB connection <br />
<br />
Here are some examples we've made on the CNC router (please add a photo of yours any time you do a job!) <br />
<br />
<gallery><br />
File:WP_20130509_004.jpg<br />
File:WP_20130624_017.jpg<br />
File:WP_20130625_001.jpg<br />
</gallery><br />
<br />
= Using the CNC Router =<br />
== Owners ==<br />
<br />
The Owners are those who have volunteered to be in charge of the equipment, organising maintenance, training others to use it, and generally being a point of contact. The current Owners of the CNC Router are:<br />
<br />
* [[User:perfectphase|Stephen Woolhead]]<br />
* Mark Mellors<br />
* Dave Ansell<br />
* David Bebb<br />
* Simon Stirley<br />
* Jason White<br />
* Rick Lupton<br />
* Robin Sterling<br />
* Shareef Jalloq<br />
* Hidde-Jan Lemstra<br />
<br />
<br />
-- Further Contacts --<br />
<br />
* Chris Abri <!--chris.abri1985@gmail.com--><br />
<br />
If you have any questions, problems or concerns around the CNC router, please use the mailing list thread:<br />
* [https://groups.google.com/d/topic/cammakespace/rkchD7VqM2c/discussion Log : CNC Router]<br />
<br />
== Training ==<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>YOU CAN ONLY USE THE CNC ROUTER IF YOU HAVE BEEN TRAINED</b><br><br />
and have been added to the [[Equipment/CNC_Router/Training#Trained_Users|Trained Users]] list by one of the Owners<br />
</div><br />
<br />
To get trained on the CNC router and be added to the qualified user list, you will need to arrange for a training session with one of the Owners. <br />
<br />
If you'd like to arrange training, please see:<br />
* [[Equipment/CNC_Router/Training|CNC Router Training]]<br />
<br />
== Health and Safety ==<br />
<br />
The CNC Router is a potentially dangerous piece of equipment which must only be operated by members who have received appropriate training and who take due care. The top things to always remember when using the CNC Router are:<br />
* '''ONLY USE THE CNC ROUTER IF YOU ARE ON THE LIST OF TRAINED USERS'''<br />
* '''NEVER LEAVE THE CNC ROUTER RUNNING UNATTENDED'''<br />
<br />
As a trained user, you should be very aware of the following risks and how to deal with them:<br />
<br />
'''FIRE''' - Cutting with the wrong settings could result in the material igniting.<br />
<br />
'''TRAPPING''' - Stand clear of the machine while in motion.<br />
<br />
'''DUST''' - Ensure extraction system is working.<br />
<br />
'''NOISE''' - Ensure that you wear the correct PPE when working with the machine for prolonged periods.<br />
<br />
Full Risk assessment[[File:CNC_Router.pdf ]]<br />
<br />
== CNC Glossary ==<br />
<br />
As with most new ventures into another profession or hobby, there is the need to learn a “new language” and its common abbreviations. We have introduced some of these in the description of the workflow process above. Here we’ll look at some in more detail. These are listed in alphabetical order.<br />
<br />
=== 2D/2.5D/3D Toolpaths ===<br />
<br />
Depending on the information source, the definitions of 2D, 2.5D and 3D can be quite vague and appear to overlap.<br />
<br />
'''2D''' is simple horizontal cuts at a constant Z depth. For example, you cut out letter or a plaque shape to hang on the wall by moving the tool down to a specific depth and tracing the shape of the part you are cutting in 2D.<br />
<br />
'''2.5D''' would be a little more complex than 2D as while the tool is cutting, the Z depth would be changing instead of staying constant. Typically this still uses 2D vector data to define the path but the way the tool moves in relation to the 2D data and its form will determine the shape that is cut. The most common example of 2.5D is VCarving. Although this cuts 2D vector shapes, the V-shaped tool “rides” on the edges of the vectors, so as it gets wider it cuts deeper and as the vector get closer together it will lift up in Z.<br />
<br />
'''3D'''' These are toolpaths that like 2.5D toolpaths can move simultaneously in all 3 (X, Y and Z) axes however the shape they cut is described by following a 3D computer model and not vectors. They are typically cut with a Ball-Nose (round ended) tool. The tool will go back and forth across the 3D model following the contours of the part similar to an old fashioned copying or digitizing machine. The smoothness of the finished part depends on the Stepover setting in the toolpath as that determines how many times the tool will pass over the model. The size of the tool is also important as the software will only let it cut the detail that the end of the tool can fit into as it traces over the virtual surface. Examples of 3D toolpaths are 3D Rouging and 3D Finishing<br />
<br />
=== 3-axis===<br />
<br />
A 3-axis CNC machine is one that can move a router bit in the 3 primary directions, X, Y and Z. The image below show 3 views of a typical CNC setup and how the axes are referenced from each viewing direction.<br />
<br />
=== CAD ===<br />
<br />
CAD has been used as an abbreviation for both “Computer Aided Design” and “Computer Aided Drafting”. Now it has become a generic term in its own right that refers to a software program that can be used to create a 2D or 3D design.<br />
<br />
=== CAM ===<br />
<br />
When you discuss designing and preparing projects for your CNC machine, the follow-on side of CAD is CAM, which stands for ‘Computer Aided Manufacturing’ or ‘Computer Aided Machining’. This is the part of the process where the geometry developed during the CAD design process are now used to create the instructions that will move your CNC machine to ‘manufacture’ or machine the part.<br />
<br />
=== Collet ===<br />
<br />
The collet assembly is the component on a router or spindle that holds the router bit securely and consists of a precision collet and a collet nut. The collet is precisely sized to hold the router bit shank and the collet nut applies a compressive, friction fit as it is properly tightened onto the router or spindle shaft. It is very important to keep the collets clean and well maintained and depending on use, they must be periodically replaced.<br />
<br />
=== Gantry ===<br />
<br />
The gantry is the part of a CNC machine that typically has one of the horizontal axes running along it and also moves along the other horizontal axis to create the X and Y movement for the tool. The Z axis is also typically mounted on the gantry.<br />
<br />
=== G-Code === <br />
<br />
This is a generic term for the code which is sent to the machine with the instructions telling it how to move. Or, to put it in our context, the file that is saved from the software using the Post Processor to format it for the CNC machine. In reality it’s a particular type of data that a lot of CNC’s use a variant of – so G-code is not necessarily interchangeable to different machines. The name comes from the fact that many of the codes within in start with a G. For example G01 specifies a Feed Rate move and G00 specifies a Rapid move etc.<br />
<br />
=== Pass ===<br />
<br />
When you have a toolpath that is too deep, too wide or a combination of both for the router bit to remove all the material at one time, the toolpath is broken up into multiple ‘Passes’ with each pass removing a part of the material.<br />
<br />
When the toolpath is too deep, a Pass Depth (see entry below) value for the bit will be set and used to indicate the maximum Z depth the tool should cut on each Pass. The amount of material a tool can remove will be determined by the tooltype, size, material being cut and many other parameters. Tooling manufacturers typically offer recommendations for these values.<br />
<br />
=== Post Processor ===<br />
<br />
There are hundreds of different brands and models of CNC machines currently in use. When it comes to controlling them, many have a lot in common, but there can and will be differences. So, if you look at this as each machine speaks a slightly different language, there has to be a way for a single CAD/CAM program to speak to each machine and this is accomplished by using an “interpreter” called a Post Processor, also sometimes simply referred to as ‘pp’ or ‘post’.<br />
<br />
For example, you design a project to cut an exact size circle out of a piece of material and calculate a toolpath to do that. When you actually save that toolpath so it can be used at your CNC machine, the correct Post Processor will ensure the instructions for cutting that circle are prepared correctly so your CNC machine can read and understand them and accurately cut the circle as you intended.<br />
<br />
=== Router Bed or Machine Bed === <br />
<br />
The ‘bed’ identifies the part of a CNC machine where the material being machined is placed and held securely in position. For best results, the bed needs to be flat and sturdy. In most designs the bed is stationary; however there are exceptions to this where the bed moves to provide either the X or Y axis movement.<br />
<br />
=== Sacrifice Sheet / Spoilboard === <br />
<br />
The spoilboard is normally a sacrificial sheet of material placed on top of the machine bed and is intended to be replaced as necessary. It protects the machine bed and allows frequent surfacing which will help to keep a truly flat surface to mount material and help maintain accuracy. This allows the stock material to be screwed down to it and the parts drilled and cut all the way through the material thickness.<br />
<br />
=== Stepover ===<br />
<br />
The Stepover setting found for most router bits allows you to control horizontal movement when machining areas wider than the router bit. Physically, stepover is the distance the center of the bit moves horizontally for each pass.<br />
<br />
The Stepover is shown in the programs as both a physical distance (0.025” or 0.5mm for example) and as a percentage of bit diameter (6%, 8%, 50%, etc.). You can enter either value and the software will automatically calculate the other one for you. Typically most users refer to Stepover by its percentage value as it is a simple whole number and can easily be translated to other tool sizes for a particular task, for example when finishing setting the Stepover to be 10% of the ballnose tools diameter normally creates a reasonably finish surface.<br />
<br />
=== Toolpath ===<br />
<br />
A toolpath is the path created during the CAM part of your project design and represents the instructions your CNC machine will use to make the router bit move to duplicate what you have designed. In the software it is typically displayed as a set of lines which show a virtual picture of the path the tool tip will move along when the toolpath is run on the machine.<br />
<br />
=== Vector ===<br />
<br />
Vector is the word used to describe a 2D line, arc or curve. A vector can be used to describe almost any 2D shape.<br />
<br />
== Instructions ==<br />
<br />
[http://wiki.makespace.org/File:MPC6610_CNC_Router_Manual_v1.0-En.pdf Router Manual]<br />
<br />
[[Equipment/CNC_Router/Hand_Controller|Hand Controller Look-up Guide]]<br />
<br />
===Setting the Z Origin Using the Z0 Sensor===<br />
''A tool that has an extremely narrow tip may break when it touches the tool sensor depending on which tool is to be used.''<br />
<br />
1. Secure the workpiece on the bed, and place the Z0 sensor at the place where you want to set the Z origin on the workpiece. Face the surface of the Z0 sensor without the magnet facing upward.<br />
<br />
[[image:Mill_z0.PNG]]<br />
<br />
2. Use the handset to move the tool to the position above the sensor.<br />
<br />
3. On the handset press OK + 8(Z-0). The tool slowly descend until it contacts the sensor. When the tool rises and stops, the setting operation is complete. <br />
<br />
Note: It is important the tool is electrically conductive from tip to shaft, and the sensor is clean. Failure to check will cause damage to the tool and sensor.<br />
<br />
4. Remove the sensor from the workpiece to a location where it will not interfere with future cutting operations.<br />
<br />
==Software==<br />
<br />
The standard software is Vectric's line of CAM software:<br />
<br />
===VCarvePro===<br />
<br />
[[image:Vcarvepro.png]]<br />
<br />
VCarve Pro provides a powerful but intuitive software solution for 2D design and calculation of 2D and 2.5D toolpaths for cutting parts on a CNC Router. <br />
<br />
The software can import 2D designs from other programs but also includes a full set of drawing and editing tools with advanced layout options such as True-Shape Nesting. The toolpath options cover all typical 2D routing operations such as Profiling, Pocketing, Auto-Inlays and Drilling as well as 2.5D strategies such as V-Carving, Prism carving, Fluting and even a decorative Texturing strategy. Each toolpath includes appropriate options to customize the settings and provide a high level of control for different types of operation. In addition all toolpaths can be previewed to show just how the part will look when it is actually cut, this allows instant feedback to allow toolpaths to be further optimized. <br />
<br />
'''Details''': http://www.vectric.com/products/vcarve-pro.htm<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/vcarve-pro<br />
<br />
===Cut3D===<br />
<br />
[[image:Vectric-cut3d.jpg|266px]]<br />
<br />
Cut3D is a dedicated toolpath engine for CNC machining 3D models that have been designed using a 3D CAD or Graphics design product such as AutoCAD, Rhino3D, 3D Studio etc. or scanned using a laser or touch probe device. Cut3D's exceptionally easy to use interface leads you step-by-step through the process of loading a model, setting the size, interactively placing tabs to hold the job in place, calculating single, double or four sided roughing and finishing toolpaths, previewing the results and finally saving the CNC code to run on your machine.<br />
<br />
3D Models that are too large / thick to machine because of gantry height, cutter length or limited material thickness can be 'Sliced' into separate pieces. Each slice can then be machined and the complete job assembled. <br />
<br />
'''Details''': http://www.vectric.com/products/cut3d.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/cut3d<br />
<br />
===PhotoVCarve===<br />
<br />
[[image:Vectric-photovcarve.gif|266px]]<br />
<br />
PhotoVCarve creates lines of grooves that vary in width and depth to represent the detail in a photograph or image. The quality of the finished result is very dependant upon a high level of contrast between the material surface and the machined grooves. This information is very important to remember when cutting designs using the PhotoVCarve software. <br />
<br />
PhotoVCarve machines dark areas in a photograph with wide groove and the lighter areas to have narrower ones. The software automatically calculates the toolpaths based on the cutter selected and maximum depth of groove required. <br />
<br />
'''Details''': http://www.vectric.com/products/photovcarve.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/photovcarve<br />
<br />
== Tooling ==<br />
<br />
=== Router Bits ===<br />
<br />
Router bits (or cutters) are the most common type of cutter, they have two or more vertical cutting edges. These are good general purpose cutters that can be found in most DIY shops. They are the same type that you would use in a manual hand held router.<br />
<br />
<gallery><br />
File:WP_20130813_025.jpg<br />
File:WP_20130813_025.jpg<br />
File:WP_20130814_002.jpg<br />
File:WP_20130814_003.jpg<br />
</gallery><br />
<br />
It is important to notice that the cutters are on the edge of the body only, they do not extend to the centre of the cutter. This means the cutter CAN NOT BE USED AS A DRILL. An holes that are made by these sorts of cutters must be made by ramping the cutter to the correct depth in a sloping or spiral motion.<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>NEVER USE ROUTER BITS THAT HAVE BEARINGS.</b> These types of cutters are designed for manual routers where you can feel the feed back of the bearing in contact with the material being cut. A CNC device has no such feedback and will press the bearing into the material has hard as it can until something gives, i.e. the cutter breaks or much worse the spindle breaks. People found using these types of cutters on the CNC router will be BANNED! Just use the version without the bearing.<br />
<br />
<gallery><br />
File:WP_20130813_018.jpg<br />
</gallery><br />
<br />
The cutting edges should always be the lowest part of the cutter.<br />
</div><br />
<br />
=== End mills ===<br />
<br />
'''Up Cut and Down Cut'''<br />
<br />
Router end mills have two variants, up cut (left) and down cut (right); there is a third type, compression, but they are quite rare.<br />
<br />
<gallery><br />
File:WP_20130813_015.jpg<br />
</gallery><br />
<br />
Most cutters are up cut, which have the cutting service on the top of the flutes and as they rotate lift the chips up and away from the material being cut.<br />
<br />
Down cut cutters have the cutting edge on the bottom of the flutes and push chips down towards the material being cut. This has the advantage of pressing the material being cut into the bed of the machine; this is especially useful for thin plastics. The other advantage is the top surface shows far less breakout and splintering, this is a big advantage for materials like laminates.<br />
<br />
On image on the left has been cut with an up-cut end mill and the image on the right a down-cut.<br />
<br />
<gallery><br />
File:WP_20130813_005.jpg<br />
File:WP_20130813_007.jpg<br />
</gallery><br />
<br />
NOTE: There is a very big disadvantage to down cut end mills, and that is that they do not clear there chips effectively in blind holes. This means they need larger ramping moves to get to the correct cutting depth and if used in pockets without enough clearance, the friction can lead to burning or melting of the material being cut.<br />
<br />
Another down side to down-cut cutters, is that when cutting pockets, the bottom surface will not be as clean as that made with an up-cut cutter, which will do a far better job of clearing the waste chips that rub between the cutter and the material with a down-cut.<br />
<br />
== Stock Tooling ==<br />
<br />
In order to keep a small stock of cutters for general use, the CNC Router needs to have a means of generating money. Because there is no material provided for use with the CNC Router there is no way to bring in any funds for such things. Therefore, we ask that if you use one of the communal cutters please put 50p into the CNC Router Honesty Box. This will go towards funding for replenishing stock and also for the replacement of the sacrificial bed once it gets worn out. Please email the list if a communal cutter is broken or missing, so that they can replace it with one from stock. <br />
<br />
There will likely be 1 or two of each of the following cutters available for use, however please do not count on this being the case:<br />
<br />
* 2.5mm square cutter - single flute<br />
* 1/8" square cutter - single flute<br />
* 1/8" ball cutter - 2 flute<br />
<br />
* 6mm square cutter - 2 flute<br />
* 6mm ball cutter - 2 flute<br />
<br />
* engraver 0.2 30deg 1/8" 30mm length (8 of)<br />
* engraver 0.8 30deg 1/8" 30mm length (2 of)<br />
<br />
* 22mm 2 flute straight <br />
* 90deg x 32mm VBit<br />
<br />
<br />
Some Suppliers are listed below:<br />
<br />
== Feeds & Speeds ==<br />
<br />
What are feeds and speeds? Why are they important?<br />
<br />
[http://www.youtube.com/watch?v=ip2jm_6aUyk&feature=c4-overview&list=UUivA7_KLKWo43tFcCkFvydw Milling machine tutorial - cutter selection, speeds and feeds]<br />
<br />
[http://en.wikipedia.org/wiki/Speeds_and_feeds Wikipedia - Speeds and feeds]<br />
<br />
The phrase speeds and feeds (or feeds and speeds) refers to two separate velocities in machine tool practice, cutting speed and feed rate. They are often considered as a pair because of their combined effect on the cutting process. Each, however, can also be considered and analyzed in its own right.<br />
<br />
Cutting speed (also called surface speed or simply speed) is the speed difference (relative velocity) between the cutting tool and the surface of the workpiece it is operating on. It is expressed in units of distance along the workpiece surface per unit of time, typically surface feet per minute (sfm) or meters per minute (m/min). Feed rate (also often styled as a solid compound, feedrate, or called simply feed) is the relative velocity at which the cutter is advanced along the workpiece; its vector is perpendicular to the vector of cutting speed. Feed rate units depend on the motion of the tool and workpiece; when the workpiece rotates (e.g., in turning and boring), the units are almost always distance per spindle revolution (inches per revolution [in/rev or ipr] or millimeters per revolution [mm/rev]). When the workpiece does not rotate (e.g., in milling), the units are typically distance per time (inches per minute [in/min or ipm] or millimeters per minute [mm/min]), although distance per revolution or per cutter tooth are also sometimes used.<br />
<br />
===Spindle speed quick reference===<br />
<br />
{| class="wikitable"<br />
!|<br />
!|400Hz <br />
!|350Hz <br />
!|300Hz <br />
!|250Hz <br />
!|200Hz <br />
!|150Hz <br />
|-<br />
!|RPM<br />
|24000 <br />
|21000 <br />
|18000 <br />
|15000 <br />
|12000 <br />
|9000 <br />
|-<br />
|}<br />
<br />
===Feed rate quick reference===<br />
<br />
{| class="wikitable" <br />
!|100% <br />
!|75% <br />
!|66% <br />
!|50% <br />
!|33% <br />
!|25% <br />
|-<br />
!|6000<br />
|4500<br />
|3960<br />
|3000<br />
|1980<br />
|1500<br />
|-<br />
!|5000<br />
|3750<br />
|3300<br />
|2500<br />
|1650<br />
|1250<br />
|-<br />
!|4000<br />
|3000<br />
|2640<br />
|2000<br />
|1320<br />
|1000<br />
|-<br />
!|3000 <br />
|2250 <br />
|1980 <br />
|1500 <br />
|990 <br />
|750 <br />
|-<br />
!|2500 <br />
|1875 <br />
|1650 <br />
|1250 <br />
|825 <br />
|625 <br />
|-<br />
!|2000 <br />
|1500 <br />
|1320 <br />
|1000 <br />
|660 <br />
|500 <br />
|-<br />
!|1500 <br />
|1125 <br />
|990 <br />
|750 <br />
|495 <br />
|375 <br />
|-<br />
!|1000 <br />
|750 <br />
|660 <br />
|500 <br />
|330 <br />
|250 <br />
|-<br />
!|500 <br />
|375 <br />
|330 <br />
|250 <br />
|165 <br />
|125 <br />
|-<br />
|}<br />
<br />
=== Sample feed rates ===<br />
<br />
For working out feeds and speeds, recommend http://www.cnccookbook.com/CCGWizard.<br />
<br />
The feeds and speeds below have been tested on our machine. The 3mm cutters were single flute carbide. 2 flute HSS cutters may require different settings to avoid breakages.<br />
<br />
{| class="wikitable"<br />
!|MDF<br />
!|1mm deep <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep <br />
|-<br />
!|3mm &Oslash;<br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|-<br />
!|6mm &Oslash; <br />
|3000/24Krpm<br />
|3000/15Krpm <br />
|2000/13Krpm <br />
|1500/11Krpm <br />
|-<br />
!|22mm &Oslash; <br />
|3000/5000rpm <br />
|N/A <br />
|N/A<br />
|N/A<br />
|-<br />
|}<br />
<br />
{| class="wikitable"<br />
!|Plywood<br />
!|1mm deep <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep<br />
|-<br />
!|3mm &Oslash; <br />
|2000/24Krpm <br />
|2000/24Krpm<br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|-<br />
!|6mm &Oslash;<br />
|3000/15Krpm<br />
|3000/15Krpm <br />
|1500/15Krpm <br />
|1000/11Krpm <br />
|-<br />
!|22mm &Oslash; <br />
|3000/5Krpm <br />
|N/A <br />
|N/A<br />
|N/A<br />
|-<br />
|}<br />
<br />
<br />
Polycarbonate:<br />
300Hz 1600mm/min<br />
<br />
Foamed PVC (foamex):<br />
6mm diameter, 10mm deep pass depth, spindle 400Hz (24krpm), feed 9000mm/min.<br />
<br />
3mm diameter, 3mm deep pass depth, 400Hz (24krpm), 9000mm/min.<br />
<br />
Polyurethane foam:<br />
<br />
6mm diameter, full depth pass (30mm+), 400Hz (24krpm), 9000mm/min.<br />
<br />
3mm diameter, 6mm deep pass depth, 400Hz (24krpm), 9000mm/min.<br />
<br />
Acetal (Delrin):<br />
<br />
6mm Cutter, 2mm deep pass depth, spindle 150 - 180Hz, feed 3000mm/min.<br />
<br />
1/8th or 3mm cutter, 1.5 - 2mm deep pass depth, spindle 130 - 160Hz, feed 2-3000mm/min.<br />
<br />
== Tips & Tricks ==<br />
<br />
= Maintenance =<br />
<br />
The maintenance of the CNC Router is carried out by the Owners, with some basic maintenance being carried out by Users on every job.<br />
<br />
== Maintenance Schedule ==<br />
Every job<br />
* Vacuum cutting dust from bed and around machine<br />
* Sand down high points created on sacrificial bed by cutting/screwing<br />
<br />
As required, by users<br />
* Empty extraction bin <br />
* check for blockages in manifold box where extraction pipes meet<br />
<br />
Monthly<br />
* Inspect extraction hoses for splits/ wear<br />
* Clean guide rails (Don't oil them, it makes dust stick)<br />
* Check level, condition and flow of cooling water and replace as necessary<br />
* Inspect sacrificial bed, re-skim or replace as required<br />
* Inspect cable from pendent to router<br />
* Inspect ER11 collet nut for wear<br />
* Inspect auto levelling probe wire<br />
* check collet set for wear/damage<br />
* Check USB socket on pendent and USB memory stick for splits/damage<br />
<br />
Annual<br />
* Check nuts on lead screws for excessive backlash and adjust if required<br />
* Inspect all covers/structure for signs of damage, cracks etc<br />
* Check tightness (or even presence) of screws holding covers in place<br />
* Check CNC electronics (and PC) cabinets for dust build up and vacuum out if required<br />
* Check feet/supports are all taking load and that the structure is level/flat<br />
* Check motor cables aren't wearing/cracking<br />
<br />
== Maintenance Log ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
3/7/13: Lower spindle clamp bolts replaced with longer stainless ones, holes through tapped as original ones had stripped.<br />
23/12/15: complete maintenance checklist completed. controller cable slightly frayed at machine end, collet nut could do with being replaced. otherwise, everything fine.<br />
<br />
== Maintenance Shopping List ==<br />
<br />
* Cutters<br />
* Sacrificial Bed (1.2m x 1.2m 12mm MDF)<br />
* ER11 collet nut<br />
* controller cable<br />
<br />
= Becoming an Owner/Trainer =<br />
<br />
Becoming an '''Owner''' of a piece of Makespace equipment means that you will be responsible for the maintenance, upkeep and H&S of that equipment. You will also be responsible for running inductions and keeping the information banks (Wiki/Forum/Google Groups) maintained.<br />
<br />
A '''Trainer''' is responsible for running inductions only but will be required to understand how the machine works in order to pass on the relevant skills. A trainer will not be required to maintain the machine but would be expected to keep an eye on its status and report any issues if they develop (as would be expected of any user).<br />
<br />
== Steps to becoming an Owner or Trainer ==<br />
<br />
* Step 1: Contact a current Owner who will talk you through the various responsibilities. [http://wiki.makespace.org/Equipment/CNC_Router#Owners Owners] or Forum: [http://makespace.org/forum/viewtopic.php?f=20&t=89 here]<br />
* Step 2: Sign up to a 'Train the Trainer Training' session on Meetup. It is likely one will need to be set up specially in order for you to sign up but the owner you spoke to should take care of this.<br />
* Step 3: Complete the training to the satisfaction of the Owner/s running the sessions.<br />
* Step 4: Have your name added to the Trainers list and set up your first solo induction session.<br />
* Step 5: Once you are a Trainer you are eligible to become an Owner of the CNC Router. To become an Owner will simply require one further meeting with one of the current owners. This will simply be to walk through the requirements and techniques of maintaining the machine along with any other responsibilites. If the other owners are happy, you can add your name to the [http://wiki.makespace.org/Equipment/CNC_Router#Owners Owners] list.<br />
<br />
== Train the Trainer Training ==<br />
<br />
The first session will be fairly informal, with a look to getting more familiar with the machine and how it operates. We will walk through the Induction cheat-sheet (located on the Wiki) and discuss methods of giving attendees the information they need to use the CNC Router safely.<br />
<br />
The follow up sessions will be arranged during the first session. The second session will include a brief look at the software, Meetup and a full dry-run induction. The third session will be an observed induction where you will be left to train 2 people (with input if necessary). Once complete you will be free to arrange as many induction sessions as you are happy to do. Although you wont be an owner of the CNC Router, if you would like to become one at this point please ask.<br />
<br />
= Further Information =<br />
<br />
== Hardware ==<br />
<br />
Controller: [[File:MPC6610 CNC Router Manual v1.0-En.pdf]]<br />
<br />
<gallery><br />
File:CNC_Router_controller_1.jpg<br />
File:CNC_Router_controller_2.jpg<br />
</gallery><br />
<br />
Z-Axis Stepper Driver: [[File:M542-05m.pdf]]<br />
<br />
X and Y Axis Stepper Driver: [[File:MA860Hm.pdf]]<br />
<br />
Y Axis Stepper motor: 86BYGH450A-06 (NEMA34 Hybid Stepper Motor, MAX torque: 495 oz-in)<br />
* Insulation Resistant - 500V DC 100MΩ Min<br />
* Insulation Strength - 50Hz 1Minute 500V Min<br />
* Ambient Temperature - -20~+50 degree<br />
* Temperature Rise - 80 Max.<br />
* Radial Play - 0.02mm Max.<br />
* End Play - 0.1-0.3mm<br />
* Model: 85BYGH450A-06<br />
* Motor dimension: 85*85*75mm<br />
* Current/phase: 4.0A<br />
* Voltage/phase: 2.0V<br />
* Inductance/phase: 2.3+/-20%mH<br />
* Resistance/phase: 0.5+/-10%ohm<br />
* Holding torque: 3.5 N. M<br />
* Shaft diameter: 13 mm<br />
* Shaft length: 31.50mm<br />
* Leading wires: 4 leading wires<br />
<br />
== Installation ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
<gallery><br />
File:Photo_1.JPG<br />
File:WP_20130509_005.jpg<br />
</gallery><br />
<br />
== Purchase ==<br />
Full Purchase, Delivery and Installation (£?????)<br />
<br />
== Notes ==<br />
<br />
http://www.shopbottools.com/mProducts/prSstandard.htm</div>Perfectphasehttp://wiki.makespace.org/Equipment/CNC_RouterEquipment/CNC Router2016-01-04T01:24:02Z<p>Perfectphase: /* Hardware */</p>
<hr />
<div>{{RedTool}}<br />
<br />
== CNC ROUTER IS DECOMMISSIONED ==<br />
<br />
Pending revision and/or replacement, the CNC router is now decommissioned. Usage is restricted to people operating with full knowledge that steps can be missed and the height can get wrong, resulting in head crashes. Be careful, wear safety goggles. No new training pending replacement or upgrade.<br />
<br />
[[Equipment|Equipment]] / CNC Router<br />
<br />
[[File:WP_20130509_005.jpg|thumb|460px|right|CNC Router]]<br />
<br />
<br />
== Summary ==<br />
<br />
A CNC router is a computer controlled shaping machine. These are related to the hand held router. Instead of hand held routing, the tool paths can be controlled via computer numerical control. It is a computer-controlled machine for cutting various hard materials, such as wood, composites, aluminum, steel, plastics, and foams. It is one of many kinds of tools that have CNC variants. A CNC router is very similar in concept to a CNC milling machine. The CNC router is controlled by a computer. Coordinates are uploaded into the machine controller from a separate CAD program<br />
<br />
* Capacity: 1200 x 1200 x 120mm<br />
* Rate (X,Y): 6000mm/min (Max) 5000mm/min (Working)<br />
* Rate (Z): 30mm/sec<br />
* Spindle Speed: 4500 to 24000rpm<br />
* Mechanical Precision: 0.01mm<br />
* Spindle Power: 1.5KW Variable Speed, Water-cooled<br />
* Blade Diameter: min 3.175mm, max 12.7mm <br />
* Order Format: HPGL, G code, u00, mmg, plt <br />
* Control System: DSP with USB connection <br />
<br />
Here are some examples we've made on the CNC router (please add a photo of yours any time you do a job!) <br />
<br />
<gallery><br />
File:WP_20130509_004.jpg<br />
File:WP_20130624_017.jpg<br />
File:WP_20130625_001.jpg<br />
</gallery><br />
<br />
= Using the CNC Router =<br />
== Owners ==<br />
<br />
The Owners are those who have volunteered to be in charge of the equipment, organising maintenance, training others to use it, and generally being a point of contact. The current Owners of the CNC Router are:<br />
<br />
* [[User:perfectphase|Stephen Woolhead]]<br />
* Mark Mellors<br />
* Dave Ansell<br />
* David Bebb<br />
* Simon Stirley<br />
* Jason White<br />
* Rick Lupton<br />
* Robin Sterling<br />
* Shareef Jalloq<br />
* Hidde-Jan Lemstra<br />
<br />
<br />
-- Further Contacts --<br />
<br />
* Chris Abri <!--chris.abri1985@gmail.com--><br />
<br />
If you have any questions, problems or concerns around the CNC router, please use the mailing list thread:<br />
* [https://groups.google.com/d/topic/cammakespace/rkchD7VqM2c/discussion Log : CNC Router]<br />
<br />
== Training ==<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>YOU CAN ONLY USE THE CNC ROUTER IF YOU HAVE BEEN TRAINED</b><br><br />
and have been added to the [[Equipment/CNC_Router/Training#Trained_Users|Trained Users]] list by one of the Owners<br />
</div><br />
<br />
To get trained on the CNC router and be added to the qualified user list, you will need to arrange for a training session with one of the Owners. <br />
<br />
If you'd like to arrange training, please see:<br />
* [[Equipment/CNC_Router/Training|CNC Router Training]]<br />
<br />
== Health and Safety ==<br />
<br />
The CNC Router is a potentially dangerous piece of equipment which must only be operated by members who have received appropriate training and who take due care. The top things to always remember when using the CNC Router are:<br />
* '''ONLY USE THE CNC ROUTER IF YOU ARE ON THE LIST OF TRAINED USERS'''<br />
* '''NEVER LEAVE THE CNC ROUTER RUNNING UNATTENDED'''<br />
<br />
As a trained user, you should be very aware of the following risks and how to deal with them:<br />
<br />
'''FIRE''' - Cutting with the wrong settings could result in the material igniting.<br />
<br />
'''TRAPPING''' - Stand clear of the machine while in motion.<br />
<br />
'''DUST''' - Ensure extraction system is working.<br />
<br />
'''NOISE''' - Ensure that you wear the correct PPE when working with the machine for prolonged periods.<br />
<br />
Full Risk assessment[[File:CNC_Router.pdf ]]<br />
<br />
== CNC Glossary ==<br />
<br />
As with most new ventures into another profession or hobby, there is the need to learn a “new language” and its common abbreviations. We have introduced some of these in the description of the workflow process above. Here we’ll look at some in more detail. These are listed in alphabetical order.<br />
<br />
=== 2D/2.5D/3D Toolpaths ===<br />
<br />
Depending on the information source, the definitions of 2D, 2.5D and 3D can be quite vague and appear to overlap.<br />
<br />
'''2D''' is simple horizontal cuts at a constant Z depth. For example, you cut out letter or a plaque shape to hang on the wall by moving the tool down to a specific depth and tracing the shape of the part you are cutting in 2D.<br />
<br />
'''2.5D''' would be a little more complex than 2D as while the tool is cutting, the Z depth would be changing instead of staying constant. Typically this still uses 2D vector data to define the path but the way the tool moves in relation to the 2D data and its form will determine the shape that is cut. The most common example of 2.5D is VCarving. Although this cuts 2D vector shapes, the V-shaped tool “rides” on the edges of the vectors, so as it gets wider it cuts deeper and as the vector get closer together it will lift up in Z.<br />
<br />
'''3D'''' These are toolpaths that like 2.5D toolpaths can move simultaneously in all 3 (X, Y and Z) axes however the shape they cut is described by following a 3D computer model and not vectors. They are typically cut with a Ball-Nose (round ended) tool. The tool will go back and forth across the 3D model following the contours of the part similar to an old fashioned copying or digitizing machine. The smoothness of the finished part depends on the Stepover setting in the toolpath as that determines how many times the tool will pass over the model. The size of the tool is also important as the software will only let it cut the detail that the end of the tool can fit into as it traces over the virtual surface. Examples of 3D toolpaths are 3D Rouging and 3D Finishing<br />
<br />
=== 3-axis===<br />
<br />
A 3-axis CNC machine is one that can move a router bit in the 3 primary directions, X, Y and Z. The image below show 3 views of a typical CNC setup and how the axes are referenced from each viewing direction.<br />
<br />
=== CAD ===<br />
<br />
CAD has been used as an abbreviation for both “Computer Aided Design” and “Computer Aided Drafting”. Now it has become a generic term in its own right that refers to a software program that can be used to create a 2D or 3D design.<br />
<br />
=== CAM ===<br />
<br />
When you discuss designing and preparing projects for your CNC machine, the follow-on side of CAD is CAM, which stands for ‘Computer Aided Manufacturing’ or ‘Computer Aided Machining’. This is the part of the process where the geometry developed during the CAD design process are now used to create the instructions that will move your CNC machine to ‘manufacture’ or machine the part.<br />
<br />
=== Collet ===<br />
<br />
The collet assembly is the component on a router or spindle that holds the router bit securely and consists of a precision collet and a collet nut. The collet is precisely sized to hold the router bit shank and the collet nut applies a compressive, friction fit as it is properly tightened onto the router or spindle shaft. It is very important to keep the collets clean and well maintained and depending on use, they must be periodically replaced.<br />
<br />
=== Gantry ===<br />
<br />
The gantry is the part of a CNC machine that typically has one of the horizontal axes running along it and also moves along the other horizontal axis to create the X and Y movement for the tool. The Z axis is also typically mounted on the gantry.<br />
<br />
=== G-Code === <br />
<br />
This is a generic term for the code which is sent to the machine with the instructions telling it how to move. Or, to put it in our context, the file that is saved from the software using the Post Processor to format it for the CNC machine. In reality it’s a particular type of data that a lot of CNC’s use a variant of – so G-code is not necessarily interchangeable to different machines. The name comes from the fact that many of the codes within in start with a G. For example G01 specifies a Feed Rate move and G00 specifies a Rapid move etc.<br />
<br />
=== Pass ===<br />
<br />
When you have a toolpath that is too deep, too wide or a combination of both for the router bit to remove all the material at one time, the toolpath is broken up into multiple ‘Passes’ with each pass removing a part of the material.<br />
<br />
When the toolpath is too deep, a Pass Depth (see entry below) value for the bit will be set and used to indicate the maximum Z depth the tool should cut on each Pass. The amount of material a tool can remove will be determined by the tooltype, size, material being cut and many other parameters. Tooling manufacturers typically offer recommendations for these values.<br />
<br />
=== Post Processor ===<br />
<br />
There are hundreds of different brands and models of CNC machines currently in use. When it comes to controlling them, many have a lot in common, but there can and will be differences. So, if you look at this as each machine speaks a slightly different language, there has to be a way for a single CAD/CAM program to speak to each machine and this is accomplished by using an “interpreter” called a Post Processor, also sometimes simply referred to as ‘pp’ or ‘post’.<br />
<br />
For example, you design a project to cut an exact size circle out of a piece of material and calculate a toolpath to do that. When you actually save that toolpath so it can be used at your CNC machine, the correct Post Processor will ensure the instructions for cutting that circle are prepared correctly so your CNC machine can read and understand them and accurately cut the circle as you intended.<br />
<br />
=== Router Bed or Machine Bed === <br />
<br />
The ‘bed’ identifies the part of a CNC machine where the material being machined is placed and held securely in position. For best results, the bed needs to be flat and sturdy. In most designs the bed is stationary; however there are exceptions to this where the bed moves to provide either the X or Y axis movement.<br />
<br />
=== Sacrifice Sheet / Spoilboard === <br />
<br />
The spoilboard is normally a sacrificial sheet of material placed on top of the machine bed and is intended to be replaced as necessary. It protects the machine bed and allows frequent surfacing which will help to keep a truly flat surface to mount material and help maintain accuracy. This allows the stock material to be screwed down to it and the parts drilled and cut all the way through the material thickness.<br />
<br />
=== Stepover ===<br />
<br />
The Stepover setting found for most router bits allows you to control horizontal movement when machining areas wider than the router bit. Physically, stepover is the distance the center of the bit moves horizontally for each pass.<br />
<br />
The Stepover is shown in the programs as both a physical distance (0.025” or 0.5mm for example) and as a percentage of bit diameter (6%, 8%, 50%, etc.). You can enter either value and the software will automatically calculate the other one for you. Typically most users refer to Stepover by its percentage value as it is a simple whole number and can easily be translated to other tool sizes for a particular task, for example when finishing setting the Stepover to be 10% of the ballnose tools diameter normally creates a reasonably finish surface.<br />
<br />
=== Toolpath ===<br />
<br />
A toolpath is the path created during the CAM part of your project design and represents the instructions your CNC machine will use to make the router bit move to duplicate what you have designed. In the software it is typically displayed as a set of lines which show a virtual picture of the path the tool tip will move along when the toolpath is run on the machine.<br />
<br />
=== Vector ===<br />
<br />
Vector is the word used to describe a 2D line, arc or curve. A vector can be used to describe almost any 2D shape.<br />
<br />
== Instructions ==<br />
<br />
[http://wiki.makespace.org/File:MPC6610_CNC_Router_Manual_v1.0-En.pdf Router Manual]<br />
<br />
[[Equipment/CNC_Router/Hand_Controller|Hand Controller Look-up Guide]]<br />
<br />
===Setting the Z Origin Using the Z0 Sensor===<br />
''A tool that has an extremely narrow tip may break when it touches the tool sensor depending on which tool is to be used.''<br />
<br />
1. Secure the workpiece on the bed, and place the Z0 sensor at the place where you want to set the Z origin on the workpiece. Face the surface of the Z0 sensor without the magnet facing upward.<br />
<br />
[[image:Mill_z0.PNG]]<br />
<br />
2. Use the handset to move the tool to the position above the sensor.<br />
<br />
3. On the handset press OK + 8(Z-0). The tool slowly descend until it contacts the sensor. When the tool rises and stops, the setting operation is complete. <br />
<br />
Note: It is important the tool is electrically conductive from tip to shaft, and the sensor is clean. Failure to check will cause damage to the tool and sensor.<br />
<br />
4. Remove the sensor from the workpiece to a location where it will not interfere with future cutting operations.<br />
<br />
==Software==<br />
<br />
The standard software is Vectric's line of CAM software:<br />
<br />
===VCarvePro===<br />
<br />
[[image:Vcarvepro.png]]<br />
<br />
VCarve Pro provides a powerful but intuitive software solution for 2D design and calculation of 2D and 2.5D toolpaths for cutting parts on a CNC Router. <br />
<br />
The software can import 2D designs from other programs but also includes a full set of drawing and editing tools with advanced layout options such as True-Shape Nesting. The toolpath options cover all typical 2D routing operations such as Profiling, Pocketing, Auto-Inlays and Drilling as well as 2.5D strategies such as V-Carving, Prism carving, Fluting and even a decorative Texturing strategy. Each toolpath includes appropriate options to customize the settings and provide a high level of control for different types of operation. In addition all toolpaths can be previewed to show just how the part will look when it is actually cut, this allows instant feedback to allow toolpaths to be further optimized. <br />
<br />
'''Details''': http://www.vectric.com/products/vcarve-pro.htm<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/vcarve-pro<br />
<br />
===Cut3D===<br />
<br />
[[image:Vectric-cut3d.jpg|266px]]<br />
<br />
Cut3D is a dedicated toolpath engine for CNC machining 3D models that have been designed using a 3D CAD or Graphics design product such as AutoCAD, Rhino3D, 3D Studio etc. or scanned using a laser or touch probe device. Cut3D's exceptionally easy to use interface leads you step-by-step through the process of loading a model, setting the size, interactively placing tabs to hold the job in place, calculating single, double or four sided roughing and finishing toolpaths, previewing the results and finally saving the CNC code to run on your machine.<br />
<br />
3D Models that are too large / thick to machine because of gantry height, cutter length or limited material thickness can be 'Sliced' into separate pieces. Each slice can then be machined and the complete job assembled. <br />
<br />
'''Details''': http://www.vectric.com/products/cut3d.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/cut3d<br />
<br />
===PhotoVCarve===<br />
<br />
[[image:Vectric-photovcarve.gif|266px]]<br />
<br />
PhotoVCarve creates lines of grooves that vary in width and depth to represent the detail in a photograph or image. The quality of the finished result is very dependant upon a high level of contrast between the material surface and the machined grooves. This information is very important to remember when cutting designs using the PhotoVCarve software. <br />
<br />
PhotoVCarve machines dark areas in a photograph with wide groove and the lighter areas to have narrower ones. The software automatically calculates the toolpaths based on the cutter selected and maximum depth of groove required. <br />
<br />
'''Details''': http://www.vectric.com/products/photovcarve.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/photovcarve<br />
<br />
== Tooling ==<br />
<br />
=== Router Bits ===<br />
<br />
Router bits (or cutters) are the most common type of cutter, they have two or more vertical cutting edges. These are good general purpose cutters that can be found in most DIY shops. They are the same type that you would use in a manual hand held router.<br />
<br />
<gallery><br />
File:WP_20130813_025.jpg<br />
File:WP_20130813_025.jpg<br />
File:WP_20130814_002.jpg<br />
File:WP_20130814_003.jpg<br />
</gallery><br />
<br />
It is important to notice that the cutters are on the edge of the body only, they do not extend to the centre of the cutter. This means the cutter CAN NOT BE USED AS A DRILL. An holes that are made by these sorts of cutters must be made by ramping the cutter to the correct depth in a sloping or spiral motion.<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>NEVER USE ROUTER BITS THAT HAVE BEARINGS.</b> These types of cutters are designed for manual routers where you can feel the feed back of the bearing in contact with the material being cut. A CNC device has no such feedback and will press the bearing into the material has hard as it can until something gives, i.e. the cutter breaks or much worse the spindle breaks. People found using these types of cutters on the CNC router will be BANNED! Just use the version without the bearing.<br />
<br />
<gallery><br />
File:WP_20130813_018.jpg<br />
</gallery><br />
<br />
The cutting edges should always be the lowest part of the cutter.<br />
</div><br />
<br />
=== End mills ===<br />
<br />
'''Up Cut and Down Cut'''<br />
<br />
Router end mills have two variants, up cut (left) and down cut (right); there is a third type, compression, but they are quite rare.<br />
<br />
<gallery><br />
File:WP_20130813_015.jpg<br />
</gallery><br />
<br />
Most cutters are up cut, which have the cutting service on the top of the flutes and as they rotate lift the chips up and away from the material being cut.<br />
<br />
Down cut cutters have the cutting edge on the bottom of the flutes and push chips down towards the material being cut. This has the advantage of pressing the material being cut into the bed of the machine; this is especially useful for thin plastics. The other advantage is the top surface shows far less breakout and splintering, this is a big advantage for materials like laminates.<br />
<br />
On image on the left has been cut with an up-cut end mill and the image on the right a down-cut.<br />
<br />
<gallery><br />
File:WP_20130813_005.jpg<br />
File:WP_20130813_007.jpg<br />
</gallery><br />
<br />
NOTE: There is a very big disadvantage to down cut end mills, and that is that they do not clear there chips effectively in blind holes. This means they need larger ramping moves to get to the correct cutting depth and if used in pockets without enough clearance, the friction can lead to burning or melting of the material being cut.<br />
<br />
Another down side to down-cut cutters, is that when cutting pockets, the bottom surface will not be as clean as that made with an up-cut cutter, which will do a far better job of clearing the waste chips that rub between the cutter and the material with a down-cut.<br />
<br />
== Stock Tooling ==<br />
<br />
In order to keep a small stock of cutters for general use, the CNC Router needs to have a means of generating money. Because there is no material provided for use with the CNC Router there is no way to bring in any funds for such things. Therefore, we ask that if you use one of the communal cutters please put 50p into the CNC Router Honesty Box. This will go towards funding for replenishing stock and also for the replacement of the sacrificial bed once it gets worn out. Please email the list if a communal cutter is broken or missing, so that they can replace it with one from stock. <br />
<br />
There will likely be 1 or two of each of the following cutters available for use, however please do not count on this being the case:<br />
<br />
* 2.5mm square cutter - single flute<br />
* 1/8" square cutter - single flute<br />
* 1/8" ball cutter - 2 flute<br />
<br />
* 6mm square cutter - 2 flute<br />
* 6mm ball cutter - 2 flute<br />
<br />
* engraver 0.2 30deg 1/8" 30mm length (8 of)<br />
* engraver 0.8 30deg 1/8" 30mm length (2 of)<br />
<br />
* 22mm 2 flute straight <br />
* 90deg x 32mm VBit<br />
<br />
<br />
Some Suppliers are listed below:<br />
<br />
== Feeds & Speeds ==<br />
<br />
What are feeds and speeds? Why are they important?<br />
<br />
[http://www.youtube.com/watch?v=ip2jm_6aUyk&feature=c4-overview&list=UUivA7_KLKWo43tFcCkFvydw Milling machine tutorial - cutter selection, speeds and feeds]<br />
<br />
[http://en.wikipedia.org/wiki/Speeds_and_feeds Wikipedia - Speeds and feeds]<br />
<br />
The phrase speeds and feeds (or feeds and speeds) refers to two separate velocities in machine tool practice, cutting speed and feed rate. They are often considered as a pair because of their combined effect on the cutting process. Each, however, can also be considered and analyzed in its own right.<br />
<br />
Cutting speed (also called surface speed or simply speed) is the speed difference (relative velocity) between the cutting tool and the surface of the workpiece it is operating on. It is expressed in units of distance along the workpiece surface per unit of time, typically surface feet per minute (sfm) or meters per minute (m/min). Feed rate (also often styled as a solid compound, feedrate, or called simply feed) is the relative velocity at which the cutter is advanced along the workpiece; its vector is perpendicular to the vector of cutting speed. Feed rate units depend on the motion of the tool and workpiece; when the workpiece rotates (e.g., in turning and boring), the units are almost always distance per spindle revolution (inches per revolution [in/rev or ipr] or millimeters per revolution [mm/rev]). When the workpiece does not rotate (e.g., in milling), the units are typically distance per time (inches per minute [in/min or ipm] or millimeters per minute [mm/min]), although distance per revolution or per cutter tooth are also sometimes used.<br />
<br />
===Spindle speed quick reference===<br />
<br />
{| class="wikitable"<br />
!|<br />
!|400Hz <br />
!|350Hz <br />
!|300Hz <br />
!|250Hz <br />
!|200Hz <br />
!|150Hz <br />
|-<br />
!|RPM<br />
|24000 <br />
|21000 <br />
|18000 <br />
|15000 <br />
|12000 <br />
|9000 <br />
|-<br />
|}<br />
<br />
===Feed rate quick reference===<br />
<br />
{| class="wikitable" <br />
!|100% <br />
!|75% <br />
!|66% <br />
!|50% <br />
!|33% <br />
!|25% <br />
|-<br />
!|6000<br />
|4500<br />
|3960<br />
|3000<br />
|1980<br />
|1500<br />
|-<br />
!|5000<br />
|3750<br />
|3300<br />
|2500<br />
|1650<br />
|1250<br />
|-<br />
!|4000<br />
|3000<br />
|2640<br />
|2000<br />
|1320<br />
|1000<br />
|-<br />
!|3000 <br />
|2250 <br />
|1980 <br />
|1500 <br />
|990 <br />
|750 <br />
|-<br />
!|2500 <br />
|1875 <br />
|1650 <br />
|1250 <br />
|825 <br />
|625 <br />
|-<br />
!|2000 <br />
|1500 <br />
|1320 <br />
|1000 <br />
|660 <br />
|500 <br />
|-<br />
!|1500 <br />
|1125 <br />
|990 <br />
|750 <br />
|495 <br />
|375 <br />
|-<br />
!|1000 <br />
|750 <br />
|660 <br />
|500 <br />
|330 <br />
|250 <br />
|-<br />
!|500 <br />
|375 <br />
|330 <br />
|250 <br />
|165 <br />
|125 <br />
|-<br />
|}<br />
<br />
=== Sample feed rates ===<br />
<br />
For working out feeds and speeds, recommend http://www.cnccookbook.com/CCGWizard.<br />
<br />
The feeds and speeds below have been tested on our machine. The 3mm cutters were single flute carbide. 2 flute HSS cutters may require different settings to avoid breakages.<br />
<br />
{| class="wikitable"<br />
!|MDF<br />
!|1mm deep <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep <br />
|-<br />
!|3mm &Oslash;<br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|-<br />
!|6mm &Oslash; <br />
|3000/24Krpm<br />
|3000/15Krpm <br />
|2000/13Krpm <br />
|1500/11Krpm <br />
|-<br />
!|22mm &Oslash; <br />
|3000/5000rpm <br />
|N/A <br />
|N/A<br />
|N/A<br />
|-<br />
|}<br />
<br />
{| class="wikitable"<br />
!|Plywood<br />
!|1mm deep <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep<br />
|-<br />
!|3mm &Oslash; <br />
|2000/24Krpm <br />
|2000/24Krpm<br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|-<br />
!|6mm &Oslash;<br />
|3000/15Krpm<br />
|3000/15Krpm <br />
|1500/15Krpm <br />
|1000/11Krpm <br />
|-<br />
!|22mm &Oslash; <br />
|3000/5Krpm <br />
|N/A <br />
|N/A<br />
|N/A<br />
|-<br />
|}<br />
<br />
<br />
Polycarbonate:<br />
300Hz 1600mm/min<br />
<br />
Foamed PVC (foamex):<br />
6mm diameter, 10mm deep pass depth, spindle 400Hz (24krpm), feed 9000mm/min.<br />
<br />
3mm diameter, 3mm deep pass depth, 400Hz (24krpm), 9000mm/min.<br />
<br />
Polyurethane foam:<br />
<br />
6mm diameter, full depth pass (30mm+), 400Hz (24krpm), 9000mm/min.<br />
<br />
3mm diameter, 6mm deep pass depth, 400Hz (24krpm), 9000mm/min.<br />
<br />
Acetal (Delrin):<br />
<br />
6mm Cutter, 2mm deep pass depth, spindle 150 - 180Hz, feed 3000mm/min.<br />
<br />
1/8th or 3mm cutter, 1.5 - 2mm deep pass depth, spindle 130 - 160Hz, feed 2-3000mm/min.<br />
<br />
== Tips & Tricks ==<br />
<br />
= Maintenance =<br />
<br />
The maintenance of the CNC Router is carried out by the Owners, with some basic maintenance being carried out by Users on every job.<br />
<br />
== Maintenance Schedule ==<br />
Every job<br />
* Vacuum cutting dust from bed and around machine<br />
* Sand down high points created on sacrificial bed by cutting/screwing<br />
<br />
As required, by users<br />
* Empty extraction bin <br />
* check for blockages in manifold box where extraction pipes meet<br />
<br />
Monthly<br />
* Inspect extraction hoses for splits/ wear<br />
* Clean guide rails (Don't oil them, it makes dust stick)<br />
* Check level, condition and flow of cooling water and replace as necessary<br />
* Inspect sacrificial bed, re-skim or replace as required<br />
* Inspect cable from pendent to router<br />
* Inspect ER11 collet nut for wear<br />
* Inspect auto levelling probe wire<br />
* check collet set for wear/damage<br />
* Check USB socket on pendent and USB memory stick for splits/damage<br />
<br />
Annual<br />
* Check nuts on lead screws for excessive backlash and adjust if required<br />
* Inspect all covers/structure for signs of damage, cracks etc<br />
* Check tightness (or even presence) of screws holding covers in place<br />
* Check CNC electronics (and PC) cabinets for dust build up and vacuum out if required<br />
* Check feet/supports are all taking load and that the structure is level/flat<br />
* Check motor cables aren't wearing/cracking<br />
<br />
== Maintenance Log ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
3/7/13: Lower spindle clamp bolts replaced with longer stainless ones, holes through tapped as original ones had stripped.<br />
23/12/15: complete maintenance checklist completed. controller cable slightly frayed at machine end, collet nut could do with being replaced. otherwise, everything fine.<br />
<br />
== Maintenance Shopping List ==<br />
<br />
* Cutters<br />
* Sacrificial Bed (1.2m x 1.2m 12mm MDF)<br />
* ER11 collet nut<br />
* controller cable<br />
<br />
= Becoming an Owner/Trainer =<br />
<br />
Becoming an '''Owner''' of a piece of Makespace equipment means that you will be responsible for the maintenance, upkeep and H&S of that equipment. You will also be responsible for running inductions and keeping the information banks (Wiki/Forum/Google Groups) maintained.<br />
<br />
A '''Trainer''' is responsible for running inductions only but will be required to understand how the machine works in order to pass on the relevant skills. A trainer will not be required to maintain the machine but would be expected to keep an eye on its status and report any issues if they develop (as would be expected of any user).<br />
<br />
== Steps to becoming an Owner or Trainer ==<br />
<br />
* Step 1: Contact a current Owner who will talk you through the various responsibilities. [http://wiki.makespace.org/Equipment/CNC_Router#Owners Owners] or Forum: [http://makespace.org/forum/viewtopic.php?f=20&t=89 here]<br />
* Step 2: Sign up to a 'Train the Trainer Training' session on Meetup. It is likely one will need to be set up specially in order for you to sign up but the owner you spoke to should take care of this.<br />
* Step 3: Complete the training to the satisfaction of the Owner/s running the sessions.<br />
* Step 4: Have your name added to the Trainers list and set up your first solo induction session.<br />
* Step 5: Once you are a Trainer you are eligible to become an Owner of the CNC Router. To become an Owner will simply require one further meeting with one of the current owners. This will simply be to walk through the requirements and techniques of maintaining the machine along with any other responsibilites. If the other owners are happy, you can add your name to the [http://wiki.makespace.org/Equipment/CNC_Router#Owners Owners] list.<br />
<br />
== Train the Trainer Training ==<br />
<br />
The first session will be fairly informal, with a look to getting more familiar with the machine and how it operates. We will walk through the Induction cheat-sheet (located on the Wiki) and discuss methods of giving attendees the information they need to use the CNC Router safely.<br />
<br />
The follow up sessions will be arranged during the first session. The second session will include a brief look at the software, Meetup and a full dry-run induction. The third session will be an observed induction where you will be left to train 2 people (with input if necessary). Once complete you will be free to arrange as many induction sessions as you are happy to do. Although you wont be an owner of the CNC Router, if you would like to become one at this point please ask.<br />
<br />
= Further Information =<br />
<br />
== Hardware ==<br />
<br />
Controller: [[File:MPC6610 CNC Router Manual v1.0-En.pdf]]<br />
<br />
Z-Axis Stepper Driver: [[File:M542-05m.pdf]]<br />
<br />
X and Y Axis Stepper Driver: [[File:MA860Hm.pdf]]<br />
<br />
Y Axis Stepper motor: 86BYGH450A-06 (NEMA34 Hybid Stepper Motor, MAX torque: 495 oz-in)<br />
* Insulation Resistant - 500V DC 100MΩ Min<br />
* Insulation Strength - 50Hz 1Minute 500V Min<br />
* Ambient Temperature - -20~+50 degree<br />
* Temperature Rise - 80 Max.<br />
* Radial Play - 0.02mm Max.<br />
* End Play - 0.1-0.3mm<br />
* Model: 85BYGH450A-06<br />
* Motor dimension: 85*85*75mm<br />
* Current/phase: 4.0A<br />
* Voltage/phase: 2.0V<br />
* Inductance/phase: 2.3+/-20%mH<br />
* Resistance/phase: 0.5+/-10%ohm<br />
* Holding torque: 3.5 N. M<br />
* Shaft diameter: 13 mm<br />
* Shaft length: 31.50mm<br />
* Leading wires: 4 leading wires<br />
<br />
== Installation ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
<gallery><br />
File:Photo_1.JPG<br />
File:WP_20130509_005.jpg<br />
File:CNC_Router_controller_1.jpg<br />
File:CNC_Router_controller_2.jpg<br />
</gallery><br />
<br />
== Purchase ==<br />
Full Purchase, Delivery and Installation (£?????)<br />
<br />
== Notes ==<br />
<br />
http://www.shopbottools.com/mProducts/prSstandard.htm</div>Perfectphasehttp://wiki.makespace.org/Equipment/CNC_RouterEquipment/CNC Router2016-01-04T01:23:19Z<p>Perfectphase: /* Hardware */</p>
<hr />
<div>{{RedTool}}<br />
<br />
== CNC ROUTER IS DECOMMISSIONED ==<br />
<br />
Pending revision and/or replacement, the CNC router is now decommissioned. Usage is restricted to people operating with full knowledge that steps can be missed and the height can get wrong, resulting in head crashes. Be careful, wear safety goggles. No new training pending replacement or upgrade.<br />
<br />
[[Equipment|Equipment]] / CNC Router<br />
<br />
[[File:WP_20130509_005.jpg|thumb|460px|right|CNC Router]]<br />
<br />
<br />
== Summary ==<br />
<br />
A CNC router is a computer controlled shaping machine. These are related to the hand held router. Instead of hand held routing, the tool paths can be controlled via computer numerical control. It is a computer-controlled machine for cutting various hard materials, such as wood, composites, aluminum, steel, plastics, and foams. It is one of many kinds of tools that have CNC variants. A CNC router is very similar in concept to a CNC milling machine. The CNC router is controlled by a computer. Coordinates are uploaded into the machine controller from a separate CAD program<br />
<br />
* Capacity: 1200 x 1200 x 120mm<br />
* Rate (X,Y): 6000mm/min (Max) 5000mm/min (Working)<br />
* Rate (Z): 30mm/sec<br />
* Spindle Speed: 4500 to 24000rpm<br />
* Mechanical Precision: 0.01mm<br />
* Spindle Power: 1.5KW Variable Speed, Water-cooled<br />
* Blade Diameter: min 3.175mm, max 12.7mm <br />
* Order Format: HPGL, G code, u00, mmg, plt <br />
* Control System: DSP with USB connection <br />
<br />
Here are some examples we've made on the CNC router (please add a photo of yours any time you do a job!) <br />
<br />
<gallery><br />
File:WP_20130509_004.jpg<br />
File:WP_20130624_017.jpg<br />
File:WP_20130625_001.jpg<br />
</gallery><br />
<br />
= Using the CNC Router =<br />
== Owners ==<br />
<br />
The Owners are those who have volunteered to be in charge of the equipment, organising maintenance, training others to use it, and generally being a point of contact. The current Owners of the CNC Router are:<br />
<br />
* [[User:perfectphase|Stephen Woolhead]]<br />
* Mark Mellors<br />
* Dave Ansell<br />
* David Bebb<br />
* Simon Stirley<br />
* Jason White<br />
* Rick Lupton<br />
* Robin Sterling<br />
* Shareef Jalloq<br />
* Hidde-Jan Lemstra<br />
<br />
<br />
-- Further Contacts --<br />
<br />
* Chris Abri <!--chris.abri1985@gmail.com--><br />
<br />
If you have any questions, problems or concerns around the CNC router, please use the mailing list thread:<br />
* [https://groups.google.com/d/topic/cammakespace/rkchD7VqM2c/discussion Log : CNC Router]<br />
<br />
== Training ==<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>YOU CAN ONLY USE THE CNC ROUTER IF YOU HAVE BEEN TRAINED</b><br><br />
and have been added to the [[Equipment/CNC_Router/Training#Trained_Users|Trained Users]] list by one of the Owners<br />
</div><br />
<br />
To get trained on the CNC router and be added to the qualified user list, you will need to arrange for a training session with one of the Owners. <br />
<br />
If you'd like to arrange training, please see:<br />
* [[Equipment/CNC_Router/Training|CNC Router Training]]<br />
<br />
== Health and Safety ==<br />
<br />
The CNC Router is a potentially dangerous piece of equipment which must only be operated by members who have received appropriate training and who take due care. The top things to always remember when using the CNC Router are:<br />
* '''ONLY USE THE CNC ROUTER IF YOU ARE ON THE LIST OF TRAINED USERS'''<br />
* '''NEVER LEAVE THE CNC ROUTER RUNNING UNATTENDED'''<br />
<br />
As a trained user, you should be very aware of the following risks and how to deal with them:<br />
<br />
'''FIRE''' - Cutting with the wrong settings could result in the material igniting.<br />
<br />
'''TRAPPING''' - Stand clear of the machine while in motion.<br />
<br />
'''DUST''' - Ensure extraction system is working.<br />
<br />
'''NOISE''' - Ensure that you wear the correct PPE when working with the machine for prolonged periods.<br />
<br />
Full Risk assessment[[File:CNC_Router.pdf ]]<br />
<br />
== CNC Glossary ==<br />
<br />
As with most new ventures into another profession or hobby, there is the need to learn a “new language” and its common abbreviations. We have introduced some of these in the description of the workflow process above. Here we’ll look at some in more detail. These are listed in alphabetical order.<br />
<br />
=== 2D/2.5D/3D Toolpaths ===<br />
<br />
Depending on the information source, the definitions of 2D, 2.5D and 3D can be quite vague and appear to overlap.<br />
<br />
'''2D''' is simple horizontal cuts at a constant Z depth. For example, you cut out letter or a plaque shape to hang on the wall by moving the tool down to a specific depth and tracing the shape of the part you are cutting in 2D.<br />
<br />
'''2.5D''' would be a little more complex than 2D as while the tool is cutting, the Z depth would be changing instead of staying constant. Typically this still uses 2D vector data to define the path but the way the tool moves in relation to the 2D data and its form will determine the shape that is cut. The most common example of 2.5D is VCarving. Although this cuts 2D vector shapes, the V-shaped tool “rides” on the edges of the vectors, so as it gets wider it cuts deeper and as the vector get closer together it will lift up in Z.<br />
<br />
'''3D'''' These are toolpaths that like 2.5D toolpaths can move simultaneously in all 3 (X, Y and Z) axes however the shape they cut is described by following a 3D computer model and not vectors. They are typically cut with a Ball-Nose (round ended) tool. The tool will go back and forth across the 3D model following the contours of the part similar to an old fashioned copying or digitizing machine. The smoothness of the finished part depends on the Stepover setting in the toolpath as that determines how many times the tool will pass over the model. The size of the tool is also important as the software will only let it cut the detail that the end of the tool can fit into as it traces over the virtual surface. Examples of 3D toolpaths are 3D Rouging and 3D Finishing<br />
<br />
=== 3-axis===<br />
<br />
A 3-axis CNC machine is one that can move a router bit in the 3 primary directions, X, Y and Z. The image below show 3 views of a typical CNC setup and how the axes are referenced from each viewing direction.<br />
<br />
=== CAD ===<br />
<br />
CAD has been used as an abbreviation for both “Computer Aided Design” and “Computer Aided Drafting”. Now it has become a generic term in its own right that refers to a software program that can be used to create a 2D or 3D design.<br />
<br />
=== CAM ===<br />
<br />
When you discuss designing and preparing projects for your CNC machine, the follow-on side of CAD is CAM, which stands for ‘Computer Aided Manufacturing’ or ‘Computer Aided Machining’. This is the part of the process where the geometry developed during the CAD design process are now used to create the instructions that will move your CNC machine to ‘manufacture’ or machine the part.<br />
<br />
=== Collet ===<br />
<br />
The collet assembly is the component on a router or spindle that holds the router bit securely and consists of a precision collet and a collet nut. The collet is precisely sized to hold the router bit shank and the collet nut applies a compressive, friction fit as it is properly tightened onto the router or spindle shaft. It is very important to keep the collets clean and well maintained and depending on use, they must be periodically replaced.<br />
<br />
=== Gantry ===<br />
<br />
The gantry is the part of a CNC machine that typically has one of the horizontal axes running along it and also moves along the other horizontal axis to create the X and Y movement for the tool. The Z axis is also typically mounted on the gantry.<br />
<br />
=== G-Code === <br />
<br />
This is a generic term for the code which is sent to the machine with the instructions telling it how to move. Or, to put it in our context, the file that is saved from the software using the Post Processor to format it for the CNC machine. In reality it’s a particular type of data that a lot of CNC’s use a variant of – so G-code is not necessarily interchangeable to different machines. The name comes from the fact that many of the codes within in start with a G. For example G01 specifies a Feed Rate move and G00 specifies a Rapid move etc.<br />
<br />
=== Pass ===<br />
<br />
When you have a toolpath that is too deep, too wide or a combination of both for the router bit to remove all the material at one time, the toolpath is broken up into multiple ‘Passes’ with each pass removing a part of the material.<br />
<br />
When the toolpath is too deep, a Pass Depth (see entry below) value for the bit will be set and used to indicate the maximum Z depth the tool should cut on each Pass. The amount of material a tool can remove will be determined by the tooltype, size, material being cut and many other parameters. Tooling manufacturers typically offer recommendations for these values.<br />
<br />
=== Post Processor ===<br />
<br />
There are hundreds of different brands and models of CNC machines currently in use. When it comes to controlling them, many have a lot in common, but there can and will be differences. So, if you look at this as each machine speaks a slightly different language, there has to be a way for a single CAD/CAM program to speak to each machine and this is accomplished by using an “interpreter” called a Post Processor, also sometimes simply referred to as ‘pp’ or ‘post’.<br />
<br />
For example, you design a project to cut an exact size circle out of a piece of material and calculate a toolpath to do that. When you actually save that toolpath so it can be used at your CNC machine, the correct Post Processor will ensure the instructions for cutting that circle are prepared correctly so your CNC machine can read and understand them and accurately cut the circle as you intended.<br />
<br />
=== Router Bed or Machine Bed === <br />
<br />
The ‘bed’ identifies the part of a CNC machine where the material being machined is placed and held securely in position. For best results, the bed needs to be flat and sturdy. In most designs the bed is stationary; however there are exceptions to this where the bed moves to provide either the X or Y axis movement.<br />
<br />
=== Sacrifice Sheet / Spoilboard === <br />
<br />
The spoilboard is normally a sacrificial sheet of material placed on top of the machine bed and is intended to be replaced as necessary. It protects the machine bed and allows frequent surfacing which will help to keep a truly flat surface to mount material and help maintain accuracy. This allows the stock material to be screwed down to it and the parts drilled and cut all the way through the material thickness.<br />
<br />
=== Stepover ===<br />
<br />
The Stepover setting found for most router bits allows you to control horizontal movement when machining areas wider than the router bit. Physically, stepover is the distance the center of the bit moves horizontally for each pass.<br />
<br />
The Stepover is shown in the programs as both a physical distance (0.025” or 0.5mm for example) and as a percentage of bit diameter (6%, 8%, 50%, etc.). You can enter either value and the software will automatically calculate the other one for you. Typically most users refer to Stepover by its percentage value as it is a simple whole number and can easily be translated to other tool sizes for a particular task, for example when finishing setting the Stepover to be 10% of the ballnose tools diameter normally creates a reasonably finish surface.<br />
<br />
=== Toolpath ===<br />
<br />
A toolpath is the path created during the CAM part of your project design and represents the instructions your CNC machine will use to make the router bit move to duplicate what you have designed. In the software it is typically displayed as a set of lines which show a virtual picture of the path the tool tip will move along when the toolpath is run on the machine.<br />
<br />
=== Vector ===<br />
<br />
Vector is the word used to describe a 2D line, arc or curve. A vector can be used to describe almost any 2D shape.<br />
<br />
== Instructions ==<br />
<br />
[http://wiki.makespace.org/File:MPC6610_CNC_Router_Manual_v1.0-En.pdf Router Manual]<br />
<br />
[[Equipment/CNC_Router/Hand_Controller|Hand Controller Look-up Guide]]<br />
<br />
===Setting the Z Origin Using the Z0 Sensor===<br />
''A tool that has an extremely narrow tip may break when it touches the tool sensor depending on which tool is to be used.''<br />
<br />
1. Secure the workpiece on the bed, and place the Z0 sensor at the place where you want to set the Z origin on the workpiece. Face the surface of the Z0 sensor without the magnet facing upward.<br />
<br />
[[image:Mill_z0.PNG]]<br />
<br />
2. Use the handset to move the tool to the position above the sensor.<br />
<br />
3. On the handset press OK + 8(Z-0). The tool slowly descend until it contacts the sensor. When the tool rises and stops, the setting operation is complete. <br />
<br />
Note: It is important the tool is electrically conductive from tip to shaft, and the sensor is clean. Failure to check will cause damage to the tool and sensor.<br />
<br />
4. Remove the sensor from the workpiece to a location where it will not interfere with future cutting operations.<br />
<br />
==Software==<br />
<br />
The standard software is Vectric's line of CAM software:<br />
<br />
===VCarvePro===<br />
<br />
[[image:Vcarvepro.png]]<br />
<br />
VCarve Pro provides a powerful but intuitive software solution for 2D design and calculation of 2D and 2.5D toolpaths for cutting parts on a CNC Router. <br />
<br />
The software can import 2D designs from other programs but also includes a full set of drawing and editing tools with advanced layout options such as True-Shape Nesting. The toolpath options cover all typical 2D routing operations such as Profiling, Pocketing, Auto-Inlays and Drilling as well as 2.5D strategies such as V-Carving, Prism carving, Fluting and even a decorative Texturing strategy. Each toolpath includes appropriate options to customize the settings and provide a high level of control for different types of operation. In addition all toolpaths can be previewed to show just how the part will look when it is actually cut, this allows instant feedback to allow toolpaths to be further optimized. <br />
<br />
'''Details''': http://www.vectric.com/products/vcarve-pro.htm<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/vcarve-pro<br />
<br />
===Cut3D===<br />
<br />
[[image:Vectric-cut3d.jpg|266px]]<br />
<br />
Cut3D is a dedicated toolpath engine for CNC machining 3D models that have been designed using a 3D CAD or Graphics design product such as AutoCAD, Rhino3D, 3D Studio etc. or scanned using a laser or touch probe device. Cut3D's exceptionally easy to use interface leads you step-by-step through the process of loading a model, setting the size, interactively placing tabs to hold the job in place, calculating single, double or four sided roughing and finishing toolpaths, previewing the results and finally saving the CNC code to run on your machine.<br />
<br />
3D Models that are too large / thick to machine because of gantry height, cutter length or limited material thickness can be 'Sliced' into separate pieces. Each slice can then be machined and the complete job assembled. <br />
<br />
'''Details''': http://www.vectric.com/products/cut3d.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/cut3d<br />
<br />
===PhotoVCarve===<br />
<br />
[[image:Vectric-photovcarve.gif|266px]]<br />
<br />
PhotoVCarve creates lines of grooves that vary in width and depth to represent the detail in a photograph or image. The quality of the finished result is very dependant upon a high level of contrast between the material surface and the machined grooves. This information is very important to remember when cutting designs using the PhotoVCarve software. <br />
<br />
PhotoVCarve machines dark areas in a photograph with wide groove and the lighter areas to have narrower ones. The software automatically calculates the toolpaths based on the cutter selected and maximum depth of groove required. <br />
<br />
'''Details''': http://www.vectric.com/products/photovcarve.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/photovcarve<br />
<br />
== Tooling ==<br />
<br />
=== Router Bits ===<br />
<br />
Router bits (or cutters) are the most common type of cutter, they have two or more vertical cutting edges. These are good general purpose cutters that can be found in most DIY shops. They are the same type that you would use in a manual hand held router.<br />
<br />
<gallery><br />
File:WP_20130813_025.jpg<br />
File:WP_20130813_025.jpg<br />
File:WP_20130814_002.jpg<br />
File:WP_20130814_003.jpg<br />
</gallery><br />
<br />
It is important to notice that the cutters are on the edge of the body only, they do not extend to the centre of the cutter. This means the cutter CAN NOT BE USED AS A DRILL. An holes that are made by these sorts of cutters must be made by ramping the cutter to the correct depth in a sloping or spiral motion.<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>NEVER USE ROUTER BITS THAT HAVE BEARINGS.</b> These types of cutters are designed for manual routers where you can feel the feed back of the bearing in contact with the material being cut. A CNC device has no such feedback and will press the bearing into the material has hard as it can until something gives, i.e. the cutter breaks or much worse the spindle breaks. People found using these types of cutters on the CNC router will be BANNED! Just use the version without the bearing.<br />
<br />
<gallery><br />
File:WP_20130813_018.jpg<br />
</gallery><br />
<br />
The cutting edges should always be the lowest part of the cutter.<br />
</div><br />
<br />
=== End mills ===<br />
<br />
'''Up Cut and Down Cut'''<br />
<br />
Router end mills have two variants, up cut (left) and down cut (right); there is a third type, compression, but they are quite rare.<br />
<br />
<gallery><br />
File:WP_20130813_015.jpg<br />
</gallery><br />
<br />
Most cutters are up cut, which have the cutting service on the top of the flutes and as they rotate lift the chips up and away from the material being cut.<br />
<br />
Down cut cutters have the cutting edge on the bottom of the flutes and push chips down towards the material being cut. This has the advantage of pressing the material being cut into the bed of the machine; this is especially useful for thin plastics. The other advantage is the top surface shows far less breakout and splintering, this is a big advantage for materials like laminates.<br />
<br />
On image on the left has been cut with an up-cut end mill and the image on the right a down-cut.<br />
<br />
<gallery><br />
File:WP_20130813_005.jpg<br />
File:WP_20130813_007.jpg<br />
</gallery><br />
<br />
NOTE: There is a very big disadvantage to down cut end mills, and that is that they do not clear there chips effectively in blind holes. This means they need larger ramping moves to get to the correct cutting depth and if used in pockets without enough clearance, the friction can lead to burning or melting of the material being cut.<br />
<br />
Another down side to down-cut cutters, is that when cutting pockets, the bottom surface will not be as clean as that made with an up-cut cutter, which will do a far better job of clearing the waste chips that rub between the cutter and the material with a down-cut.<br />
<br />
== Stock Tooling ==<br />
<br />
In order to keep a small stock of cutters for general use, the CNC Router needs to have a means of generating money. Because there is no material provided for use with the CNC Router there is no way to bring in any funds for such things. Therefore, we ask that if you use one of the communal cutters please put 50p into the CNC Router Honesty Box. This will go towards funding for replenishing stock and also for the replacement of the sacrificial bed once it gets worn out. Please email the list if a communal cutter is broken or missing, so that they can replace it with one from stock. <br />
<br />
There will likely be 1 or two of each of the following cutters available for use, however please do not count on this being the case:<br />
<br />
* 2.5mm square cutter - single flute<br />
* 1/8" square cutter - single flute<br />
* 1/8" ball cutter - 2 flute<br />
<br />
* 6mm square cutter - 2 flute<br />
* 6mm ball cutter - 2 flute<br />
<br />
* engraver 0.2 30deg 1/8" 30mm length (8 of)<br />
* engraver 0.8 30deg 1/8" 30mm length (2 of)<br />
<br />
* 22mm 2 flute straight <br />
* 90deg x 32mm VBit<br />
<br />
<br />
Some Suppliers are listed below:<br />
<br />
== Feeds & Speeds ==<br />
<br />
What are feeds and speeds? Why are they important?<br />
<br />
[http://www.youtube.com/watch?v=ip2jm_6aUyk&feature=c4-overview&list=UUivA7_KLKWo43tFcCkFvydw Milling machine tutorial - cutter selection, speeds and feeds]<br />
<br />
[http://en.wikipedia.org/wiki/Speeds_and_feeds Wikipedia - Speeds and feeds]<br />
<br />
The phrase speeds and feeds (or feeds and speeds) refers to two separate velocities in machine tool practice, cutting speed and feed rate. They are often considered as a pair because of their combined effect on the cutting process. Each, however, can also be considered and analyzed in its own right.<br />
<br />
Cutting speed (also called surface speed or simply speed) is the speed difference (relative velocity) between the cutting tool and the surface of the workpiece it is operating on. It is expressed in units of distance along the workpiece surface per unit of time, typically surface feet per minute (sfm) or meters per minute (m/min). Feed rate (also often styled as a solid compound, feedrate, or called simply feed) is the relative velocity at which the cutter is advanced along the workpiece; its vector is perpendicular to the vector of cutting speed. Feed rate units depend on the motion of the tool and workpiece; when the workpiece rotates (e.g., in turning and boring), the units are almost always distance per spindle revolution (inches per revolution [in/rev or ipr] or millimeters per revolution [mm/rev]). When the workpiece does not rotate (e.g., in milling), the units are typically distance per time (inches per minute [in/min or ipm] or millimeters per minute [mm/min]), although distance per revolution or per cutter tooth are also sometimes used.<br />
<br />
===Spindle speed quick reference===<br />
<br />
{| class="wikitable"<br />
!|<br />
!|400Hz <br />
!|350Hz <br />
!|300Hz <br />
!|250Hz <br />
!|200Hz <br />
!|150Hz <br />
|-<br />
!|RPM<br />
|24000 <br />
|21000 <br />
|18000 <br />
|15000 <br />
|12000 <br />
|9000 <br />
|-<br />
|}<br />
<br />
===Feed rate quick reference===<br />
<br />
{| class="wikitable" <br />
!|100% <br />
!|75% <br />
!|66% <br />
!|50% <br />
!|33% <br />
!|25% <br />
|-<br />
!|6000<br />
|4500<br />
|3960<br />
|3000<br />
|1980<br />
|1500<br />
|-<br />
!|5000<br />
|3750<br />
|3300<br />
|2500<br />
|1650<br />
|1250<br />
|-<br />
!|4000<br />
|3000<br />
|2640<br />
|2000<br />
|1320<br />
|1000<br />
|-<br />
!|3000 <br />
|2250 <br />
|1980 <br />
|1500 <br />
|990 <br />
|750 <br />
|-<br />
!|2500 <br />
|1875 <br />
|1650 <br />
|1250 <br />
|825 <br />
|625 <br />
|-<br />
!|2000 <br />
|1500 <br />
|1320 <br />
|1000 <br />
|660 <br />
|500 <br />
|-<br />
!|1500 <br />
|1125 <br />
|990 <br />
|750 <br />
|495 <br />
|375 <br />
|-<br />
!|1000 <br />
|750 <br />
|660 <br />
|500 <br />
|330 <br />
|250 <br />
|-<br />
!|500 <br />
|375 <br />
|330 <br />
|250 <br />
|165 <br />
|125 <br />
|-<br />
|}<br />
<br />
=== Sample feed rates ===<br />
<br />
For working out feeds and speeds, recommend http://www.cnccookbook.com/CCGWizard.<br />
<br />
The feeds and speeds below have been tested on our machine. The 3mm cutters were single flute carbide. 2 flute HSS cutters may require different settings to avoid breakages.<br />
<br />
{| class="wikitable"<br />
!|MDF<br />
!|1mm deep <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep <br />
|-<br />
!|3mm &Oslash;<br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|-<br />
!|6mm &Oslash; <br />
|3000/24Krpm<br />
|3000/15Krpm <br />
|2000/13Krpm <br />
|1500/11Krpm <br />
|-<br />
!|22mm &Oslash; <br />
|3000/5000rpm <br />
|N/A <br />
|N/A<br />
|N/A<br />
|-<br />
|}<br />
<br />
{| class="wikitable"<br />
!|Plywood<br />
!|1mm deep <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep<br />
|-<br />
!|3mm &Oslash; <br />
|2000/24Krpm <br />
|2000/24Krpm<br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|-<br />
!|6mm &Oslash;<br />
|3000/15Krpm<br />
|3000/15Krpm <br />
|1500/15Krpm <br />
|1000/11Krpm <br />
|-<br />
!|22mm &Oslash; <br />
|3000/5Krpm <br />
|N/A <br />
|N/A<br />
|N/A<br />
|-<br />
|}<br />
<br />
<br />
Polycarbonate:<br />
300Hz 1600mm/min<br />
<br />
Foamed PVC (foamex):<br />
6mm diameter, 10mm deep pass depth, spindle 400Hz (24krpm), feed 9000mm/min.<br />
<br />
3mm diameter, 3mm deep pass depth, 400Hz (24krpm), 9000mm/min.<br />
<br />
Polyurethane foam:<br />
<br />
6mm diameter, full depth pass (30mm+), 400Hz (24krpm), 9000mm/min.<br />
<br />
3mm diameter, 6mm deep pass depth, 400Hz (24krpm), 9000mm/min.<br />
<br />
Acetal (Delrin):<br />
<br />
6mm Cutter, 2mm deep pass depth, spindle 150 - 180Hz, feed 3000mm/min.<br />
<br />
1/8th or 3mm cutter, 1.5 - 2mm deep pass depth, spindle 130 - 160Hz, feed 2-3000mm/min.<br />
<br />
== Tips & Tricks ==<br />
<br />
= Maintenance =<br />
<br />
The maintenance of the CNC Router is carried out by the Owners, with some basic maintenance being carried out by Users on every job.<br />
<br />
== Maintenance Schedule ==<br />
Every job<br />
* Vacuum cutting dust from bed and around machine<br />
* Sand down high points created on sacrificial bed by cutting/screwing<br />
<br />
As required, by users<br />
* Empty extraction bin <br />
* check for blockages in manifold box where extraction pipes meet<br />
<br />
Monthly<br />
* Inspect extraction hoses for splits/ wear<br />
* Clean guide rails (Don't oil them, it makes dust stick)<br />
* Check level, condition and flow of cooling water and replace as necessary<br />
* Inspect sacrificial bed, re-skim or replace as required<br />
* Inspect cable from pendent to router<br />
* Inspect ER11 collet nut for wear<br />
* Inspect auto levelling probe wire<br />
* check collet set for wear/damage<br />
* Check USB socket on pendent and USB memory stick for splits/damage<br />
<br />
Annual<br />
* Check nuts on lead screws for excessive backlash and adjust if required<br />
* Inspect all covers/structure for signs of damage, cracks etc<br />
* Check tightness (or even presence) of screws holding covers in place<br />
* Check CNC electronics (and PC) cabinets for dust build up and vacuum out if required<br />
* Check feet/supports are all taking load and that the structure is level/flat<br />
* Check motor cables aren't wearing/cracking<br />
<br />
== Maintenance Log ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
3/7/13: Lower spindle clamp bolts replaced with longer stainless ones, holes through tapped as original ones had stripped.<br />
23/12/15: complete maintenance checklist completed. controller cable slightly frayed at machine end, collet nut could do with being replaced. otherwise, everything fine.<br />
<br />
== Maintenance Shopping List ==<br />
<br />
* Cutters<br />
* Sacrificial Bed (1.2m x 1.2m 12mm MDF)<br />
* ER11 collet nut<br />
* controller cable<br />
<br />
= Becoming an Owner/Trainer =<br />
<br />
Becoming an '''Owner''' of a piece of Makespace equipment means that you will be responsible for the maintenance, upkeep and H&S of that equipment. You will also be responsible for running inductions and keeping the information banks (Wiki/Forum/Google Groups) maintained.<br />
<br />
A '''Trainer''' is responsible for running inductions only but will be required to understand how the machine works in order to pass on the relevant skills. A trainer will not be required to maintain the machine but would be expected to keep an eye on its status and report any issues if they develop (as would be expected of any user).<br />
<br />
== Steps to becoming an Owner or Trainer ==<br />
<br />
* Step 1: Contact a current Owner who will talk you through the various responsibilities. [http://wiki.makespace.org/Equipment/CNC_Router#Owners Owners] or Forum: [http://makespace.org/forum/viewtopic.php?f=20&t=89 here]<br />
* Step 2: Sign up to a 'Train the Trainer Training' session on Meetup. It is likely one will need to be set up specially in order for you to sign up but the owner you spoke to should take care of this.<br />
* Step 3: Complete the training to the satisfaction of the Owner/s running the sessions.<br />
* Step 4: Have your name added to the Trainers list and set up your first solo induction session.<br />
* Step 5: Once you are a Trainer you are eligible to become an Owner of the CNC Router. To become an Owner will simply require one further meeting with one of the current owners. This will simply be to walk through the requirements and techniques of maintaining the machine along with any other responsibilites. If the other owners are happy, you can add your name to the [http://wiki.makespace.org/Equipment/CNC_Router#Owners Owners] list.<br />
<br />
== Train the Trainer Training ==<br />
<br />
The first session will be fairly informal, with a look to getting more familiar with the machine and how it operates. We will walk through the Induction cheat-sheet (located on the Wiki) and discuss methods of giving attendees the information they need to use the CNC Router safely.<br />
<br />
The follow up sessions will be arranged during the first session. The second session will include a brief look at the software, Meetup and a full dry-run induction. The third session will be an observed induction where you will be left to train 2 people (with input if necessary). Once complete you will be free to arrange as many induction sessions as you are happy to do. Although you wont be an owner of the CNC Router, if you would like to become one at this point please ask.<br />
<br />
= Further Information =<br />
<br />
== Hardware ==<br />
<br />
Controller: [[File:MPC6610 CNC Router Manual v1.0-En.pdf]]<br />
<br />
Z-Axis Stepper Driver: [[File:M542-05m.pdf]]<br />
<br />
X and Y Axis Stepper Driver: [[File:MA860Hm.pdf]]<br />
<br />
Y Axis Stepper motor: 86BYGH450A-06 (NEMA34 Hybid Stepper Motor, MAX torque: 495 oz-in)<br />
Insulation Resistant - 500V DC 100MΩ Min<br />
Insulation Strength - 50Hz 1Minute 500V Min<br />
Ambient Temperature - -20~+50 degree<br />
Temperature Rise - 80 Max.<br />
Radial Play - 0.02mm Max.<br />
End Play - 0.1-0.3mm<br />
Model: 85BYGH450A-06<br />
Motor dimension: 85*85*75mm<br />
Current/phase: 4.0A<br />
Voltage/phase: 2.0V<br />
Inductance/phase: 2.3+/-20%mH<br />
Resistance/phase: 0.5+/-10%ohm<br />
Holding torque: 3.5 N. M<br />
Shaft diameter: 13 mm<br />
Shaft length: 31.50mm<br />
Leading wires: 4 leading wires<br />
<br />
== Installation ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
<gallery><br />
File:Photo_1.JPG<br />
File:WP_20130509_005.jpg<br />
File:CNC_Router_controller_1.jpg<br />
File:CNC_Router_controller_2.jpg<br />
</gallery><br />
<br />
== Purchase ==<br />
Full Purchase, Delivery and Installation (£?????)<br />
<br />
== Notes ==<br />
<br />
http://www.shopbottools.com/mProducts/prSstandard.htm</div>Perfectphasehttp://wiki.makespace.org/Equipment/CNC_RouterEquipment/CNC Router2016-01-04T01:22:52Z<p>Perfectphase: /* Further Information */</p>
<hr />
<div>{{RedTool}}<br />
<br />
== CNC ROUTER IS DECOMMISSIONED ==<br />
<br />
Pending revision and/or replacement, the CNC router is now decommissioned. Usage is restricted to people operating with full knowledge that steps can be missed and the height can get wrong, resulting in head crashes. Be careful, wear safety goggles. No new training pending replacement or upgrade.<br />
<br />
[[Equipment|Equipment]] / CNC Router<br />
<br />
[[File:WP_20130509_005.jpg|thumb|460px|right|CNC Router]]<br />
<br />
<br />
== Summary ==<br />
<br />
A CNC router is a computer controlled shaping machine. These are related to the hand held router. Instead of hand held routing, the tool paths can be controlled via computer numerical control. It is a computer-controlled machine for cutting various hard materials, such as wood, composites, aluminum, steel, plastics, and foams. It is one of many kinds of tools that have CNC variants. A CNC router is very similar in concept to a CNC milling machine. The CNC router is controlled by a computer. Coordinates are uploaded into the machine controller from a separate CAD program<br />
<br />
* Capacity: 1200 x 1200 x 120mm<br />
* Rate (X,Y): 6000mm/min (Max) 5000mm/min (Working)<br />
* Rate (Z): 30mm/sec<br />
* Spindle Speed: 4500 to 24000rpm<br />
* Mechanical Precision: 0.01mm<br />
* Spindle Power: 1.5KW Variable Speed, Water-cooled<br />
* Blade Diameter: min 3.175mm, max 12.7mm <br />
* Order Format: HPGL, G code, u00, mmg, plt <br />
* Control System: DSP with USB connection <br />
<br />
Here are some examples we've made on the CNC router (please add a photo of yours any time you do a job!) <br />
<br />
<gallery><br />
File:WP_20130509_004.jpg<br />
File:WP_20130624_017.jpg<br />
File:WP_20130625_001.jpg<br />
</gallery><br />
<br />
= Using the CNC Router =<br />
== Owners ==<br />
<br />
The Owners are those who have volunteered to be in charge of the equipment, organising maintenance, training others to use it, and generally being a point of contact. The current Owners of the CNC Router are:<br />
<br />
* [[User:perfectphase|Stephen Woolhead]]<br />
* Mark Mellors<br />
* Dave Ansell<br />
* David Bebb<br />
* Simon Stirley<br />
* Jason White<br />
* Rick Lupton<br />
* Robin Sterling<br />
* Shareef Jalloq<br />
* Hidde-Jan Lemstra<br />
<br />
<br />
-- Further Contacts --<br />
<br />
* Chris Abri <!--chris.abri1985@gmail.com--><br />
<br />
If you have any questions, problems or concerns around the CNC router, please use the mailing list thread:<br />
* [https://groups.google.com/d/topic/cammakespace/rkchD7VqM2c/discussion Log : CNC Router]<br />
<br />
== Training ==<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>YOU CAN ONLY USE THE CNC ROUTER IF YOU HAVE BEEN TRAINED</b><br><br />
and have been added to the [[Equipment/CNC_Router/Training#Trained_Users|Trained Users]] list by one of the Owners<br />
</div><br />
<br />
To get trained on the CNC router and be added to the qualified user list, you will need to arrange for a training session with one of the Owners. <br />
<br />
If you'd like to arrange training, please see:<br />
* [[Equipment/CNC_Router/Training|CNC Router Training]]<br />
<br />
== Health and Safety ==<br />
<br />
The CNC Router is a potentially dangerous piece of equipment which must only be operated by members who have received appropriate training and who take due care. The top things to always remember when using the CNC Router are:<br />
* '''ONLY USE THE CNC ROUTER IF YOU ARE ON THE LIST OF TRAINED USERS'''<br />
* '''NEVER LEAVE THE CNC ROUTER RUNNING UNATTENDED'''<br />
<br />
As a trained user, you should be very aware of the following risks and how to deal with them:<br />
<br />
'''FIRE''' - Cutting with the wrong settings could result in the material igniting.<br />
<br />
'''TRAPPING''' - Stand clear of the machine while in motion.<br />
<br />
'''DUST''' - Ensure extraction system is working.<br />
<br />
'''NOISE''' - Ensure that you wear the correct PPE when working with the machine for prolonged periods.<br />
<br />
Full Risk assessment[[File:CNC_Router.pdf ]]<br />
<br />
== CNC Glossary ==<br />
<br />
As with most new ventures into another profession or hobby, there is the need to learn a “new language” and its common abbreviations. We have introduced some of these in the description of the workflow process above. Here we’ll look at some in more detail. These are listed in alphabetical order.<br />
<br />
=== 2D/2.5D/3D Toolpaths ===<br />
<br />
Depending on the information source, the definitions of 2D, 2.5D and 3D can be quite vague and appear to overlap.<br />
<br />
'''2D''' is simple horizontal cuts at a constant Z depth. For example, you cut out letter or a plaque shape to hang on the wall by moving the tool down to a specific depth and tracing the shape of the part you are cutting in 2D.<br />
<br />
'''2.5D''' would be a little more complex than 2D as while the tool is cutting, the Z depth would be changing instead of staying constant. Typically this still uses 2D vector data to define the path but the way the tool moves in relation to the 2D data and its form will determine the shape that is cut. The most common example of 2.5D is VCarving. Although this cuts 2D vector shapes, the V-shaped tool “rides” on the edges of the vectors, so as it gets wider it cuts deeper and as the vector get closer together it will lift up in Z.<br />
<br />
'''3D'''' These are toolpaths that like 2.5D toolpaths can move simultaneously in all 3 (X, Y and Z) axes however the shape they cut is described by following a 3D computer model and not vectors. They are typically cut with a Ball-Nose (round ended) tool. The tool will go back and forth across the 3D model following the contours of the part similar to an old fashioned copying or digitizing machine. The smoothness of the finished part depends on the Stepover setting in the toolpath as that determines how many times the tool will pass over the model. The size of the tool is also important as the software will only let it cut the detail that the end of the tool can fit into as it traces over the virtual surface. Examples of 3D toolpaths are 3D Rouging and 3D Finishing<br />
<br />
=== 3-axis===<br />
<br />
A 3-axis CNC machine is one that can move a router bit in the 3 primary directions, X, Y and Z. The image below show 3 views of a typical CNC setup and how the axes are referenced from each viewing direction.<br />
<br />
=== CAD ===<br />
<br />
CAD has been used as an abbreviation for both “Computer Aided Design” and “Computer Aided Drafting”. Now it has become a generic term in its own right that refers to a software program that can be used to create a 2D or 3D design.<br />
<br />
=== CAM ===<br />
<br />
When you discuss designing and preparing projects for your CNC machine, the follow-on side of CAD is CAM, which stands for ‘Computer Aided Manufacturing’ or ‘Computer Aided Machining’. This is the part of the process where the geometry developed during the CAD design process are now used to create the instructions that will move your CNC machine to ‘manufacture’ or machine the part.<br />
<br />
=== Collet ===<br />
<br />
The collet assembly is the component on a router or spindle that holds the router bit securely and consists of a precision collet and a collet nut. The collet is precisely sized to hold the router bit shank and the collet nut applies a compressive, friction fit as it is properly tightened onto the router or spindle shaft. It is very important to keep the collets clean and well maintained and depending on use, they must be periodically replaced.<br />
<br />
=== Gantry ===<br />
<br />
The gantry is the part of a CNC machine that typically has one of the horizontal axes running along it and also moves along the other horizontal axis to create the X and Y movement for the tool. The Z axis is also typically mounted on the gantry.<br />
<br />
=== G-Code === <br />
<br />
This is a generic term for the code which is sent to the machine with the instructions telling it how to move. Or, to put it in our context, the file that is saved from the software using the Post Processor to format it for the CNC machine. In reality it’s a particular type of data that a lot of CNC’s use a variant of – so G-code is not necessarily interchangeable to different machines. The name comes from the fact that many of the codes within in start with a G. For example G01 specifies a Feed Rate move and G00 specifies a Rapid move etc.<br />
<br />
=== Pass ===<br />
<br />
When you have a toolpath that is too deep, too wide or a combination of both for the router bit to remove all the material at one time, the toolpath is broken up into multiple ‘Passes’ with each pass removing a part of the material.<br />
<br />
When the toolpath is too deep, a Pass Depth (see entry below) value for the bit will be set and used to indicate the maximum Z depth the tool should cut on each Pass. The amount of material a tool can remove will be determined by the tooltype, size, material being cut and many other parameters. Tooling manufacturers typically offer recommendations for these values.<br />
<br />
=== Post Processor ===<br />
<br />
There are hundreds of different brands and models of CNC machines currently in use. When it comes to controlling them, many have a lot in common, but there can and will be differences. So, if you look at this as each machine speaks a slightly different language, there has to be a way for a single CAD/CAM program to speak to each machine and this is accomplished by using an “interpreter” called a Post Processor, also sometimes simply referred to as ‘pp’ or ‘post’.<br />
<br />
For example, you design a project to cut an exact size circle out of a piece of material and calculate a toolpath to do that. When you actually save that toolpath so it can be used at your CNC machine, the correct Post Processor will ensure the instructions for cutting that circle are prepared correctly so your CNC machine can read and understand them and accurately cut the circle as you intended.<br />
<br />
=== Router Bed or Machine Bed === <br />
<br />
The ‘bed’ identifies the part of a CNC machine where the material being machined is placed and held securely in position. For best results, the bed needs to be flat and sturdy. In most designs the bed is stationary; however there are exceptions to this where the bed moves to provide either the X or Y axis movement.<br />
<br />
=== Sacrifice Sheet / Spoilboard === <br />
<br />
The spoilboard is normally a sacrificial sheet of material placed on top of the machine bed and is intended to be replaced as necessary. It protects the machine bed and allows frequent surfacing which will help to keep a truly flat surface to mount material and help maintain accuracy. This allows the stock material to be screwed down to it and the parts drilled and cut all the way through the material thickness.<br />
<br />
=== Stepover ===<br />
<br />
The Stepover setting found for most router bits allows you to control horizontal movement when machining areas wider than the router bit. Physically, stepover is the distance the center of the bit moves horizontally for each pass.<br />
<br />
The Stepover is shown in the programs as both a physical distance (0.025” or 0.5mm for example) and as a percentage of bit diameter (6%, 8%, 50%, etc.). You can enter either value and the software will automatically calculate the other one for you. Typically most users refer to Stepover by its percentage value as it is a simple whole number and can easily be translated to other tool sizes for a particular task, for example when finishing setting the Stepover to be 10% of the ballnose tools diameter normally creates a reasonably finish surface.<br />
<br />
=== Toolpath ===<br />
<br />
A toolpath is the path created during the CAM part of your project design and represents the instructions your CNC machine will use to make the router bit move to duplicate what you have designed. In the software it is typically displayed as a set of lines which show a virtual picture of the path the tool tip will move along when the toolpath is run on the machine.<br />
<br />
=== Vector ===<br />
<br />
Vector is the word used to describe a 2D line, arc or curve. A vector can be used to describe almost any 2D shape.<br />
<br />
== Instructions ==<br />
<br />
[http://wiki.makespace.org/File:MPC6610_CNC_Router_Manual_v1.0-En.pdf Router Manual]<br />
<br />
[[Equipment/CNC_Router/Hand_Controller|Hand Controller Look-up Guide]]<br />
<br />
===Setting the Z Origin Using the Z0 Sensor===<br />
''A tool that has an extremely narrow tip may break when it touches the tool sensor depending on which tool is to be used.''<br />
<br />
1. Secure the workpiece on the bed, and place the Z0 sensor at the place where you want to set the Z origin on the workpiece. Face the surface of the Z0 sensor without the magnet facing upward.<br />
<br />
[[image:Mill_z0.PNG]]<br />
<br />
2. Use the handset to move the tool to the position above the sensor.<br />
<br />
3. On the handset press OK + 8(Z-0). The tool slowly descend until it contacts the sensor. When the tool rises and stops, the setting operation is complete. <br />
<br />
Note: It is important the tool is electrically conductive from tip to shaft, and the sensor is clean. Failure to check will cause damage to the tool and sensor.<br />
<br />
4. Remove the sensor from the workpiece to a location where it will not interfere with future cutting operations.<br />
<br />
==Software==<br />
<br />
The standard software is Vectric's line of CAM software:<br />
<br />
===VCarvePro===<br />
<br />
[[image:Vcarvepro.png]]<br />
<br />
VCarve Pro provides a powerful but intuitive software solution for 2D design and calculation of 2D and 2.5D toolpaths for cutting parts on a CNC Router. <br />
<br />
The software can import 2D designs from other programs but also includes a full set of drawing and editing tools with advanced layout options such as True-Shape Nesting. The toolpath options cover all typical 2D routing operations such as Profiling, Pocketing, Auto-Inlays and Drilling as well as 2.5D strategies such as V-Carving, Prism carving, Fluting and even a decorative Texturing strategy. Each toolpath includes appropriate options to customize the settings and provide a high level of control for different types of operation. In addition all toolpaths can be previewed to show just how the part will look when it is actually cut, this allows instant feedback to allow toolpaths to be further optimized. <br />
<br />
'''Details''': http://www.vectric.com/products/vcarve-pro.htm<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/vcarve-pro<br />
<br />
===Cut3D===<br />
<br />
[[image:Vectric-cut3d.jpg|266px]]<br />
<br />
Cut3D is a dedicated toolpath engine for CNC machining 3D models that have been designed using a 3D CAD or Graphics design product such as AutoCAD, Rhino3D, 3D Studio etc. or scanned using a laser or touch probe device. Cut3D's exceptionally easy to use interface leads you step-by-step through the process of loading a model, setting the size, interactively placing tabs to hold the job in place, calculating single, double or four sided roughing and finishing toolpaths, previewing the results and finally saving the CNC code to run on your machine.<br />
<br />
3D Models that are too large / thick to machine because of gantry height, cutter length or limited material thickness can be 'Sliced' into separate pieces. Each slice can then be machined and the complete job assembled. <br />
<br />
'''Details''': http://www.vectric.com/products/cut3d.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/cut3d<br />
<br />
===PhotoVCarve===<br />
<br />
[[image:Vectric-photovcarve.gif|266px]]<br />
<br />
PhotoVCarve creates lines of grooves that vary in width and depth to represent the detail in a photograph or image. The quality of the finished result is very dependant upon a high level of contrast between the material surface and the machined grooves. This information is very important to remember when cutting designs using the PhotoVCarve software. <br />
<br />
PhotoVCarve machines dark areas in a photograph with wide groove and the lighter areas to have narrower ones. The software automatically calculates the toolpaths based on the cutter selected and maximum depth of groove required. <br />
<br />
'''Details''': http://www.vectric.com/products/photovcarve.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/photovcarve<br />
<br />
== Tooling ==<br />
<br />
=== Router Bits ===<br />
<br />
Router bits (or cutters) are the most common type of cutter, they have two or more vertical cutting edges. These are good general purpose cutters that can be found in most DIY shops. They are the same type that you would use in a manual hand held router.<br />
<br />
<gallery><br />
File:WP_20130813_025.jpg<br />
File:WP_20130813_025.jpg<br />
File:WP_20130814_002.jpg<br />
File:WP_20130814_003.jpg<br />
</gallery><br />
<br />
It is important to notice that the cutters are on the edge of the body only, they do not extend to the centre of the cutter. This means the cutter CAN NOT BE USED AS A DRILL. An holes that are made by these sorts of cutters must be made by ramping the cutter to the correct depth in a sloping or spiral motion.<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>NEVER USE ROUTER BITS THAT HAVE BEARINGS.</b> These types of cutters are designed for manual routers where you can feel the feed back of the bearing in contact with the material being cut. A CNC device has no such feedback and will press the bearing into the material has hard as it can until something gives, i.e. the cutter breaks or much worse the spindle breaks. People found using these types of cutters on the CNC router will be BANNED! Just use the version without the bearing.<br />
<br />
<gallery><br />
File:WP_20130813_018.jpg<br />
</gallery><br />
<br />
The cutting edges should always be the lowest part of the cutter.<br />
</div><br />
<br />
=== End mills ===<br />
<br />
'''Up Cut and Down Cut'''<br />
<br />
Router end mills have two variants, up cut (left) and down cut (right); there is a third type, compression, but they are quite rare.<br />
<br />
<gallery><br />
File:WP_20130813_015.jpg<br />
</gallery><br />
<br />
Most cutters are up cut, which have the cutting service on the top of the flutes and as they rotate lift the chips up and away from the material being cut.<br />
<br />
Down cut cutters have the cutting edge on the bottom of the flutes and push chips down towards the material being cut. This has the advantage of pressing the material being cut into the bed of the machine; this is especially useful for thin plastics. The other advantage is the top surface shows far less breakout and splintering, this is a big advantage for materials like laminates.<br />
<br />
On image on the left has been cut with an up-cut end mill and the image on the right a down-cut.<br />
<br />
<gallery><br />
File:WP_20130813_005.jpg<br />
File:WP_20130813_007.jpg<br />
</gallery><br />
<br />
NOTE: There is a very big disadvantage to down cut end mills, and that is that they do not clear there chips effectively in blind holes. This means they need larger ramping moves to get to the correct cutting depth and if used in pockets without enough clearance, the friction can lead to burning or melting of the material being cut.<br />
<br />
Another down side to down-cut cutters, is that when cutting pockets, the bottom surface will not be as clean as that made with an up-cut cutter, which will do a far better job of clearing the waste chips that rub between the cutter and the material with a down-cut.<br />
<br />
== Stock Tooling ==<br />
<br />
In order to keep a small stock of cutters for general use, the CNC Router needs to have a means of generating money. Because there is no material provided for use with the CNC Router there is no way to bring in any funds for such things. Therefore, we ask that if you use one of the communal cutters please put 50p into the CNC Router Honesty Box. This will go towards funding for replenishing stock and also for the replacement of the sacrificial bed once it gets worn out. Please email the list if a communal cutter is broken or missing, so that they can replace it with one from stock. <br />
<br />
There will likely be 1 or two of each of the following cutters available for use, however please do not count on this being the case:<br />
<br />
* 2.5mm square cutter - single flute<br />
* 1/8" square cutter - single flute<br />
* 1/8" ball cutter - 2 flute<br />
<br />
* 6mm square cutter - 2 flute<br />
* 6mm ball cutter - 2 flute<br />
<br />
* engraver 0.2 30deg 1/8" 30mm length (8 of)<br />
* engraver 0.8 30deg 1/8" 30mm length (2 of)<br />
<br />
* 22mm 2 flute straight <br />
* 90deg x 32mm VBit<br />
<br />
<br />
Some Suppliers are listed below:<br />
<br />
== Feeds & Speeds ==<br />
<br />
What are feeds and speeds? Why are they important?<br />
<br />
[http://www.youtube.com/watch?v=ip2jm_6aUyk&feature=c4-overview&list=UUivA7_KLKWo43tFcCkFvydw Milling machine tutorial - cutter selection, speeds and feeds]<br />
<br />
[http://en.wikipedia.org/wiki/Speeds_and_feeds Wikipedia - Speeds and feeds]<br />
<br />
The phrase speeds and feeds (or feeds and speeds) refers to two separate velocities in machine tool practice, cutting speed and feed rate. They are often considered as a pair because of their combined effect on the cutting process. Each, however, can also be considered and analyzed in its own right.<br />
<br />
Cutting speed (also called surface speed or simply speed) is the speed difference (relative velocity) between the cutting tool and the surface of the workpiece it is operating on. It is expressed in units of distance along the workpiece surface per unit of time, typically surface feet per minute (sfm) or meters per minute (m/min). Feed rate (also often styled as a solid compound, feedrate, or called simply feed) is the relative velocity at which the cutter is advanced along the workpiece; its vector is perpendicular to the vector of cutting speed. Feed rate units depend on the motion of the tool and workpiece; when the workpiece rotates (e.g., in turning and boring), the units are almost always distance per spindle revolution (inches per revolution [in/rev or ipr] or millimeters per revolution [mm/rev]). When the workpiece does not rotate (e.g., in milling), the units are typically distance per time (inches per minute [in/min or ipm] or millimeters per minute [mm/min]), although distance per revolution or per cutter tooth are also sometimes used.<br />
<br />
===Spindle speed quick reference===<br />
<br />
{| class="wikitable"<br />
!|<br />
!|400Hz <br />
!|350Hz <br />
!|300Hz <br />
!|250Hz <br />
!|200Hz <br />
!|150Hz <br />
|-<br />
!|RPM<br />
|24000 <br />
|21000 <br />
|18000 <br />
|15000 <br />
|12000 <br />
|9000 <br />
|-<br />
|}<br />
<br />
===Feed rate quick reference===<br />
<br />
{| class="wikitable" <br />
!|100% <br />
!|75% <br />
!|66% <br />
!|50% <br />
!|33% <br />
!|25% <br />
|-<br />
!|6000<br />
|4500<br />
|3960<br />
|3000<br />
|1980<br />
|1500<br />
|-<br />
!|5000<br />
|3750<br />
|3300<br />
|2500<br />
|1650<br />
|1250<br />
|-<br />
!|4000<br />
|3000<br />
|2640<br />
|2000<br />
|1320<br />
|1000<br />
|-<br />
!|3000 <br />
|2250 <br />
|1980 <br />
|1500 <br />
|990 <br />
|750 <br />
|-<br />
!|2500 <br />
|1875 <br />
|1650 <br />
|1250 <br />
|825 <br />
|625 <br />
|-<br />
!|2000 <br />
|1500 <br />
|1320 <br />
|1000 <br />
|660 <br />
|500 <br />
|-<br />
!|1500 <br />
|1125 <br />
|990 <br />
|750 <br />
|495 <br />
|375 <br />
|-<br />
!|1000 <br />
|750 <br />
|660 <br />
|500 <br />
|330 <br />
|250 <br />
|-<br />
!|500 <br />
|375 <br />
|330 <br />
|250 <br />
|165 <br />
|125 <br />
|-<br />
|}<br />
<br />
=== Sample feed rates ===<br />
<br />
For working out feeds and speeds, recommend http://www.cnccookbook.com/CCGWizard.<br />
<br />
The feeds and speeds below have been tested on our machine. The 3mm cutters were single flute carbide. 2 flute HSS cutters may require different settings to avoid breakages.<br />
<br />
{| class="wikitable"<br />
!|MDF<br />
!|1mm deep <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep <br />
|-<br />
!|3mm &Oslash;<br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|-<br />
!|6mm &Oslash; <br />
|3000/24Krpm<br />
|3000/15Krpm <br />
|2000/13Krpm <br />
|1500/11Krpm <br />
|-<br />
!|22mm &Oslash; <br />
|3000/5000rpm <br />
|N/A <br />
|N/A<br />
|N/A<br />
|-<br />
|}<br />
<br />
{| class="wikitable"<br />
!|Plywood<br />
!|1mm deep <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep<br />
|-<br />
!|3mm &Oslash; <br />
|2000/24Krpm <br />
|2000/24Krpm<br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|-<br />
!|6mm &Oslash;<br />
|3000/15Krpm<br />
|3000/15Krpm <br />
|1500/15Krpm <br />
|1000/11Krpm <br />
|-<br />
!|22mm &Oslash; <br />
|3000/5Krpm <br />
|N/A <br />
|N/A<br />
|N/A<br />
|-<br />
|}<br />
<br />
<br />
Polycarbonate:<br />
300Hz 1600mm/min<br />
<br />
Foamed PVC (foamex):<br />
6mm diameter, 10mm deep pass depth, spindle 400Hz (24krpm), feed 9000mm/min.<br />
<br />
3mm diameter, 3mm deep pass depth, 400Hz (24krpm), 9000mm/min.<br />
<br />
Polyurethane foam:<br />
<br />
6mm diameter, full depth pass (30mm+), 400Hz (24krpm), 9000mm/min.<br />
<br />
3mm diameter, 6mm deep pass depth, 400Hz (24krpm), 9000mm/min.<br />
<br />
Acetal (Delrin):<br />
<br />
6mm Cutter, 2mm deep pass depth, spindle 150 - 180Hz, feed 3000mm/min.<br />
<br />
1/8th or 3mm cutter, 1.5 - 2mm deep pass depth, spindle 130 - 160Hz, feed 2-3000mm/min.<br />
<br />
== Tips & Tricks ==<br />
<br />
= Maintenance =<br />
<br />
The maintenance of the CNC Router is carried out by the Owners, with some basic maintenance being carried out by Users on every job.<br />
<br />
== Maintenance Schedule ==<br />
Every job<br />
* Vacuum cutting dust from bed and around machine<br />
* Sand down high points created on sacrificial bed by cutting/screwing<br />
<br />
As required, by users<br />
* Empty extraction bin <br />
* check for blockages in manifold box where extraction pipes meet<br />
<br />
Monthly<br />
* Inspect extraction hoses for splits/ wear<br />
* Clean guide rails (Don't oil them, it makes dust stick)<br />
* Check level, condition and flow of cooling water and replace as necessary<br />
* Inspect sacrificial bed, re-skim or replace as required<br />
* Inspect cable from pendent to router<br />
* Inspect ER11 collet nut for wear<br />
* Inspect auto levelling probe wire<br />
* check collet set for wear/damage<br />
* Check USB socket on pendent and USB memory stick for splits/damage<br />
<br />
Annual<br />
* Check nuts on lead screws for excessive backlash and adjust if required<br />
* Inspect all covers/structure for signs of damage, cracks etc<br />
* Check tightness (or even presence) of screws holding covers in place<br />
* Check CNC electronics (and PC) cabinets for dust build up and vacuum out if required<br />
* Check feet/supports are all taking load and that the structure is level/flat<br />
* Check motor cables aren't wearing/cracking<br />
<br />
== Maintenance Log ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
3/7/13: Lower spindle clamp bolts replaced with longer stainless ones, holes through tapped as original ones had stripped.<br />
23/12/15: complete maintenance checklist completed. controller cable slightly frayed at machine end, collet nut could do with being replaced. otherwise, everything fine.<br />
<br />
== Maintenance Shopping List ==<br />
<br />
* Cutters<br />
* Sacrificial Bed (1.2m x 1.2m 12mm MDF)<br />
* ER11 collet nut<br />
* controller cable<br />
<br />
= Becoming an Owner/Trainer =<br />
<br />
Becoming an '''Owner''' of a piece of Makespace equipment means that you will be responsible for the maintenance, upkeep and H&S of that equipment. You will also be responsible for running inductions and keeping the information banks (Wiki/Forum/Google Groups) maintained.<br />
<br />
A '''Trainer''' is responsible for running inductions only but will be required to understand how the machine works in order to pass on the relevant skills. A trainer will not be required to maintain the machine but would be expected to keep an eye on its status and report any issues if they develop (as would be expected of any user).<br />
<br />
== Steps to becoming an Owner or Trainer ==<br />
<br />
* Step 1: Contact a current Owner who will talk you through the various responsibilities. [http://wiki.makespace.org/Equipment/CNC_Router#Owners Owners] or Forum: [http://makespace.org/forum/viewtopic.php?f=20&t=89 here]<br />
* Step 2: Sign up to a 'Train the Trainer Training' session on Meetup. It is likely one will need to be set up specially in order for you to sign up but the owner you spoke to should take care of this.<br />
* Step 3: Complete the training to the satisfaction of the Owner/s running the sessions.<br />
* Step 4: Have your name added to the Trainers list and set up your first solo induction session.<br />
* Step 5: Once you are a Trainer you are eligible to become an Owner of the CNC Router. To become an Owner will simply require one further meeting with one of the current owners. This will simply be to walk through the requirements and techniques of maintaining the machine along with any other responsibilites. If the other owners are happy, you can add your name to the [http://wiki.makespace.org/Equipment/CNC_Router#Owners Owners] list.<br />
<br />
== Train the Trainer Training ==<br />
<br />
The first session will be fairly informal, with a look to getting more familiar with the machine and how it operates. We will walk through the Induction cheat-sheet (located on the Wiki) and discuss methods of giving attendees the information they need to use the CNC Router safely.<br />
<br />
The follow up sessions will be arranged during the first session. The second session will include a brief look at the software, Meetup and a full dry-run induction. The third session will be an observed induction where you will be left to train 2 people (with input if necessary). Once complete you will be free to arrange as many induction sessions as you are happy to do. Although you wont be an owner of the CNC Router, if you would like to become one at this point please ask.<br />
<br />
= Further Information =<br />
<br />
== Hardware ==<br />
<br />
Controller: [[File:MPC6610 CNC Router Manual v1.0-En.pdf]]<br />
<br />
Z-Axis Stepper Driver: [[File:M542-05m.pdf]]<br />
X and Y Axis Stepper Driver: [[File:MA860Hm.pdf]]<br />
<br />
Y Axis Stepper motor: 86BYGH450A-06 (NEMA34 Hybid Stepper Motor, MAX torque: 495 oz-in)<br />
Insulation Resistant - 500V DC 100MΩ Min<br />
Insulation Strength - 50Hz 1Minute 500V Min<br />
Ambient Temperature - -20~+50 degree<br />
Temperature Rise - 80 Max.<br />
Radial Play - 0.02mm Max.<br />
End Play - 0.1-0.3mm<br />
Model: 85BYGH450A-06<br />
Motor dimension: 85*85*75mm<br />
Current/phase: 4.0A<br />
Voltage/phase: 2.0V<br />
Inductance/phase: 2.3+/-20%mH<br />
Resistance/phase: 0.5+/-10%ohm<br />
Holding torque: 3.5 N. M<br />
Shaft diameter: 13 mm<br />
Shaft length: 31.50mm<br />
Leading wires: 4 leading wires<br />
<br />
== Installation ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
<gallery><br />
File:Photo_1.JPG<br />
File:WP_20130509_005.jpg<br />
File:CNC_Router_controller_1.jpg<br />
File:CNC_Router_controller_2.jpg<br />
</gallery><br />
<br />
== Purchase ==<br />
Full Purchase, Delivery and Installation (£?????)<br />
<br />
== Notes ==<br />
<br />
http://www.shopbottools.com/mProducts/prSstandard.htm</div>Perfectphasehttp://wiki.makespace.org/File:MA860Hm.pdfFile:MA860Hm.pdf2016-01-04T01:18:59Z<p>Perfectphase: </p>
<hr />
<div></div>Perfectphasehttp://wiki.makespace.org/File:M542-05m.pdfFile:M542-05m.pdf2016-01-04T01:15:35Z<p>Perfectphase: M542-05 High Performance Microstepping Driver used in CNC router</p>
<hr />
<div>M542-05 High Performance Microstepping Driver used in CNC router</div>Perfectphasehttp://wiki.makespace.org/Equipment/TShirtPressEquipment/TShirtPress2015-10-18T21:05:49Z<p>Perfectphase: Fixed bad link formatting</p>
<hr />
<div><br />
The TShirt Press transfers iron-on vinyl (NOT the sticky type!) to TShirts and other clothing. Cut it out with the vinyl cutter, transfer it with the heat press. Works like an iron, except with uniform temperature, pressure and it automatically stops when it's finished.<br />
<br />
[http://www.lovecut.co.uk/16x20-clam-heat-press-automatic-439-p.asp LoveCut Automatic 16" x 20" Heat Press]<br />
<br />
The TShirt Press is orange, "Take Care". But you can use it without training.<br />
<br />
[[TShirtsGallery|Gallery page of finished TShirts]]<br />
<br />
== Owners ==<br />
<br />
*[[User:Mat-c|Mat Cook]]<br />
*Matthew Taylor<br />
<br />
== Training ==<br />
<br />
See the owners for occasional demos and training.<br />
<br />
== Warnings ==<br />
<br />
*Machine gets hot, especially upper platen<br />
*Do not trap any part of yourself or anyone else in it<br />
*The lid springs up automatically on completion, do not be above it when this happens.<br />
*Turn off after use<br />
*Only use heat-press vinyl, NOT the sticky backed stuff.<br />
<br />
== Instructions ==<br />
<br />
'''Read all instructions and warnings before you start'''<br><br />
<br />
If using sticky vinyl, ie NOT HeatTShirtVinyl, see [[Equipment/Vinyl_Cutter]] for instructions without mirroring.<br />
<br />
Overall idea:<br />
*Create in Inkscape (see notes below about scaling if you use Illustrator!)<br />
**There are TShirt creation resources on the Vinyl Cutter machine (templates etc)<br />
*Load into SureCutsALot<br />
*Cut on the Silver Bullet<br />
*Press on the heat press<br />
<br />
Detail:<br />
*Create your vinyl masterpiece in Inkscape<br />
**Convert all your objects to path<br />
**Check with view outlines it's what you want (line thickness is ignored remember)<br />
**View -> Display Mode -> Outline<br />
**Save as SVG<br />
**<br />
*Import into Sure Cuts A Lot (SCAL) on the vinyl cutter PC<br />
**Check scale (you'll need to make things 25% larger if using Illustrator. Please don't change SCAL import settings)<br />
**Mirror it (Menu: Object -> Transform -> Flip horizontal)<br />
**View as outline to check (sometimes this will show things that it otherwise hides)<br />
**Position top right in SCAL (**add this to the normal cutter instructions)<br />
**Check tool offset is 0.25mm (Cutter -> Cutter Settings)<br />
**Check mat orientation in SCAL<br />
<br />
'''Set up Silver Bullet'''<br />
*Check correct tip installed (45 degree standard cutter, "Click blade holder", the red one)<br />
*Only ever use hot press Tshirt Heat Vinyl. The sticky backed vinyl is unsuitable.<br />
*Please put money for the vinyl in the honesty box straight away<br />
*Load up Silver Bullet with Heat Vinyl (matt side up) <br />
*Use the Silver Bullet Cutting Sheet to make life easy, you can get away <br />
without it for large vinyl pieces but it sometimes buckles. Portrait or Landscape to match Cutting Sheet.<br />
*Check cut depth on red Click Blade Holder (4?)<br />
*ZERO it (offline mode, cross hair button).<br />
**After Zeroing, press Test to do a test rectangle. Check it cuts the vinyl but not the backing.<br />
*Move cutting head to bottom right of sheet (material at back of printer) and zero it (offline, cross hair)<br />
*Double check you zero'd it and press Online on the Silver Bullet.<br />
<br />
'''In SCAL:'''<br />
**Delete any colours you're not cutting (undo with ctrl-Z later, but don't undo your mirroring!)<br />
**Menu: Cutter -> Cut With Silver Bullet.<br />
**Select Use Software Speed and Pressure. Set to Speed = 200 and f=60. (only use f=60 if you have a backing sheet. may need less if feeding from a roll. speed=200 unknown if optimum)<br />
**Select "Origin Point". Bottom right of piece to match location in SCAL.<br />
**Check Silver Bullet is Online.<br />
**"Cut" to start<br />
**Will start immediately. If there is a delay, you probably forgot Online mode and you should wait for it to download before pressing Online (probably - needs checking)<br />
<br />
Pay for your vinyl<br />
*Cut the backing sheet roughly to size - you can reuse largish areas of uncut vinyl.<br />
*Peel away the vinyl that you don't want on your finished design from the backing sheet (this is tricky and you might need a craft knife to separate the layers)<br />
*Weed it (remove the bits you don't want from the backing sheet with pointy thing and tweezers).<br />
*Stick piece to TShirt. Worn TShirts look more narrow, so stick to the centre area.<br />
**Shiny side up. Backing is sticky side down (won't mark TShirt, but will help keep things located)<br />
**Backing is sticky, everything is the right way round at this point and you can see what you're doing<br />
**Check you've got front and back of TShirt the right way round.<br />
<br />
Start up the TShirt press<br />
*Be careful - the TShirt Press upper platen gets hot<br />
*Check the machine is in order. No frayed wires, damage etc.<br />
*With the machine off, check the lid can be pressed down firmly (it will not latch with the power off)<br />
*Turn the machine on<br />
**Switch on the right side, at the back of the press.<br />
**30 Minute limit is on a green button. Clear directions to find this are near/under the machine. (This is to stop the machine being left on after use.)<br />
*Lower the lid slightly to adjust the settings on the back. (Press warms up straight away - caution, hot!)<br />
**There are three modes, the default displays the current temperature at the top and the desired temp at the bottom<br />
**Click SET button and it moves to "SH". Adjust temp with up/down.<br />
**Click SET again and it moves to "ST. Adjust time (in seconds) with up/down.<br />
**Click SET once more to return to the default temperature indication.<br />
**Suggested settings: temp=160 time=16 (seconds). Varies with different vinyls.<br />
**Upper readout shows current temp, wait for it to hit 160 degrees.<br />
**UPPER PLATEN HOT<br />
<br />
Lay out and press your TShirt<br />
*UPPER PLATEN VERY HOT<br />
**Optionally flatten your TShirt in the Heat Press (whole TShirt between the platens, press down gently for a few seconds, not far enough for the magnet to catch and timer to start, but don't worry if it does). UPPER PLATEN HOT be careful.<br />
*Lay out your TShirt on the table (facing you if you want to print on the front, etc)<br />
*After the weeding (removal of bits you don't want) there is a tacky backing to the clear carrier. This goes face down against the TShirt (don't worry, won't stick)<br />
*Place the vinyl on the TShirt, dull sticky side down, shiny carrier towards you, everything the correct way round.<br />
*Bear in mind that the TShirt will be super wide when flattened, so stay in the central half.<br />
*Generally designs go much higher up a TShirt than you might think - the centre is often around the midpoint of the arms. Look at other TShirts or try TShirt on in the mirror to get an idea.<br />
*Insert the whole TShirt between the platens being VERY CAREFUL of the top bed. It's hot and easy to catch yourself on it, especially at the back. Be careful not to dislodge your masterpiece.<br />
**Make it wrinkle free but not stretched.<br />
*Make sure you, other users and objects are clear of the platens<br />
*Carefully but firmly push the clamp down until it clicks into position. The timer will start and the lid will hold itself down.<br />
**Keep clear of the lid, it will pop up automatically on completion or at any time if power is cut.<br />
**When the timer has elapsed, the lid will gently pop up.<br />
*Remove the backing sheet while still hot (this may differ between vinyls)<br />
*'''Turn the machine off after use'''<br />
*Carefully remove TShirt, being careful of the hot upper platen.<br />
<br />
'''Double check you have turned the TShirt Press off, paid for your vinyl and tidied up'''<br />
<br />
Warnings<br />
*Do not trap any part of you or anyone else in the press.<br />
*Do not trap any cables or other equipment in the press.<br />
*The lid pops up when it's finished - do not be near it when it is clamped down<br />
*Do not put anything in the heat press other than clothing. No paper, tissue, bacon or pizza. No matter how tempting that is.<br />
<br />
== Advanced Tips ==<br />
<br />
*Consider a stencil font to make weeding faster and easier (eg Bodoni)<br />
*If you have individual shapes or letters, place a box or ellipse in the unwanted space around them, to separate the weeding into smaller chunks.<br />
*To stack colours, you can either cut around them and line them up together, or heat press the lowest colour and then heat press the next one.<br />
**Multi colours are easier than expected: you can overly vinyl onto previous layers (don't stack the backing sheets though - do multiple presses). (Cannot stack flock nor reflective / shiny / gold / irridescent / silver etc)<br />
<br />
== Vinyl Stock ==<br />
<br />
Heat press vinyl stock (NOT the sticky backed type) is available on the usual honesty box system. Please pay for all vinyl that you use or damage by the sheet. We restock from the honesty box and this expected to be self sustaining. We do not make any profit on the honesty boxes.<br />
<br />
== Problems ==<br />
<br />
See the [[Equipment/Vinyl_Cutter#Problems|vinyl cutter]] page if having problems connecting to the Silver Bullet.<br />
<br />
[[Equipment/TShirtPress/RiskAssessment|Risk Assessment]]</div>Perfectphasehttp://wiki.makespace.org/EMF_2014EMF 20142014-07-27T03:48:17Z<p>Perfectphase: </p>
<hr />
<div>(Taken from https://www.emfcamp.org/)<br />
<br />
August 29th–31st 2014 Bletchley, UK<br />
<br />
Electromagnetic Field is a UK camping festival for those with an inquisitive mind or an interest in making things: hackers, artists, geeks, crafters, scientists, and engineers.<br />
<br />
<br />
Tickets are currently £95 for weekend camping, there are add-on tickets for car parking and camper van/caravan parking.<br />
<br />
The EMF camp wiki is: http://wiki.emfcamp.org/wiki/Electromagnetic_Field_2014<br />
<br />
==Things to Bring==<br />
(See http://wiki.emfcamp.org/wiki/Packing_List for more details)<br />
* Yourself<br />
* A tent<br />
* A torch<br />
* Money to buy awesome things<br />
* A ~10m mains extension cable<br />
* A ~10m ethernet cable<br />
* Electronicy geeky things obviously<br />
<br />
==Members @ EMF==<br />
===Definitely Going===<br />
* [[User:Pinski1|Robert K]] +1 (lift might be available)<br />
** I'll be bringing a 3D printer, a 13.6kg combat robot, an LED Display, 100Watt LED.<br />
* Toby M<br />
** Potentially a large quadcopter if my flying skills improve enough :)<br />
* Mat C +1 (lift might be available)<br />
* Brian C<br />
* Mark T<br />
* Mark M (lift might be available from Hitchin)<br />
* Mark C + kids (6 & 8)<br />
* Stephen<br />
* Tom O<br />
* Tom M<br />
** I'll bring my project, a 3D printer that makes clothes. I've also applied to do a talk about it.<br />
* JCGS (bringing Land-Rover camper, can give lifts to up to 12 or 13 at a pinch)<br />
* Kim SJ + wife and maybe niece<br />
** I'll bring the Badger, at least. And maybe some Pi stuff.<br />
<br />
===Possibly Going===<br />
* Anne H. & friend<br />
* Laura J + Michael D (subject to other commitments)<br />
<br />
===Makespace Village===<br />
There has been a suggestion of setting up Makespace Cambridge in the Hackspace Village. This would allow us to have a central Makespace tent and a place to show off our (un)finished projects!<br />
We have an offer of 2 marquees; 10m x 4m (can be put up as 6mx4m) and 12m x 6m from Kim SJ's brother. We need to decide what we want to do for our Makespace Camp.<br />
<br />
==Transport==<br />
(Taken from http://wiki.emfcamp.org/wiki/Travel)<br />
<br />
The site has the postcode MK17 0BU. This is roughly a mile outside of Newton Longville.<br />
<br />
Public transport links don't look to be the best with Google Maps estimating it to be a 3 bus 3 hour journey or a 4 hour trip via London. It would thus be advisable to lift share with others.</div>Perfectphasehttp://wiki.makespace.org/User:PerfectphaseUser:Perfectphase2014-06-11T22:46:27Z<p>Perfectphase: </p>
<hr />
<div>[[File:Perfectphase profile 4.PNG|thumb]]<br />
<br />
== About Me ==<br />
Name: Stephen Woolhead<br /><br />
Location: Sandy, Bedfordshire<br /><br />
Email: Stephen@perfectphase.com<br /><br />
<br />
== Work ==<br />
I work as a programmer and Team Leader for a company that builds software and hardware solutions in the areas of Access Control, Building Management, CCTV and Time & Attendance. I also dabble in IT matters when needed.<br />
<br />
== Interests ==<br />
I started with a degree in Physics with Space Science, but ended up building software. While I don't get to put my physics and space background to much use in my day job these days, I keep a spark alive in my main hobby which is Amateur rocketry<br />
<br />
<gallery><br />
File:PerfectPhase_Profile_1.jpg<br />
File:Perfectphase profile_2.jpg<br />
File:Perfectphase_profile_3.jpg<br />
</gallery><br />
<br />
I have lots of interests and over the years have dabbled in many things with various levels of success, including:<br />
* Metalworking / Turning<br />
* Composites (Carbon/glass fiber)<br />
* DIY<br />
* Electronics<br />
* Programming<br />
<br />
== Projects ==<br />
I have loads of ideas but I'm going to start at Makespace with projects that help me learn (re-learn in some cases) basic skills. These will then form building blocks for bigger projects in the future.<br />
<br />
=== Current Projects ===<br />
<br />
[[PCB Milling on the Roland]]<br />
<br />
=== Completed Projects ===</div>Perfectphasehttp://wiki.makespace.org/Equipment/CNC_RouterEquipment/CNC Router2014-06-11T22:44:37Z<p>Perfectphase: /* Owners */</p>
<hr />
<div>{{RedTool}}<br />
<br />
[[Equipment|Equipment]] / CNC Router<br />
<br />
[[File:WP_20130509_005.jpg|thumb|460px|right|CNC Router]]<br />
<br />
<br />
== Summary ==<br />
<br />
A CNC router is a computer controlled shaping machine. These are related to the hand held router. Instead of hand held routing, the tool paths can be controlled via computer numerical control. It is a computer-controlled machine for cutting various hard materials, such as wood, composites, aluminum, steel, plastics, and foams. It is one of many kinds of tools that have CNC variants. A CNC router is very similar in concept to a CNC milling machine. The CNC router is controlled by a computer. Coordinates are uploaded into the machine controller from a separate CAD program<br />
<br />
* Capacity: 1200 x 1200 x 120mm<br />
* Rate (X,Y): 6000mm/min (Max) 5000mm/min (Working)<br />
* Rate (Z): 30mm/sec<br />
* Spindle Speed: 4500 to 24000rpm<br />
* Mechanical Precision: 0.01mm<br />
* Spindle Power: 1.5KW Variable Speed, Water-cooled<br />
* Blade Diameter: min 3.175mm, max 12.7mm <br />
* Order Format: HPGL, G code, u00, mmg, plt <br />
* Control System: DSP with USB connection <br />
<br />
Here are some examples we've made on the CNC router (please add a photo of yours any time you do a job!) <br />
<br />
<gallery><br />
File:WP_20130509_004.jpg<br />
File:WP_20130624_017.jpg<br />
File:WP_20130625_001.jpg<br />
</gallery><br />
<br />
= Using the CNC Router =<br />
== Owners ==<br />
<br />
The Owners are those who have volunteered to be in charge of the equipment, organising maintenance, training others to use it, and generally being a point of contact. The current Owners of the CNC Router are:<br />
<br />
* [[User:perfectphase|Stephen Woolhead]]<br />
* Chris Abri - chris.abri1985@gmail.com<br />
* Mark Mellors<br />
* Dave Ansell<br />
* David Bebb<br />
* Simon Stirley<br />
<br />
If you have any questions, problems or concerns around the CNC router, please use the mailing list thread:<br />
* [https://groups.google.com/d/topic/cammakespace/rkchD7VqM2c/discussion Log : CNC Router]<br />
<br />
== Training ==<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>YOU CAN ONLY USE THE CNC ROUTER IF YOU HAVE BEEN TRAINED</b><br><br />
and have been added to the [[Equipment/CNC_Router/Training#Trained_Users|Trained Users]] list by one of the Owners<br />
</div><br />
<br />
To get trained on the CNC router and be added to the qualified user list, you will need to arrange for a training session with one of the Owners. <br />
<br />
If you'd like to arrange training, please see:<br />
* [[Equipment/CNC_Router/Training|CNC Router Training]]<br />
<br />
== Health and Safety ==<br />
<br />
The CNC Router is a potentially dangerous piece of equipment which must only be operated by members who have received appropriate training and who take due care. The top things to always remember when using the CNC Router are:<br />
* '''ONLY USE THE CNC ROUTER IF YOU ARE ON THE LIST OF TRAINED USERS'''<br />
* '''NEVER LEAVE THE CNC ROUTER RUNNING UNATTENDED'''<br />
<br />
As a trained user, you should be very aware of the following risks and how to deal with them:<br />
<br />
'''FIRE''' - Cutting with the wrong settings could result in the material igniting.<br />
<br />
'''TRAPPING''' - Stand clear of the machine while in motion.<br />
<br />
'''DUST''' - Ensure extraction system is working.<br />
<br />
'''NOISE''' - Ensure that you wear the correct PPE when working with the machine for prolonged periods.<br />
<br />
== CNC Glossary ==<br />
<br />
As with most new ventures into another profession or hobby, there is the need to learn a “new language” and its common abbreviations. We have introduced some of these in the description of the workflow process above. Here we’ll look at some in more detail. These are listed in alphabetical order.<br />
<br />
=== 2D/2.5D/3D Toolpaths ===<br />
<br />
Depending on the information source, the definitions of 2D, 2.5D and 3D can be quite vague and appear to overlap.<br />
<br />
'''2D''' is simple horizontal cuts at a constant Z depth. For example, you cut out letter or a plaque shape to hang on the wall by moving the tool down to a specific depth and tracing the shape of the part you are cutting in 2D.<br />
<br />
'''2.5D''' would be a little more complex than 2D as while the tool is cutting, the Z depth would be changing instead of staying constant. Typically this still uses 2D vector data to define the path but the way the tool moves in relation to the 2D data and its form will determine the shape that is cut. The most common example of 2.5D is VCarving. Although this cuts 2D vector shapes, the V-shaped tool “rides” on the edges of the vectors, so as it gets wider it cuts deeper and as the vector get closer together it will lift up in Z.<br />
<br />
'''3D'''' These are toolpaths that like 2.5D toolpaths can move simultaneously in all 3 (X, Y and Z) axes however the shape they cut is described by following a 3D computer model and not vectors. They are typically cut with a Ball-Nose (round ended) tool. The tool will go back and forth across the 3D model following the contours of the part similar to an old fashioned copying or digitizing machine. The smoothness of the finished part depends on the Stepover setting in the toolpath as that determines how many times the tool will pass over the model. The size of the tool is also important as the software will only let it cut the detail that the end of the tool can fit into as it traces over the virtual surface. Examples of 3D toolpaths are 3D Rouging and 3D Finishing<br />
<br />
=== 3-axis===<br />
<br />
A 3-axis CNC machine is one that can move a router bit in the 3 primary directions, X, Y and Z. The image below show 3 views of a typical CNC setup and how the axes are referenced from each viewing direction.<br />
<br />
=== CAD ===<br />
<br />
CAD has been used as an abbreviation for both “Computer Aided Design” and “Computer Aided Drafting”. Now it has become a generic term in its own right that refers to a software program that can be used to create a 2D or 3D design.<br />
<br />
=== CAM ===<br />
<br />
When you discuss designing and preparing projects for your CNC machine, the follow-on side of CAD is CAM, which stands for ‘Computer Aided Manufacturing’ or ‘Computer Aided Machining’. This is the part of the process where the geometry developed during the CAD design process are now used to create the instructions that will move your CNC machine to ‘manufacture’ or machine the part.<br />
<br />
=== Collet ===<br />
<br />
The collet assembly is the component on a router or spindle that holds the router bit securely and consists of a precision collet and a collet nut. The collet is precisely sized to hold the router bit shank and the collet nut applies a compressive, friction fit as it is properly tightened onto the router or spindle shaft. It is very important to keep the collets clean and well maintained and depending on use, they must be periodically replaced.<br />
<br />
=== Gantry ===<br />
<br />
The gantry is the part of a CNC machine that typically has one of the horizontal axes running along it and also moves along the other horizontal axis to create the X and Y movement for the tool. The Z axis is also typically mounted on the gantry.<br />
<br />
=== G-Code === <br />
<br />
This is a generic term for the code which is sent to the machine with the instructions telling it how to move. Or, to put it in our context, the file that is saved from the software using the Post Processor to format it for the CNC machine. In reality it’s a particular type of data that a lot of CNC’s use a variant of – so G-code is not necessarily interchangeable to different machines. The name comes from the fact that many of the codes within in start with a G. For example G01 specifies a Feed Rate move and G00 specifies a Rapid move etc.<br />
<br />
=== Pass ===<br />
<br />
When you have a toolpath that is too deep, too wide or a combination of both for the router bit to remove all the material at one time, the toolpath is broken up into multiple ‘Passes’ with each pass removing a part of the material.<br />
<br />
When the toolpath is too deep, a Pass Depth (see entry below) value for the bit will be set and used to indicate the maximum Z depth the tool should cut on each Pass. The amount of material a tool can remove will be determined by the tooltype, size, material being cut and many other parameters. Tooling manufacturers typically offer recommendations for these values.<br />
<br />
=== Post Processor ===<br />
<br />
There are hundreds of different brands and models of CNC machines currently in use. When it comes to controlling them, many have a lot in common, but there can and will be differences. So, if you look at this as each machine speaks a slightly different language, there has to be a way for a single CAD/CAM program to speak to each machine and this is accomplished by using an “interpreter” called a Post Processor, also sometimes simply referred to as ‘pp’ or ‘post’.<br />
<br />
For example, you design a project to cut an exact size circle out of a piece of material and calculate a toolpath to do that. When you actually save that toolpath so it can be used at your CNC machine, the correct Post Processor will ensure the instructions for cutting that circle are prepared correctly so your CNC machine can read and understand them and accurately cut the circle as you intended.<br />
<br />
=== Router Bed or Machine Bed === <br />
<br />
The ‘bed’ identifies the part of a CNC machine where the material being machined is placed and held securely in position. For best results, the bed needs to be flat and sturdy. In most designs the bed is stationary; however there are exceptions to this where the bed moves to provide either the X or Y axis movement.<br />
<br />
=== Sacrifice Sheet / Spoilboard === <br />
<br />
The spoilboard is normally a sacrificial sheet of material placed on top of the machine bed and is intended to be replaced as necessary. It protects the machine bed and allows frequent surfacing which will help to keep a truly flat surface to mount material and help maintain accuracy. This allows the stock material to be screwed down to it and the parts drilled and cut all the way through the material thickness.<br />
<br />
=== Stepover ===<br />
<br />
The Stepover setting found for most router bits allows you to control horizontal movement when machining areas wider than the router bit. Physically, stepover is the distance the center of the bit moves horizontally for each pass.<br />
<br />
The Stepover is shown in the programs as both a physical distance (0.025” or 0.5mm for example) and as a percentage of bit diameter (6%, 8%, 50%, etc.). You can enter either value and the software will automatically calculate the other one for you. Typically most users refer to Stepover by its percentage value as it is a simple whole number and can easily be translated to other tool sizes for a particular task, for example when finishing setting the Stepover to be 10% of the ballnose tools diameter normally creates a reasonably finish surface.<br />
<br />
=== Toolpath ===<br />
<br />
A toolpath is the path created during the CAM part of your project design and represents the instructions your CNC machine will use to make the router bit move to duplicate what you have designed. In the software it is typically displayed as a set of lines which show a virtual picture of the path the tool tip will move along when the toolpath is run on the machine.<br />
<br />
=== Vector ===<br />
<br />
Vector is the word used to describe a 2D line, arc or curve. A vector can be used to describe almost any 2D shape.<br />
<br />
== Instructions ==<br />
<br />
[http://wiki.makespace.org/File:MPC6610_CNC_Router_Manual_v1.0-En.pdf Router Manual]<br />
<br />
[[Equipment/CNC_Router/Hand_Controller|Hand Controller Look-up Guide]]<br />
<br />
===Setting the Z Origin Using the Z0 Sensor===<br />
''A tool that has an extremely narrow tip may break when it touches the tool sensor depending on which tool is to be used.''<br />
<br />
1. Secure the workpiece on the bed, and place the Z0 sensor at the place where you want to set the Z origin on the workpiece. Face the surface of the Z0 sensor without the magnet facing upward.<br />
<br />
[[image:Mill_z0.PNG]]<br />
<br />
2. Use the handset to move the tool to the position above the sensor.<br />
<br />
3. On the handset press OK + 8(Z-0). The tool slowly descend until it contacts the sensor. When the tool rises and stops, the setting operation is complete. <br />
<br />
Note: It is important the tool is electrically conductive from tip to shaft, and the sensor is clean. Failure to check will cause damage to the tool and sensor.<br />
<br />
4. Remove the sensor from the workpiece to a location where it will not interfere with future cutting operations.<br />
<br />
==Software==<br />
<br />
The standard software is Vectric's line of CAM software:<br />
<br />
===VCarvePro===<br />
<br />
[[image:Vcarvepro.png]]<br />
<br />
VCarve Pro provides a powerful but intuitive software solution for 2D design and calculation of 2D and 2.5D toolpaths for cutting parts on a CNC Router. <br />
<br />
The software can import 2D designs from other programs but also includes a full set of drawing and editing tools with advanced layout options such as True-Shape Nesting. The toolpath options cover all typical 2D routing operations such as Profiling, Pocketing, Auto-Inlays and Drilling as well as 2.5D strategies such as V-Carving, Prism carving, Fluting and even a decorative Texturing strategy. Each toolpath includes appropriate options to customize the settings and provide a high level of control for different types of operation. In addition all toolpaths can be previewed to show just how the part will look when it is actually cut, this allows instant feedback to allow toolpaths to be further optimized. <br />
<br />
'''Details''': http://www.vectric.com/products/vcarve-pro.htm<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/vcarve-pro<br />
<br />
===Cut3D===<br />
<br />
[[image:Vectric-cut3d.jpg|266px]]<br />
<br />
Cut3D is a dedicated toolpath engine for CNC machining 3D models that have been designed using a 3D CAD or Graphics design product such as AutoCAD, Rhino3D, 3D Studio etc. or scanned using a laser or touch probe device. Cut3D's exceptionally easy to use interface leads you step-by-step through the process of loading a model, setting the size, interactively placing tabs to hold the job in place, calculating single, double or four sided roughing and finishing toolpaths, previewing the results and finally saving the CNC code to run on your machine.<br />
<br />
3D Models that are too large / thick to machine because of gantry height, cutter length or limited material thickness can be 'Sliced' into separate pieces. Each slice can then be machined and the complete job assembled. <br />
<br />
'''Details''': http://www.vectric.com/products/cut3d.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/cut3d<br />
<br />
===PhotoVCarve===<br />
<br />
[[image:Vectric-photovcarve.gif|266px]]<br />
<br />
PhotoVCarve creates lines of grooves that vary in width and depth to represent the detail in a photograph or image. The quality of the finished result is very dependant upon a high level of contrast between the material surface and the machined grooves. This information is very important to remember when cutting designs using the PhotoVCarve software. <br />
<br />
PhotoVCarve machines dark areas in a photograph with wide groove and the lighter areas to have narrower ones. The software automatically calculates the toolpaths based on the cutter selected and maximum depth of groove required. <br />
<br />
'''Details''': http://www.vectric.com/products/photovcarve.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/photovcarve<br />
<br />
== Tooling ==<br />
<br />
=== Router Bits ===<br />
<br />
Router bits (or cutters) are the most common type of cutter, they have two or more vertical cutting edges. These are good general purpose cutters that can be found in most DIY shops. They are the same type that you would use in a manual hand held router.<br />
<br />
<gallery><br />
File:WP_20130813_025.jpg<br />
File:WP_20130813_025.jpg<br />
File:WP_20130814_002.jpg<br />
File:WP_20130814_003.jpg<br />
</gallery><br />
<br />
It is important to notice that the cutters are on the edge of the body only, they do not extend to the centre of the cutter. This means the cutter CAN NOT BE USED AS A DRILL. An holes that are made by these sorts of cutters must be made by ramping the cutter to the correct depth in a sloping or spiral motion.<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>NEVER USE ROUTER BITS THAT HAVE BEARINGS.</b> These types of cutters are designed for manual routers where you can feel the feed back of the bearing in contact with the material being cut. A CNC device has no such feedback and will press the bearing into the material has hard as it can until something gives, i.e. the cutter breaks or much worse the spindle breaks. People found using these types of cutters on the CNC router will be BANNED! Just use the version without the bearing.<br />
<br />
<gallery><br />
File:WP_20130813_018.jpg<br />
</gallery><br />
<br />
The cutting edges should always be the lowest part of the cutter.<br />
</div><br />
<br />
=== End mills ===<br />
<br />
'''Up Cut and Down Cut'''<br />
<br />
Router end mills have two variants, up cut (left) and down cut (right); there is a third type, compression, but they are quite rare.<br />
<br />
<gallery><br />
File:WP_20130813_015.jpg<br />
</gallery><br />
<br />
Most cutters are up cut, which have the cutting service on the top of the flutes and as they rotate lift the chips up and away from the material being cut.<br />
<br />
Down cut cutters have the cutting edge on the bottom of the flutes and push chips down towards the material being cut. This has the advantage of pressing the material being cut into the bed of the machine; this is especially useful for thin plastics. The other advantage is the top surface shows far less breakout and splintering, this is a big advantage for materials like laminates.<br />
<br />
On image on the left has been cut with an up-cut end mill and the image on the right a down-cut.<br />
<br />
<gallery><br />
File:WP_20130813_005.jpg<br />
File:WP_20130813_007.jpg<br />
</gallery><br />
<br />
NOTE: There is a very big disadvantage to down cut end mills, and that is that they do not clear there chips effectively in blind holes. This means they need larger ramping moves to get to the correct cutting depth and if used in pockets without enough clearance, the friction can lead to burning or melting of the material being cut.<br />
<br />
Another down side to down-cut cutters, is that when cutting pockets, the bottom surface will not be as clean as that made with an up-cut cutter, which will do a far better job of clearing the waste chips that rub between the cutter and the material with a down-cut.<br />
<br />
== Stock Tooling ==<br />
<br />
In order to keep a small stock of cutters for general use, the CNC Router needs to have a means of generating money. Because there is no material provided for use with the CNC Router there is no way to bring in any funds for such things. Therefore, we ask that if you use one of the communal cutters please put 50p into the CNC Router Honesty Box. This will go towards funding for replenishing stock and also for the replacement of the sacrificial bed once it gets worn out.<br />
<br />
There will likely be 1 or two of each of the following cutters available for use, however please do not count on this being the case:<br />
<br />
* 2.5mm square cutter - single flute<br />
* 1/8" square cutter - single flute<br />
* 1/8" ball cutter - 2 flute<br />
<br />
* 6mm square cutter - 2 flute<br />
* 6mm ball cutter - 2 flute<br />
<br />
* engraver 0.2 30deg 1/8" 30mm length (8 of)<br />
* engraver 0.8 30deg 1/8" 30mm length (2 of)<br />
<br />
* 22mm 2 flute straight <br />
* 90deg x 32mm VBit<br />
<br />
<br />
Some Suppliers are listed below:<br />
<br />
== Feeds & Speeds ==<br />
<br />
What are feeds and speeds? Why are they important?<br />
<br />
[http://www.youtube.com/watch?v=ip2jm_6aUyk&feature=c4-overview&list=UUivA7_KLKWo43tFcCkFvydw Milling machine tutorial - cutter selection, speeds and feeds]<br />
<br />
[http://en.wikipedia.org/wiki/Speeds_and_feeds Wikipedia - Speeds and feeds]<br />
<br />
The phrase speeds and feeds (or feeds and speeds) refers to two separate velocities in machine tool practice, cutting speed and feed rate. They are often considered as a pair because of their combined effect on the cutting process. Each, however, can also be considered and analyzed in its own right.<br />
<br />
Cutting speed (also called surface speed or simply speed) is the speed difference (relative velocity) between the cutting tool and the surface of the workpiece it is operating on. It is expressed in units of distance along the workpiece surface per unit of time, typically surface feet per minute (sfm) or meters per minute (m/min). Feed rate (also often styled as a solid compound, feedrate, or called simply feed) is the relative velocity at which the cutter is advanced along the workpiece; its vector is perpendicular to the vector of cutting speed. Feed rate units depend on the motion of the tool and workpiece; when the workpiece rotates (e.g., in turning and boring), the units are almost always distance per spindle revolution (inches per revolution [in/rev or ipr] or millimeters per revolution [mm/rev]). When the workpiece does not rotate (e.g., in milling), the units are typically distance per time (inches per minute [in/min or ipm] or millimeters per minute [mm/min]), although distance per revolution or per cutter tooth are also sometimes used.<br />
<br />
===Spindle speed quick reference===<br />
<br />
{| class="wikitable"<br />
!|<br />
!|400Hz <br />
!|350Hz <br />
!|300Hz <br />
!|250Hz <br />
!|200Hz <br />
!|150Hz <br />
|-<br />
!|RPM<br />
|24000 <br />
|21000 <br />
|18000 <br />
|15000 <br />
|12000 <br />
|9000 <br />
|-<br />
|}<br />
<br />
===Feed rate quick reference===<br />
<br />
{| class="wikitable" <br />
!|100% <br />
!|75% <br />
!|66% <br />
!|50% <br />
!|33% <br />
!|25% <br />
|-<br />
!|6000<br />
|4500<br />
|3960<br />
|3000<br />
|1980<br />
|1500<br />
|-<br />
!|5000<br />
|3750<br />
|3300<br />
|2500<br />
|1650<br />
|1250<br />
|-<br />
!|4000<br />
|3000<br />
|2640<br />
|2000<br />
|1320<br />
|1000<br />
|-<br />
!|3000 <br />
|2250 <br />
|1980 <br />
|1500 <br />
|990 <br />
|750 <br />
|-<br />
!|2500 <br />
|1875 <br />
|1650 <br />
|1250 <br />
|825 <br />
|625 <br />
|-<br />
!|2000 <br />
|1500 <br />
|1320 <br />
|1000 <br />
|660 <br />
|500 <br />
|-<br />
!|1500 <br />
|1125 <br />
|990 <br />
|750 <br />
|495 <br />
|375 <br />
|-<br />
!|1000 <br />
|750 <br />
|660 <br />
|500 <br />
|330 <br />
|250 <br />
|-<br />
!|500 <br />
|375 <br />
|330 <br />
|250 <br />
|165 <br />
|125 <br />
|-<br />
|}<br />
<br />
=== Sample feed rates ===<br />
<br />
For working out feeds and speeds, recommend http://www.cnccookbook.com/CCGWizard.<br />
<br />
The feeds and speeds below have been tested on our machine. The 3mm cutters were single flute carbide. 2 flute HSS cutters may require different settings to avoid breakages.<br />
<br />
{| class="wikitable"<br />
!|MDF <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep <br />
|-<br />
!|3mm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|-<br />
!|6mm <br />
|3000/15Krpm <br />
|2000/13Krpm <br />
|1500/11Krpm <br />
|-<br />
!|22mm <br />
|3000/5000rpm <br />
|3000/5000rpm <br />
|1500/4Krpm<br />
|-<br />
|}<br />
<br />
{| class="wikitable"<br />
!|Plywood <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep<br />
|-<br />
!|3mm <br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|-<br />
!|6mm <br />
|3000/15Krpm <br />
|1500/15Krpm <br />
|1000/11Krpm <br />
|-<br />
!|22mm <br />
|3000/5Krpm <br />
|3000/5Krpm <br />
|1500/4Krpm <br />
|-<br />
|}<br />
<br />
<br />
Polycarbonate:<br />
300Hz 1600mm/min<br />
<br />
== Tips & Tricks ==<br />
<br />
= Maintenance =<br />
<br />
The maintenance of the CNC Router is carried out by the Owners, with some basic maintenance being carried out by Users on every job.<br />
<br />
== Maintenance Schedule ==<br />
Every job<br />
* Vacuum cutting dust from bed and around machine<br />
* Sand down high points created on sacrificial bed by cutting/screwing<br />
<br />
As required, by users<br />
* Empty extraction bin <br />
<br />
Monthly<br />
* Inspect extraction hoses for splits/ wear<br />
* Clean and oil guide rails<br />
* Check level and condition of cooling water and replace as necessary<br />
* Inspect sacrificial bed, re-skim or replace as required<br />
<br />
== Maintenance Log ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
3/7/13: Lower spindle clamp bolts replaced with longer stainless ones, holes through tapped as original ones had stripped.<br />
<br />
== Maintenance Shopping List ==<br />
<br />
* Cutters<br />
* Sacrificial Bed (1.2m x 1.2m 12mm MDF)<br />
<br />
= Becoming an Owner/Trainer =<br />
<br />
Becoming an '''Owner''' of a piece of Makespace equipment means that you will be responsible for the maintenance, upkeep and H&S of that equipment. You will also be responsible for running inductions and keeping the information banks (Wiki/Forum/Google Groups) maintained.<br />
<br />
A '''Trainer''' is responsible for running inductions only but will be required to understand how the machine works in order to pass on the relevant skills. A trainer will not be required to maintain the machine but would be expected to keep an eye on its status and report any issues if they develop (as would be expected of any user).<br />
<br />
== Steps to becoming an Owner or Trainer ==<br />
<br />
* Step 1: Contact a current Owner who will talk you through the various responsibilities. [http://wiki.makespace.org/Equipment/CNC_Router#Owners Owners] or Forum: [http://makespace.org/forum/viewtopic.php?f=20&t=89 here]<br />
* Step 2: Sign up to a 'Train the Trainer Training' session on Meetup. It is likely one will need to be set up specially in order for you to sign up but the owner you spoke to should take care of this.<br />
* Step 3: Complete the training to the satisfaction of the Owner/s running the sessions.<br />
* Step 4: Have your name added to the Trainers list and set up your first solo induction session.<br />
* Step 5: Once you are a Trainer you are eligible to become an Owner of the CNC Router. To become an Owner will simply require one further meeting with one of the current owners. This will simply be to walk through the requirements and techniques of maintaining the machine along with any other responsibilites. If the other owners are happy, you can add your name to the [http://wiki.makespace.org/Equipment/CNC_Router#Owners Owners] list.<br />
<br />
== Train the Trainer Training ==<br />
<br />
The first session will be fairly informal, with a look to getting more familiar with the machine and how it operates. We will walk through the Induction cheat-sheet (located on the Wiki) and discuss methods of giving attendees the information they need to use the CNC Router safely.<br />
<br />
The follow up sessions will be arranged during the first session. The second session will include a brief look at the software, Meetup and a full dry-run induction. The third session will be an observed induction where you will be left to train 2 people (with input if necessary). Once complete you will be free to arrange as many induction sessions as you are happy to do. Although you wont be an owner of the CNC Router, if you would like to become one at this point please ask.<br />
<br />
= Further Information =<br />
<br />
== Installation ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
<gallery><br />
File:Photo_1.JPG<br />
File:WP_20130509_005.jpg<br />
File:CNC_Router_controller_1.jpg<br />
File:CNC_Router_controller_2.jpg<br />
</gallery><br />
<br />
== Purchase ==<br />
Full Purchase, Delivery and Installation (£?????)<br />
<br />
== Notes ==<br />
<br />
http://www.shopbottools.com/mProducts/prSstandard.htm</div>Perfectphasehttp://wiki.makespace.org/Equipment/CNC_Model_Mill/TrainingEquipment/CNC Model Mill/Training2013-09-05T18:33:47Z<p>Perfectphase: /* Trained Users */</p>
<hr />
<div>[[Equipment|Equipment]] / [[Equipment/CNC_Model_Mill|CNC Model Mill]] / Training<br />
<br />
= Roland Mill Training =<br />
<br />
This page documents the process for being trained to use the, and the list of members who have completed that training.<br />
<br />
== Summary ==<br />
<br />
Training takes place in three main steps:<br />
* Group Training of 1-4 members, going through the equipment and how to use it (~1hr)<br />
* Individual Training Task, where an individual member is set a task to complete to prove and improve understanding (~30min each)<br />
* Project Oversight, where more experienced users oversee the projects being undertaken when cutting (first 2-3 projects)<br />
<br />
Training on the mill is run by the mill Owners. The mill Owners are a group of people responsible for maintaining and training on the mill, and hence have been trained to train, and trained to perform the weekly and monthly maintenance on the mill. <br />
<br />
== Booking ==<br />
<br />
Sessions are advertised on '''http://meetup.makespace.org'''<br />
* For discussing training, or requesting additional slots if needed, use the mailing list thread: [https://groups.google.com/d/msg/cammakespace/Nvf0GPRhLAY/fkvHEQ2sDz4J Training : Roland Mill]<br />
<br />
Notes:<br />
* You can only be trained if you have your name allocated to a slot (groups will be restricted to four at a time, so please don't make up additional spaces)<br />
* You must do the group and individual training on the same day<br />
<br />
= Trained Users =<br />
<br />
The following members of Makespace are owners of the mill, so are trained to use and teach use of the Mill:<br />
* Stephen Woolhead<br />
<br />
The following members of Makespace are trained and qualified to use the Mill (note, they are not qualified to train others however):<br />
* Alexis Mather (Stephen Woolhead, 4/04/2013)<br />
* Rachel Rayns (Stephen Woolhead, 10/04/2013)<br />
* Henry Gomersall (Stephen Woolhead, 10/04/2013)<br />
* Andrew Dunn (Stephen Woolhead, 10/04/2013)<br />
* Edward Imhagwe (Stephen Woolhead, 10/04/2013)<br />
* Kim Spence-Jones (Stephen Woolhead, 10/04/2013)<br />
* Chris Voth (Stephen Woolhead, 11/04/2013)<br />
* Chris Abri (Stephen Woolhead, 11/04/2013) <br />
* Joe Tapply (Stephen Woolhead, 11/04/2013)<br />
* Dave Ansell (Stephen Woolhead, 16/04/2013)<br />
* Gaye Soykok (Stephen Woolhead, 16/04/2013)<br />
* Martin de Selincourt (Stephen Woolhead, 16/04/2013)<br />
* Andy Fisher (Stephen Woolhead, 16/04/2013)<br />
* Mark Tillotson (Stephen Woolhead, 16/04/2013)<br />
* Tom Ingham(Stephen Woolhead, 17/04/2013)<br />
* David Esteves (Stephen Woolhead, 17/04/2013)<br />
* Wayne Keenan (Stephen Woolhead, 17/04/2013)<br />
* David Bebb (Stephen Woolhead 9/5/2013)<br />
* Patrick Greaney (Stephen Woolhead 9/5/2013)<br />
* Paul Osborn (Stephen Woolhead 9/5/2013)<br />
* Adrian Carr (Stephen Woolhead 9/5/2013)<br />
* ST John (Stephen Woolhead 14/5/2013)<br />
* Anne Harrison (Stephen Woolhead 14/5/2013) <br />
* Maciek Piatek (Stephen Woolhead 14/5/2013) <br />
* Tim Thornton (Stephen Woolhead 14/5/2013) <br />
* J. Antonio Barragan (Stephen Woolhead 14/5/2013)<br />
* John Sturdy (Stephen Woolhead 16/5/2013)<br />
* Peter Provis (Stephen Woolhead 16/5/2013)<br />
* Steve Upton (Stephen Woolhead 16/5/2013)<br />
* Moin Ali(Stephen Woolhead 16/5/2013)<br />
* Dan Tidhar (Stephen Woolhead 21/8/2013)<br />
* Jason White (Stephen Woolhead 21/8/2013)<br />
* Adrian van den Heever (Stephen Woolhead 21/8/2013)<br />
* Stacy ??? (Stephen Woolhead 21/8/2013)<br />
* Toby Moncaster (Stephen Woolhead 28/8/2013)<br />
* Arun (Jake) Rao (Stephen Woolhead 28/8/2013) <br />
* Benyahmin Kidder (Stephen Woolhead 28/8/2013) <br />
* James Waldmeyer (Stephen Woolhead 28/8/2013)<br />
<br />
= Training Cheatsheet =<br />
<br />
The training structure and prompt sheet. Please note, this is used by the Mill Owners as a prompt to ensure training is executed in a consistent and complete fashion; this does not constitute and is not a substitute for the training itself. <br />
<br />
== Group Training ==<br />
<br />
The group training introduction structure, suitable for 1-4 members at a time in a 1 hr session.<br />
<br />
'''Mill Basics'''<br />
* Cover the basic mechanics of an 3 axis mill.<br />
* Explain the difference between machine co-ordinates and user co-ordinates<br />
* Cover the different types of cutters, ball, square etc.<br />
* Explain collets and how to change the cutter.<br />
* Cover types of materials than can be cut on the mill, wood, plastics, '''NO METAL'''<br />
* Cover how to fix work piece to bed.<br />
<br />
'''VPanel'''<br />
* Show how to move cutter around in X, Y and Z free hand<br />
* Show how to change the rapid speed, and explain difference between low/high and steps<br />
* Show how to set XYZ origins.<br />
* Show how to set Z origin using sensor.<br />
* Show how to move to set co-ordinates and make relative moves.<br />
* Explain how to switch to G-Code load G-Code files<br />
<br />
'''Click Mill'''<br />
* Explain how to do basic operations such as pocket and surface.<br />
* Cover the basic cutting parameters, such as feed rates, spindle speed, cutting in amount and path interval.<br />
<br />
'''SRP Player'''<br />
* File formats that can be loaded (STL/IGES/Rhino)<br />
* Rotating imported model to correct orientation.<br />
* Scale model if needed.<br />
* Cover type of milling<br />
** Surface finish<br />
** Flat / curved<br />
** What cutting top or top and bottom means<br />
** Adding supports<br />
* Explain creation of tool paths<br />
* Set the size of the work piece and material<br />
* Create initial tool path<br />
* Show cutting preview and explain how it can show cutting errors by flicking between model and preview.<br />
* Show how to edit cutting paths, change tools and cutting area and depth.<br />
* Show margins and slope and re-generate tool paths.<br />
* Open and show the sample project 'thing.srp' as an example of how tool paths can be tweaked to reduce cutting times and optimize support material.<br />
<br />
'''Cut 2D'''<br />
* Open sample project to show basics of tool paths and 3D preview.<br />
* Refer people to the videos on the Cut2D website.<br />
<br />
'''Q and A'''<br />
<br />
== Individual Training Task ==<br />
<br />
The individual task to get familiar, prompt questions and check understanding:<br />
<br />
* Power machine on<br />
* Change the current tool, demonstrating understand of the collet system and correct positioning of cutter in collet. Ensure that the cutter is not dropped.<br />
* Position the cutter over the XY origin and set as origin in user co-ordinates.<br />
* Set the Z origin using the sensor.<br />
* Using the ClickMill software cut a 20x20mm pocket 5mm deep offset by 5,5mm from the origin.<br />
* Pause the job midway through, then restart it.<br />
* Clean machine. <br />
* Turn off.<br />
<br />
== Project Oversight ==<br />
<br />
For next 2-3 projects or until they are comfortable, projects should be machine out of soft materials only such as foam, that way if a mistake is made no damage will be caused to the machine and an expensive block of material lost. If possible the newly trained user should find another more experienced trained user to support them (second pair of eyes) in their first couple of projects, or any time they are unsure.<br />
<br />
'''If in doubt ask for advice!!'''</div>Perfectphasehttp://wiki.makespace.org/File:Metabo-BAS-260-Swift.pdfFile:Metabo-BAS-260-Swift.pdf2013-09-04T15:58:45Z<p>Perfectphase: </p>
<hr />
<div></div>Perfectphasehttp://wiki.makespace.org/Equipment/CNC_Model_Mill/TrainingEquipment/CNC Model Mill/Training2013-08-27T20:18:09Z<p>Perfectphase: /* Trained Users */</p>
<hr />
<div>[[Equipment|Equipment]] / [[Equipment/CNC_Model_Mill|CNC Model Mill]] / Training<br />
<br />
= Roland Mill Training =<br />
<br />
This page documents the process for being trained to use the, and the list of members who have completed that training.<br />
<br />
== Summary ==<br />
<br />
Training takes place in three main steps:<br />
* Group Training of 1-4 members, going through the equipment and how to use it (~1hr)<br />
* Individual Training Task, where an individual member is set a task to complete to prove and improve understanding (~30min each)<br />
* Project Oversight, where more experienced users oversee the projects being undertaken when cutting (first 2-3 projects)<br />
<br />
Training on the mill is run by the mill Owners. The mill Owners are a group of people responsible for maintaining and training on the mill, and hence have been trained to train, and trained to perform the weekly and monthly maintenance on the mill. <br />
<br />
== Booking ==<br />
<br />
Sessions are advertised on '''http://meetup.makespace.org'''<br />
* For discussing training, or requesting additional slots if needed, use the mailing list thread: [https://groups.google.com/d/msg/cammakespace/Nvf0GPRhLAY/fkvHEQ2sDz4J Training : Roland Mill]<br />
<br />
Notes:<br />
* You can only be trained if you have your name allocated to a slot (groups will be restricted to four at a time, so please don't make up additional spaces)<br />
* You must do the group and individual training on the same day<br />
<br />
= Trained Users =<br />
<br />
The following members of Makespace are owners of the mill, so are trained to use and teach use of the Mill:<br />
* Stephen Woolhead<br />
<br />
The following members of Makespace are trained and qualified to use the Mill (note, they are not qualified to train others however):<br />
* Alexis Mather (Stephen Woolhead, 4/04/2013)<br />
* Rachel Rayns (Stephen Woolhead, 10/04/2013)<br />
* Henry Gomersall (Stephen Woolhead, 10/04/2013)<br />
* Andrew Dunn (Stephen Woolhead, 10/04/2013)<br />
* Edward Imhagwe (Stephen Woolhead, 10/04/2013)<br />
* Kim Spence-Jones (Stephen Woolhead, 10/04/2013)<br />
* Chris Voth (Stephen Woolhead, 11/04/2013)<br />
* Chris Abri (Stephen Woolhead, 11/04/2013) <br />
* Joe Tapply (Stephen Woolhead, 11/04/2013)<br />
* Dave Ansell (Stephen Woolhead, 16/04/2013)<br />
* Gaye Soykok (Stephen Woolhead, 16/04/2013)<br />
* Martin de Selincourt (Stephen Woolhead, 16/04/2013)<br />
* Andy Fisher (Stephen Woolhead, 16/04/2013)<br />
* Mark Tillotson (Stephen Woolhead, 16/04/2013)<br />
* Tom Ingham(Stephen Woolhead, 17/04/2013)<br />
* David Esteves (Stephen Woolhead, 17/04/2013)<br />
* Wayne Keenan (Stephen Woolhead, 17/04/2013)<br />
* David Bebb (Stephen Woolhead 9/5/2013)<br />
* Patrick Greaney (Stephen Woolhead 9/5/2013)<br />
* Paul Osborn (Stephen Woolhead 9/5/2013)<br />
* Adrian Carr (Stephen Woolhead 9/5/2013)<br />
* ST John (Stephen Woolhead 14/5/2013)<br />
* Anne Harrison (Stephen Woolhead 14/5/2013) <br />
* Maciek Piatek (Stephen Woolhead 14/5/2013) <br />
* Tim Thornton (Stephen Woolhead 14/5/2013) <br />
* J. Antonio Barragan (Stephen Woolhead 14/5/2013)<br />
* John Sturdy (Stephen Woolhead 16/5/2013)<br />
* Peter Provis (Stephen Woolhead 16/5/2013)<br />
* Steve Upton (Stephen Woolhead 16/5/2013)<br />
* Moin Ali(Stephen Woolhead 16/5/2013)<br />
* Dan Tidhar (Stephen Woolhead 21/8/2013)<br />
* Jason White (Stephen Woolhead 21/8/2013)<br />
* Adrian van den Heever (Stephen Woolhead 21/8/2013)<br />
* Stacy ??? (Stephen Woolhead 21/8/2013)<br />
<br />
= Training Cheatsheet =<br />
<br />
The training structure and prompt sheet. Please note, this is used by the Mill Owners as a prompt to ensure training is executed in a consistent and complete fashion; this does not constitute and is not a substitute for the training itself. <br />
<br />
== Group Training ==<br />
<br />
The group training introduction structure, suitable for 1-4 members at a time in a 1 hr session.<br />
<br />
'''Mill Basics'''<br />
* Cover the basic mechanics of an 3 axis mill.<br />
* Explain the difference between machine co-ordinates and user co-ordinates<br />
* Cover the different types of cutters, ball, square etc.<br />
* Explain collets and how to change the cutter.<br />
* Cover types of materials than can be cut on the mill, wood, plastics, '''NO METAL'''<br />
* Cover how to fix work piece to bed.<br />
<br />
'''VPanel'''<br />
* Show how to move cutter around in X, Y and Z free hand<br />
* Show how to change the rapid speed, and explain difference between low/high and steps<br />
* Show how to set XYZ origins.<br />
* Show how to set Z origin using sensor.<br />
* Show how to move to set co-ordinates and make relative moves.<br />
* Explain how to switch to G-Code load G-Code files<br />
<br />
'''Click Mill'''<br />
* Explain how to do basic operations such as pocket and surface.<br />
* Cover the basic cutting parameters, such as feed rates, spindle speed, cutting in amount and path interval.<br />
<br />
'''SRP Player'''<br />
* File formats that can be loaded (STL/IGES/Rhino)<br />
* Rotating imported model to correct orientation.<br />
* Scale model if needed.<br />
* Cover type of milling<br />
** Surface finish<br />
** Flat / curved<br />
** What cutting top or top and bottom means<br />
** Adding supports<br />
* Explain creation of tool paths<br />
* Set the size of the work piece and material<br />
* Create initial tool path<br />
* Show cutting preview and explain how it can show cutting errors by flicking between model and preview.<br />
* Show how to edit cutting paths, change tools and cutting area and depth.<br />
* Show margins and slope and re-generate tool paths.<br />
* Open and show the sample project 'thing.srp' as an example of how tool paths can be tweaked to reduce cutting times and optimize support material.<br />
<br />
'''Cut 2D'''<br />
* Open sample project to show basics of tool paths and 3D preview.<br />
* Refer people to the videos on the Cut2D website.<br />
<br />
'''Q and A'''<br />
<br />
== Individual Training Task ==<br />
<br />
The individual task to get familiar, prompt questions and check understanding:<br />
<br />
* Power machine on<br />
* Change the current tool, demonstrating understand of the collet system and correct positioning of cutter in collet. Ensure that the cutter is not dropped.<br />
* Position the cutter over the XY origin and set as origin in user co-ordinates.<br />
* Set the Z origin using the sensor.<br />
* Using the ClickMill software cut a 20x20mm pocket 5mm deep offset by 5,5mm from the origin.<br />
* Pause the job midway through, then restart it.<br />
* Clean machine. <br />
* Turn off.<br />
<br />
== Project Oversight ==<br />
<br />
For next 2-3 projects or until they are comfortable, projects should be machine out of soft materials only such as foam, that way if a mistake is made no damage will be caused to the machine and an expensive block of material lost. If possible the newly trained user should find another more experienced trained user to support them (second pair of eyes) in their first couple of projects, or any time they are unsure.<br />
<br />
'''If in doubt ask for advice!!'''</div>Perfectphasehttp://wiki.makespace.org/Equipment/CNC_RouterEquipment/CNC Router2013-08-16T23:20:41Z<p>Perfectphase: /* 3-axis= */</p>
<hr />
<div>{{RedTool}}<br />
<br />
[[Equipment|Equipment]] / CNC Router<br />
<br />
[[File:WP_20130509_005.jpg|thumb|460px|right|CNC Router]]<br />
<br />
<br />
== Summary ==<br />
<br />
A CNC router is a computer controlled shaping machine. These are related to the hand held router. Instead of hand held routing, the tool paths can be controlled via computer numerical control. It is a computer-controlled machine for cutting various hard materials, such as wood, composites, aluminum, steel, plastics, and foams. It is one of many kinds of tools that have CNC variants. A CNC router is very similar in concept to a CNC milling machine. The CNC router is controlled by a computer. Coordinates are uploaded into the machine controller from a separate CAD program<br />
<br />
* Capacity: 1200 x 1200 x 120mm<br />
* Rate (X,Y): 6000mm/min (Max) 5000mm/min (Working)<br />
* Rate (Z): 30mm/sec<br />
* Spindle Speed: 4500 to 24000rpm<br />
* Mechanical Precision: 0.01mm<br />
* Spindle Power: 1.5KW Variable Speed, Water-cooled<br />
* Blade Diameter: min 3.175mm, max 12.7mm <br />
* Order Format: HPGL, G code, u00, mmg, plt <br />
* Control System: DSP with USB connection <br />
<br />
Here are some examples we've made on the CNC router (please add a photo of yours any time you do a job!) <br />
<br />
<gallery><br />
File:WP_20130509_004.jpg<br />
File:WP_20130624_017.jpg<br />
File:WP_20130625_001.jpg<br />
</gallery><br />
<br />
= Using the CNC Router =<br />
== Owners ==<br />
<br />
The Owners are those who have volunteered to be in charge of the equipment, organising maintenance, training others to use it, and generally being a point of contact. The current Owners of the CNC Router are:<br />
<br />
* Stephen Woolhead<br />
* Chris Abri<br />
* Mark Mellors<br />
* Dave Ansell<br />
* David Bebb<br />
* Simon Stirley<br />
<br />
If you have any questions, problems or concerns around the CNC router, please use the mailing list thread:<br />
* [https://groups.google.com/d/topic/cammakespace/rkchD7VqM2c/discussion Log : CNC Router]<br />
<br />
== Training ==<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>YOU CAN ONLY USE THE CNC ROUTER IF YOU HAVE BEEN TRAINED</b><br><br />
and have been added to the [[Equipment/CNC_Router/Training#Trained_Users|Trained Users]] list by one of the Owners<br />
</div><br />
<br />
To get trained on the CNC router and be added to the qualified user list, you will need to arrange for a training session with one of the Owners. <br />
<br />
If you'd like to arrange training, please see:<br />
* [[Equipment/CNC_Router/Training|CNC Router Training]]<br />
<br />
== Health and Safety ==<br />
<br />
The CNC Router is a potentially dangerous piece of equipment which must only be operated by members who have received appropriate training and who take due care. The top things to always remember when using the CNC Router are:<br />
* '''ONLY USE THE CNC ROUTER IF YOU ARE ON THE LIST OF TRAINED USERS'''<br />
* '''NEVER LEAVE THE CNC ROUTER RUNNING UNATTENDED'''<br />
<br />
As a trained user, you should be very aware of the following risks and how to deal with them:<br />
<br />
'''FIRE''' - Cutting with the wrong settings could result in the material igniting.<br />
<br />
'''TRAPPING''' - Stand clear of the machine while in motion.<br />
<br />
'''DUST''' - Ensure extraction system is working.<br />
<br />
'''NOISE''' - Ensure that you wear the correct PPE when working with the machine for prolonged periods.<br />
<br />
== CNC Glossary ==<br />
<br />
As with most new ventures into another profession or hobby, there is the need to learn a “new language” and its common abbreviations. We have introduced some of these in the description of the workflow process above. Here we’ll look at some in more detail. These are listed in alphabetical order.<br />
<br />
=== 2D/2.5D/3D Toolpaths ===<br />
<br />
Depending on the information source, the definitions of 2D, 2.5D and 3D can be quite vague and appear to overlap.<br />
<br />
'''2D''' is simple horizontal cuts at a constant Z depth. For example, you cut out letter or a plaque shape to hang on the wall by moving the tool down to a specific depth and tracing the shape of the part you are cutting in 2D.<br />
<br />
'''2.5D''' would be a little more complex than 2D as while the tool is cutting, the Z depth would be changing instead of staying constant. Typically this still uses 2D vector data to define the path but the way the tool moves in relation to the 2D data and its form will determine the shape that is cut. The most common example of 2.5D is VCarving. Although this cuts 2D vector shapes, the V-shaped tool “rides” on the edges of the vectors, so as it gets wider it cuts deeper and as the vector get closer together it will lift up in Z.<br />
<br />
'''3D'''' These are toolpaths that like 2.5D toolpaths can move simultaneously in all 3 (X, Y and Z) axes however the shape they cut is described by following a 3D computer model and not vectors. They are typically cut with a Ball-Nose (round ended) tool. The tool will go back and forth across the 3D model following the contours of the part similar to an old fashioned copying or digitizing machine. The smoothness of the finished part depends on the Stepover setting in the toolpath as that determines how many times the tool will pass over the model. The size of the tool is also important as the software will only let it cut the detail that the end of the tool can fit into as it traces over the virtual surface. Examples of 3D toolpaths are 3D Rouging and 3D Finishing<br />
<br />
=== 3-axis===<br />
<br />
A 3-axis CNC machine is one that can move a router bit in the 3 primary directions, X, Y and Z. The image below show 3 views of a typical CNC setup and how the axes are referenced from each viewing direction.<br />
<br />
=== CAD ===<br />
<br />
CAD has been used as an abbreviation for both “Computer Aided Design” and “Computer Aided Drafting”. Now it has become a generic term in its own right that refers to a software program that can be used to create a 2D or 3D design.<br />
<br />
=== CAM ===<br />
<br />
When you discuss designing and preparing projects for your CNC machine, the follow-on side of CAD is CAM, which stands for ‘Computer Aided Manufacturing’ or ‘Computer Aided Machining’. This is the part of the process where the geometry developed during the CAD design process are now used to create the instructions that will move your CNC machine to ‘manufacture’ or machine the part.<br />
<br />
=== Collet ===<br />
<br />
The collet assembly is the component on a router or spindle that holds the router bit securely and consists of a precision collet and a collet nut. The collet is precisely sized to hold the router bit shank and the collet nut applies a compressive, friction fit as it is properly tightened onto the router or spindle shaft. It is very important to keep the collets clean and well maintained and depending on use, they must be periodically replaced.<br />
<br />
=== Gantry ===<br />
<br />
The gantry is the part of a CNC machine that typically has one of the horizontal axes running along it and also moves along the other horizontal axis to create the X and Y movement for the tool. The Z axis is also typically mounted on the gantry.<br />
<br />
=== G-Code === <br />
<br />
This is a generic term for the code which is sent to the machine with the instructions telling it how to move. Or, to put it in our context, the file that is saved from the software using the Post Processor to format it for the CNC machine. In reality it’s a particular type of data that a lot of CNC’s use a variant of – so G-code is not necessarily interchangeable to different machines. The name comes from the fact that many of the codes within in start with a G. For example G01 specifies a Feed Rate move and G00 specifies a Rapid move etc.<br />
<br />
=== Pass ===<br />
<br />
When you have a toolpath that is too deep, too wide or a combination of both for the router bit to remove all the material at one time, the toolpath is broken up into multiple ‘Passes’ with each pass removing a part of the material.<br />
<br />
When the toolpath is too deep, a Pass Depth (see entry below) value for the bit will be set and used to indicate the maximum Z depth the tool should cut on each Pass. The amount of material a tool can remove will be determined by the tooltype, size, material being cut and many other parameters. Tooling manufacturers typically offer recommendations for these values.<br />
<br />
=== Post Processor ===<br />
<br />
There are hundreds of different brands and models of CNC machines currently in use. When it comes to controlling them, many have a lot in common, but there can and will be differences. So, if you look at this as each machine speaks a slightly different language, there has to be a way for a single CAD/CAM program to speak to each machine and this is accomplished by using an “interpreter” called a Post Processor, also sometimes simply referred to as ‘pp’ or ‘post’.<br />
<br />
For example, you design a project to cut an exact size circle out of a piece of material and calculate a toolpath to do that. When you actually save that toolpath so it can be used at your CNC machine, the correct Post Processor will ensure the instructions for cutting that circle are prepared correctly so your CNC machine can read and understand them and accurately cut the circle as you intended.<br />
<br />
=== Router Bed or Machine Bed === <br />
<br />
The ‘bed’ identifies the part of a CNC machine where the material being machined is placed and held securely in position. For best results, the bed needs to be flat and sturdy. In most designs the bed is stationary; however there are exceptions to this where the bed moves to provide either the X or Y axis movement.<br />
<br />
=== Sacrifice Sheet / Spoilboard === <br />
<br />
The spoilboard is normally a sacrificial sheet of material placed on top of the machine bed and is intended to be replaced as necessary. It protects the machine bed and allows frequent surfacing which will help to keep a truly flat surface to mount material and help maintain accuracy. This allows the stock material to be screwed down to it and the parts drilled and cut all the way through the material thickness.<br />
<br />
=== Stepover ===<br />
<br />
The Stepover setting found for most router bits allows you to control horizontal movement when machining areas wider than the router bit. Physically, stepover is the distance the center of the bit moves horizontally for each pass.<br />
<br />
The Stepover is shown in the programs as both a physical distance (0.025” or 0.5mm for example) and as a percentage of bit diameter (6%, 8%, 50%, etc.). You can enter either value and the software will automatically calculate the other one for you. Typically most users refer to Stepover by its percentage value as it is a simple whole number and can easily be translated to other tool sizes for a particular task, for example when finishing setting the Stepover to be 10% of the ballnose tools diameter normally creates a reasonably finish surface.<br />
<br />
=== Toolpath ===<br />
<br />
A toolpath is the path created during the CAM part of your project design and represents the instructions your CNC machine will use to make the router bit move to duplicate what you have designed. In the software it is typically displayed as a set of lines which show a virtual picture of the path the tool tip will move along when the toolpath is run on the machine.<br />
<br />
=== Vector ===<br />
<br />
Vector is the word used to describe a 2D line, arc or curve. A vector can be used to describe almost any 2D shape.<br />
<br />
== Instructions ==<br />
<br />
[http://wiki.makespace.org/File:MPC6610_CNC_Router_Manual_v1.0-En.pdf Router Manual]<br />
<br />
[[Equipment/CNC_Router/Hand_Controller|Hand Controller Look-up Guide]]<br />
<br />
===Setting the Z Origin Using the Z0 Sensor===<br />
''A tool that has an extremely narrow tip may break when it touches the tool sensor depending on which tool is to be used.''<br />
<br />
1. Secure the workpiece on the bed, and place the Z0 sensor at the place where you want to set the Z origin on the workpiece. Face the surface of the Z0 sensor without the magnet facing upward.<br />
<br />
[[image:Mill_z0.PNG]]<br />
<br />
2. Use the handset to move the tool to the position above the sensor.<br />
<br />
3. On the handset press OK + 8(Z-0). The tool slowly descend until it contacts the sensor. When the tool rises and stops, the setting operation is complete. <br />
<br />
Note: It is important the tool is electrically conductive from tip to shaft, and the sensor is clean. Failure to check will cause damage to the tool and sensor.<br />
<br />
4. Remove the sensor from the workpiece to a location where it will not interfere with future cutting operations.<br />
<br />
==Software==<br />
<br />
The standard software is Vectric's line of CAM software:<br />
<br />
===VCarvePro===<br />
<br />
[[image:Vcarvepro.png]]<br />
<br />
VCarve Pro provides a powerful but intuitive software solution for 2D design and calculation of 2D and 2.5D toolpaths for cutting parts on a CNC Router. <br />
<br />
The software can import 2D designs from other programs but also includes a full set of drawing and editing tools with advanced layout options such as True-Shape Nesting. The toolpath options cover all typical 2D routing operations such as Profiling, Pocketing, Auto-Inlays and Drilling as well as 2.5D strategies such as V-Carving, Prism carving, Fluting and even a decorative Texturing strategy. Each toolpath includes appropriate options to customize the settings and provide a high level of control for different types of operation. In addition all toolpaths can be previewed to show just how the part will look when it is actually cut, this allows instant feedback to allow toolpaths to be further optimized. <br />
<br />
'''Details''': http://www.vectric.com/products/vcarve-pro.htm<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/vcarve-pro<br />
<br />
===Cut3D===<br />
<br />
[[image:Vectric-cut3d.jpg|266px]]<br />
<br />
Cut3D is a dedicated toolpath engine for CNC machining 3D models that have been designed using a 3D CAD or Graphics design product such as AutoCAD, Rhino3D, 3D Studio etc. or scanned using a laser or touch probe device. Cut3D's exceptionally easy to use interface leads you step-by-step through the process of loading a model, setting the size, interactively placing tabs to hold the job in place, calculating single, double or four sided roughing and finishing toolpaths, previewing the results and finally saving the CNC code to run on your machine.<br />
<br />
3D Models that are too large / thick to machine because of gantry height, cutter length or limited material thickness can be 'Sliced' into separate pieces. Each slice can then be machined and the complete job assembled. <br />
<br />
'''Details''': http://www.vectric.com/products/cut3d.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/cut3d<br />
<br />
===PhotoVCarve===<br />
<br />
[[image:Vectric-photovcarve.gif|266px]]<br />
<br />
PhotoVCarve creates lines of grooves that vary in width and depth to represent the detail in a photograph or image. The quality of the finished result is very dependant upon a high level of contrast between the material surface and the machined grooves. This information is very important to remember when cutting designs using the PhotoVCarve software. <br />
<br />
PhotoVCarve machines dark areas in a photograph with wide groove and the lighter areas to have narrower ones. The software automatically calculates the toolpaths based on the cutter selected and maximum depth of groove required. <br />
<br />
'''Details''': http://www.vectric.com/products/photovcarve.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/photovcarve<br />
<br />
== Tooling ==<br />
<br />
=== Router Bits ===<br />
<br />
Router bits (or cutters) are the most common type of cutter, they have two or more vertical cutting edges. These are good general purpose cutters that can be found in most DIY shops. They are the same type that you would use in a manual hand held router.<br />
<br />
<gallery><br />
File:WP_20130813_025.jpg<br />
File:WP_20130813_025.jpg<br />
File:WP_20130814_002.jpg<br />
File:WP_20130814_003.jpg<br />
</gallery><br />
<br />
It is important to notice that the cutters are on the edge of the body only, they do not extend to the centre of the cutter. This means the cutter CAN NOT BE USED AS A DRILL. An holes that are made by these sorts of cutters must be made by ramping the cutter to the correct depth in a sloping or spiral motion.<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>NEVER USE ROUTER BITS THAT HAVE BEARINGS.</b> These types of cutters are designed for manual routers where you can feel the feed back of the bearing in contact with the material being cut. A CNC device has no such feedback and will press the bearing into the material has hard as it can until something gives, i.e. the cutter breaks or much worse the spindle breaks. People found using these types of cutters on the CNC router will be BANNED! Just use the version without the bearing.<br />
<br />
<gallery><br />
File:WP_20130813_018.jpg<br />
</gallery><br />
<br />
The cutting edges should always be the lowest part of the cutter.<br />
</div><br />
<br />
=== End mills ===<br />
<br />
'''Up Cut and Down Cut'''<br />
<br />
Router end mills have two variants, up cut (left) and down cut (right); there is a third type, compression, but they are quite rare.<br />
<br />
<gallery><br />
File:WP_20130813_015.jpg<br />
</gallery><br />
<br />
Most cutters are up cut, which have the cutting service on the top of the flutes and as they rotate lift the chips up and away from the material being cut.<br />
<br />
Down cut cutters have the cutting edge on the bottom of the flutes and push chips down towards the material being cut. This has the advantage of pressing the material being cut into the bed of the machine; this is especially useful for thin plastics. The other advantage is the top surface shows far less breakout and splintering, this is a big advantage for materials like laminates.<br />
<br />
On image on the left has been cut with an up-cut end mill and the image on the right a down-cut.<br />
<br />
<gallery><br />
File:WP_20130813_005.jpg<br />
File:WP_20130813_007.jpg<br />
</gallery><br />
<br />
NOTE: There is a very big disadvantage to down cut end mills, and that is that they do not clear there chips effectively in blind holes. This means they need larger ramping moves to get to the correct cutting depth and if used in pockets without enough clearance, the friction can lead to burning or melting of the material being cut.<br />
<br />
Another down side to down-cut cutters, is that when cutting pockets, the bottom surface will not be as clean as that made with an up-cut cutter, which will do a far better job of clearing the waste chips that rub between the cutter and the material with a down-cut.<br />
<br />
== Stock Tooling ==<br />
<br />
In order to keep a small stock of cutters for general use, the CNC Router needs to have a means of generating money. Because there is no material provided for use with the CNC Router there is no way to bring in any funds for such things. Therefore, we ask that if you use one of the communal cutters please put 50p into the CNC Router Honesty Box. This will go towards funding for replenishing stock and also for the replacement of the sacrificial bed once it gets worn out.<br />
<br />
There will likely be 1 or two of each of the following cutters available for use, however please do not count on this being the case:<br />
<br />
* 2.5mm square cutter - single flute<br />
* 1/8" square cutter - single flute<br />
* 1/8" ball cutter - 2 flute<br />
<br />
* 6mm square cutter - 2 flute<br />
* 6mm ball cutter - 2 flute<br />
<br />
* engraver 0.2 30deg 1/8" 30mm length (8 of)<br />
* engraver 0.8 30deg 1/8" 30mm length (2 of)<br />
<br />
* 22mm 2 flute straight <br />
* 90deg x 32mm VBit<br />
<br />
<br />
Some Suppliers are listed below:<br />
<br />
== Feeds & Speeds ==<br />
<br />
What are feeds and speeds? Why are they important?<br />
<br />
[http://www.youtube.com/watch?v=ip2jm_6aUyk&feature=c4-overview&list=UUivA7_KLKWo43tFcCkFvydw Milling machine tutorial - cutter selection, speeds and feeds]<br />
<br />
[http://en.wikipedia.org/wiki/Speeds_and_feeds Wikipedia - Speeds and feeds]<br />
<br />
The phrase speeds and feeds (or feeds and speeds) refers to two separate velocities in machine tool practice, cutting speed and feed rate. They are often considered as a pair because of their combined effect on the cutting process. Each, however, can also be considered and analyzed in its own right.<br />
<br />
Cutting speed (also called surface speed or simply speed) is the speed difference (relative velocity) between the cutting tool and the surface of the workpiece it is operating on. It is expressed in units of distance along the workpiece surface per unit of time, typically surface feet per minute (sfm) or meters per minute (m/min). Feed rate (also often styled as a solid compound, feedrate, or called simply feed) is the relative velocity at which the cutter is advanced along the workpiece; its vector is perpendicular to the vector of cutting speed. Feed rate units depend on the motion of the tool and workpiece; when the workpiece rotates (e.g., in turning and boring), the units are almost always distance per spindle revolution (inches per revolution [in/rev or ipr] or millimeters per revolution [mm/rev]). When the workpiece does not rotate (e.g., in milling), the units are typically distance per time (inches per minute [in/min or ipm] or millimeters per minute [mm/min]), although distance per revolution or per cutter tooth are also sometimes used.<br />
<br />
===Spindle speed quick reference===<br />
<br />
{| class="wikitable"<br />
!|<br />
!|400Hz <br />
!|350Hz <br />
!|300Hz <br />
!|250Hz <br />
!|200Hz <br />
!|150Hz <br />
|-<br />
!|RPM<br />
|24000 <br />
|21000 <br />
|18000 <br />
|15000 <br />
|12000 <br />
|9000 <br />
|-<br />
|}<br />
<br />
===Feed rate quick reference===<br />
<br />
{| class="wikitable" <br />
!|100% <br />
!|75% <br />
!|66% <br />
!|50% <br />
!|33% <br />
!|25% <br />
|-<br />
!|6000<br />
|4500<br />
|3960<br />
|3000<br />
|1980<br />
|1500<br />
|-<br />
!|5000<br />
|3750<br />
|3300<br />
|2500<br />
|1650<br />
|1250<br />
|-<br />
!|4000<br />
|3000<br />
|2640<br />
|2000<br />
|1320<br />
|1000<br />
|-<br />
!|3000 <br />
|2250 <br />
|1980 <br />
|1500 <br />
|990 <br />
|750 <br />
|-<br />
!|2500 <br />
|1875 <br />
|1650 <br />
|1250 <br />
|825 <br />
|625 <br />
|-<br />
!|2000 <br />
|1500 <br />
|1320 <br />
|1000 <br />
|660 <br />
|500 <br />
|-<br />
!|1500 <br />
|1125 <br />
|990 <br />
|750 <br />
|495 <br />
|375 <br />
|-<br />
!|1000 <br />
|750 <br />
|660 <br />
|500 <br />
|330 <br />
|250 <br />
|-<br />
!|500 <br />
|375 <br />
|330 <br />
|250 <br />
|165 <br />
|125 <br />
|-<br />
|}<br />
<br />
=== Sample feed rates ===<br />
<br />
For working out feeds and speeds, recommend http://www.cnccookbook.com/CCGWizard.<br />
<br />
The feeds and speeds below have been tested on our machine. The 3mm cutters were single flute carbide. 2 flute HSS cutters may require different settings to avoid breakages.<br />
<br />
{| class="wikitable"<br />
!|MDF <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep <br />
|-<br />
!|3mm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|-<br />
!|6mm <br />
|3000/15Krpm <br />
|2000/13Krpm <br />
|1500/11Krpm <br />
|-<br />
!|22mm <br />
|3000/5000rpm <br />
|3000/5000rpm <br />
|1500/4Krpm<br />
|-<br />
|}<br />
<br />
{| class="wikitable"<br />
!|Plywood <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep<br />
|-<br />
!|3mm <br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|-<br />
!|6mm <br />
|3000/15Krpm <br />
|1500/15Krpm <br />
|1000/11Krpm <br />
|-<br />
!|22mm <br />
|3000/5Krpm <br />
|3000/5Krpm <br />
|1500/4Krpm <br />
|-<br />
|}<br />
<br />
== Tips & Tricks ==<br />
<br />
= Maintenance =<br />
<br />
The maintenance of the CNC Router is carried out by the Owners, with some basic maintenance being carried out by Users on every job.<br />
<br />
== Maintenance Schedule ==<br />
Every job<br />
* Vacuum cutting dust from bed and around machine<br />
* Sand down high points created on sacrificial bed by cutting/screwing<br />
<br />
As required, by users<br />
* Empty extraction bin <br />
<br />
Monthly<br />
* Inspect extraction hoses for splits/ wear<br />
* Clean and oil guide rails<br />
* Check level and condition of cooling water and replace as necessary<br />
* Inspect sacrificial bed, re-skim or replace as required<br />
<br />
== Maintenance Log ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
3/7/13: Lower spindle clamp bolts replaced with longer stainless ones, holes through tapped as original ones had stripped.<br />
<br />
== Maintenance Shopping List ==<br />
<br />
* Cutters<br />
* Sacrificial Bed (1.2m x 1.2m 12mm MDF)<br />
<br />
= Further Information =<br />
<br />
== Installation ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
<gallery><br />
File:Photo_1.JPG<br />
File:WP_20130509_005.jpg<br />
File:CNC_Router_controller_1.jpg<br />
File:CNC_Router_controller_2.jpg<br />
</gallery><br />
<br />
== Purchase ==<br />
Full Purchase, Delivery and Installation (£?????)<br />
<br />
== Notes ==<br />
<br />
http://www.shopbottools.com/mProducts/prSstandard.htm</div>Perfectphasehttp://wiki.makespace.org/Equipment/CNC_RouterEquipment/CNC Router2013-08-16T23:20:25Z<p>Perfectphase: /* Health and Safety */</p>
<hr />
<div>{{RedTool}}<br />
<br />
[[Equipment|Equipment]] / CNC Router<br />
<br />
[[File:WP_20130509_005.jpg|thumb|460px|right|CNC Router]]<br />
<br />
<br />
== Summary ==<br />
<br />
A CNC router is a computer controlled shaping machine. These are related to the hand held router. Instead of hand held routing, the tool paths can be controlled via computer numerical control. It is a computer-controlled machine for cutting various hard materials, such as wood, composites, aluminum, steel, plastics, and foams. It is one of many kinds of tools that have CNC variants. A CNC router is very similar in concept to a CNC milling machine. The CNC router is controlled by a computer. Coordinates are uploaded into the machine controller from a separate CAD program<br />
<br />
* Capacity: 1200 x 1200 x 120mm<br />
* Rate (X,Y): 6000mm/min (Max) 5000mm/min (Working)<br />
* Rate (Z): 30mm/sec<br />
* Spindle Speed: 4500 to 24000rpm<br />
* Mechanical Precision: 0.01mm<br />
* Spindle Power: 1.5KW Variable Speed, Water-cooled<br />
* Blade Diameter: min 3.175mm, max 12.7mm <br />
* Order Format: HPGL, G code, u00, mmg, plt <br />
* Control System: DSP with USB connection <br />
<br />
Here are some examples we've made on the CNC router (please add a photo of yours any time you do a job!) <br />
<br />
<gallery><br />
File:WP_20130509_004.jpg<br />
File:WP_20130624_017.jpg<br />
File:WP_20130625_001.jpg<br />
</gallery><br />
<br />
= Using the CNC Router =<br />
== Owners ==<br />
<br />
The Owners are those who have volunteered to be in charge of the equipment, organising maintenance, training others to use it, and generally being a point of contact. The current Owners of the CNC Router are:<br />
<br />
* Stephen Woolhead<br />
* Chris Abri<br />
* Mark Mellors<br />
* Dave Ansell<br />
* David Bebb<br />
* Simon Stirley<br />
<br />
If you have any questions, problems or concerns around the CNC router, please use the mailing list thread:<br />
* [https://groups.google.com/d/topic/cammakespace/rkchD7VqM2c/discussion Log : CNC Router]<br />
<br />
== Training ==<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>YOU CAN ONLY USE THE CNC ROUTER IF YOU HAVE BEEN TRAINED</b><br><br />
and have been added to the [[Equipment/CNC_Router/Training#Trained_Users|Trained Users]] list by one of the Owners<br />
</div><br />
<br />
To get trained on the CNC router and be added to the qualified user list, you will need to arrange for a training session with one of the Owners. <br />
<br />
If you'd like to arrange training, please see:<br />
* [[Equipment/CNC_Router/Training|CNC Router Training]]<br />
<br />
== Health and Safety ==<br />
<br />
The CNC Router is a potentially dangerous piece of equipment which must only be operated by members who have received appropriate training and who take due care. The top things to always remember when using the CNC Router are:<br />
* '''ONLY USE THE CNC ROUTER IF YOU ARE ON THE LIST OF TRAINED USERS'''<br />
* '''NEVER LEAVE THE CNC ROUTER RUNNING UNATTENDED'''<br />
<br />
As a trained user, you should be very aware of the following risks and how to deal with them:<br />
<br />
'''FIRE''' - Cutting with the wrong settings could result in the material igniting.<br />
<br />
'''TRAPPING''' - Stand clear of the machine while in motion.<br />
<br />
'''DUST''' - Ensure extraction system is working.<br />
<br />
'''NOISE''' - Ensure that you wear the correct PPE when working with the machine for prolonged periods.<br />
<br />
== CNC Glossary ==<br />
<br />
As with most new ventures into another profession or hobby, there is the need to learn a “new language” and its common abbreviations. We have introduced some of these in the description of the workflow process above. Here we’ll look at some in more detail. These are listed in alphabetical order.<br />
<br />
=== 2D/2.5D/3D Toolpaths ===<br />
<br />
Depending on the information source, the definitions of 2D, 2.5D and 3D can be quite vague and appear to overlap.<br />
<br />
'''2D''' is simple horizontal cuts at a constant Z depth. For example, you cut out letter or a plaque shape to hang on the wall by moving the tool down to a specific depth and tracing the shape of the part you are cutting in 2D.<br />
<br />
'''2.5D''' would be a little more complex than 2D as while the tool is cutting, the Z depth would be changing instead of staying constant. Typically this still uses 2D vector data to define the path but the way the tool moves in relation to the 2D data and its form will determine the shape that is cut. The most common example of 2.5D is VCarving. Although this cuts 2D vector shapes, the V-shaped tool “rides” on the edges of the vectors, so as it gets wider it cuts deeper and as the vector get closer together it will lift up in Z.<br />
<br />
'''3D'''' These are toolpaths that like 2.5D toolpaths can move simultaneously in all 3 (X, Y and Z) axes however the shape they cut is described by following a 3D computer model and not vectors. They are typically cut with a Ball-Nose (round ended) tool. The tool will go back and forth across the 3D model following the contours of the part similar to an old fashioned copying or digitizing machine. The smoothness of the finished part depends on the Stepover setting in the toolpath as that determines how many times the tool will pass over the model. The size of the tool is also important as the software will only let it cut the detail that the end of the tool can fit into as it traces over the virtual surface. Examples of 3D toolpaths are 3D Rouging and 3D Finishing<br />
<br />
=== 3-axis====<br />
<br />
A 3-axis CNC machine is one that can move a router bit in the 3 primary directions, X, Y and Z. The image below show 3 views of a typical CNC setup and how the axes are referenced from each viewing direction.<br />
<br />
=== CAD ===<br />
<br />
CAD has been used as an abbreviation for both “Computer Aided Design” and “Computer Aided Drafting”. Now it has become a generic term in its own right that refers to a software program that can be used to create a 2D or 3D design.<br />
<br />
=== CAM ===<br />
<br />
When you discuss designing and preparing projects for your CNC machine, the follow-on side of CAD is CAM, which stands for ‘Computer Aided Manufacturing’ or ‘Computer Aided Machining’. This is the part of the process where the geometry developed during the CAD design process are now used to create the instructions that will move your CNC machine to ‘manufacture’ or machine the part.<br />
<br />
=== Collet ===<br />
<br />
The collet assembly is the component on a router or spindle that holds the router bit securely and consists of a precision collet and a collet nut. The collet is precisely sized to hold the router bit shank and the collet nut applies a compressive, friction fit as it is properly tightened onto the router or spindle shaft. It is very important to keep the collets clean and well maintained and depending on use, they must be periodically replaced.<br />
<br />
=== Gantry ===<br />
<br />
The gantry is the part of a CNC machine that typically has one of the horizontal axes running along it and also moves along the other horizontal axis to create the X and Y movement for the tool. The Z axis is also typically mounted on the gantry.<br />
<br />
=== G-Code === <br />
<br />
This is a generic term for the code which is sent to the machine with the instructions telling it how to move. Or, to put it in our context, the file that is saved from the software using the Post Processor to format it for the CNC machine. In reality it’s a particular type of data that a lot of CNC’s use a variant of – so G-code is not necessarily interchangeable to different machines. The name comes from the fact that many of the codes within in start with a G. For example G01 specifies a Feed Rate move and G00 specifies a Rapid move etc.<br />
<br />
=== Pass ===<br />
<br />
When you have a toolpath that is too deep, too wide or a combination of both for the router bit to remove all the material at one time, the toolpath is broken up into multiple ‘Passes’ with each pass removing a part of the material.<br />
<br />
When the toolpath is too deep, a Pass Depth (see entry below) value for the bit will be set and used to indicate the maximum Z depth the tool should cut on each Pass. The amount of material a tool can remove will be determined by the tooltype, size, material being cut and many other parameters. Tooling manufacturers typically offer recommendations for these values.<br />
<br />
=== Post Processor ===<br />
<br />
There are hundreds of different brands and models of CNC machines currently in use. When it comes to controlling them, many have a lot in common, but there can and will be differences. So, if you look at this as each machine speaks a slightly different language, there has to be a way for a single CAD/CAM program to speak to each machine and this is accomplished by using an “interpreter” called a Post Processor, also sometimes simply referred to as ‘pp’ or ‘post’.<br />
<br />
For example, you design a project to cut an exact size circle out of a piece of material and calculate a toolpath to do that. When you actually save that toolpath so it can be used at your CNC machine, the correct Post Processor will ensure the instructions for cutting that circle are prepared correctly so your CNC machine can read and understand them and accurately cut the circle as you intended.<br />
<br />
=== Router Bed or Machine Bed === <br />
<br />
The ‘bed’ identifies the part of a CNC machine where the material being machined is placed and held securely in position. For best results, the bed needs to be flat and sturdy. In most designs the bed is stationary; however there are exceptions to this where the bed moves to provide either the X or Y axis movement.<br />
<br />
=== Sacrifice Sheet / Spoilboard === <br />
<br />
The spoilboard is normally a sacrificial sheet of material placed on top of the machine bed and is intended to be replaced as necessary. It protects the machine bed and allows frequent surfacing which will help to keep a truly flat surface to mount material and help maintain accuracy. This allows the stock material to be screwed down to it and the parts drilled and cut all the way through the material thickness.<br />
<br />
=== Stepover ===<br />
<br />
The Stepover setting found for most router bits allows you to control horizontal movement when machining areas wider than the router bit. Physically, stepover is the distance the center of the bit moves horizontally for each pass.<br />
<br />
The Stepover is shown in the programs as both a physical distance (0.025” or 0.5mm for example) and as a percentage of bit diameter (6%, 8%, 50%, etc.). You can enter either value and the software will automatically calculate the other one for you. Typically most users refer to Stepover by its percentage value as it is a simple whole number and can easily be translated to other tool sizes for a particular task, for example when finishing setting the Stepover to be 10% of the ballnose tools diameter normally creates a reasonably finish surface.<br />
<br />
=== Toolpath ===<br />
<br />
A toolpath is the path created during the CAM part of your project design and represents the instructions your CNC machine will use to make the router bit move to duplicate what you have designed. In the software it is typically displayed as a set of lines which show a virtual picture of the path the tool tip will move along when the toolpath is run on the machine.<br />
<br />
=== Vector ===<br />
<br />
Vector is the word used to describe a 2D line, arc or curve. A vector can be used to describe almost any 2D shape.<br />
<br />
== Instructions ==<br />
<br />
[http://wiki.makespace.org/File:MPC6610_CNC_Router_Manual_v1.0-En.pdf Router Manual]<br />
<br />
[[Equipment/CNC_Router/Hand_Controller|Hand Controller Look-up Guide]]<br />
<br />
===Setting the Z Origin Using the Z0 Sensor===<br />
''A tool that has an extremely narrow tip may break when it touches the tool sensor depending on which tool is to be used.''<br />
<br />
1. Secure the workpiece on the bed, and place the Z0 sensor at the place where you want to set the Z origin on the workpiece. Face the surface of the Z0 sensor without the magnet facing upward.<br />
<br />
[[image:Mill_z0.PNG]]<br />
<br />
2. Use the handset to move the tool to the position above the sensor.<br />
<br />
3. On the handset press OK + 8(Z-0). The tool slowly descend until it contacts the sensor. When the tool rises and stops, the setting operation is complete. <br />
<br />
Note: It is important the tool is electrically conductive from tip to shaft, and the sensor is clean. Failure to check will cause damage to the tool and sensor.<br />
<br />
4. Remove the sensor from the workpiece to a location where it will not interfere with future cutting operations.<br />
<br />
==Software==<br />
<br />
The standard software is Vectric's line of CAM software:<br />
<br />
===VCarvePro===<br />
<br />
[[image:Vcarvepro.png]]<br />
<br />
VCarve Pro provides a powerful but intuitive software solution for 2D design and calculation of 2D and 2.5D toolpaths for cutting parts on a CNC Router. <br />
<br />
The software can import 2D designs from other programs but also includes a full set of drawing and editing tools with advanced layout options such as True-Shape Nesting. The toolpath options cover all typical 2D routing operations such as Profiling, Pocketing, Auto-Inlays and Drilling as well as 2.5D strategies such as V-Carving, Prism carving, Fluting and even a decorative Texturing strategy. Each toolpath includes appropriate options to customize the settings and provide a high level of control for different types of operation. In addition all toolpaths can be previewed to show just how the part will look when it is actually cut, this allows instant feedback to allow toolpaths to be further optimized. <br />
<br />
'''Details''': http://www.vectric.com/products/vcarve-pro.htm<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/vcarve-pro<br />
<br />
===Cut3D===<br />
<br />
[[image:Vectric-cut3d.jpg|266px]]<br />
<br />
Cut3D is a dedicated toolpath engine for CNC machining 3D models that have been designed using a 3D CAD or Graphics design product such as AutoCAD, Rhino3D, 3D Studio etc. or scanned using a laser or touch probe device. Cut3D's exceptionally easy to use interface leads you step-by-step through the process of loading a model, setting the size, interactively placing tabs to hold the job in place, calculating single, double or four sided roughing and finishing toolpaths, previewing the results and finally saving the CNC code to run on your machine.<br />
<br />
3D Models that are too large / thick to machine because of gantry height, cutter length or limited material thickness can be 'Sliced' into separate pieces. Each slice can then be machined and the complete job assembled. <br />
<br />
'''Details''': http://www.vectric.com/products/cut3d.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/cut3d<br />
<br />
===PhotoVCarve===<br />
<br />
[[image:Vectric-photovcarve.gif|266px]]<br />
<br />
PhotoVCarve creates lines of grooves that vary in width and depth to represent the detail in a photograph or image. The quality of the finished result is very dependant upon a high level of contrast between the material surface and the machined grooves. This information is very important to remember when cutting designs using the PhotoVCarve software. <br />
<br />
PhotoVCarve machines dark areas in a photograph with wide groove and the lighter areas to have narrower ones. The software automatically calculates the toolpaths based on the cutter selected and maximum depth of groove required. <br />
<br />
'''Details''': http://www.vectric.com/products/photovcarve.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/photovcarve<br />
<br />
== Tooling ==<br />
<br />
=== Router Bits ===<br />
<br />
Router bits (or cutters) are the most common type of cutter, they have two or more vertical cutting edges. These are good general purpose cutters that can be found in most DIY shops. They are the same type that you would use in a manual hand held router.<br />
<br />
<gallery><br />
File:WP_20130813_025.jpg<br />
File:WP_20130813_025.jpg<br />
File:WP_20130814_002.jpg<br />
File:WP_20130814_003.jpg<br />
</gallery><br />
<br />
It is important to notice that the cutters are on the edge of the body only, they do not extend to the centre of the cutter. This means the cutter CAN NOT BE USED AS A DRILL. An holes that are made by these sorts of cutters must be made by ramping the cutter to the correct depth in a sloping or spiral motion.<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>NEVER USE ROUTER BITS THAT HAVE BEARINGS.</b> These types of cutters are designed for manual routers where you can feel the feed back of the bearing in contact with the material being cut. A CNC device has no such feedback and will press the bearing into the material has hard as it can until something gives, i.e. the cutter breaks or much worse the spindle breaks. People found using these types of cutters on the CNC router will be BANNED! Just use the version without the bearing.<br />
<br />
<gallery><br />
File:WP_20130813_018.jpg<br />
</gallery><br />
<br />
The cutting edges should always be the lowest part of the cutter.<br />
</div><br />
<br />
=== End mills ===<br />
<br />
'''Up Cut and Down Cut'''<br />
<br />
Router end mills have two variants, up cut (left) and down cut (right); there is a third type, compression, but they are quite rare.<br />
<br />
<gallery><br />
File:WP_20130813_015.jpg<br />
</gallery><br />
<br />
Most cutters are up cut, which have the cutting service on the top of the flutes and as they rotate lift the chips up and away from the material being cut.<br />
<br />
Down cut cutters have the cutting edge on the bottom of the flutes and push chips down towards the material being cut. This has the advantage of pressing the material being cut into the bed of the machine; this is especially useful for thin plastics. The other advantage is the top surface shows far less breakout and splintering, this is a big advantage for materials like laminates.<br />
<br />
On image on the left has been cut with an up-cut end mill and the image on the right a down-cut.<br />
<br />
<gallery><br />
File:WP_20130813_005.jpg<br />
File:WP_20130813_007.jpg<br />
</gallery><br />
<br />
NOTE: There is a very big disadvantage to down cut end mills, and that is that they do not clear there chips effectively in blind holes. This means they need larger ramping moves to get to the correct cutting depth and if used in pockets without enough clearance, the friction can lead to burning or melting of the material being cut.<br />
<br />
Another down side to down-cut cutters, is that when cutting pockets, the bottom surface will not be as clean as that made with an up-cut cutter, which will do a far better job of clearing the waste chips that rub between the cutter and the material with a down-cut.<br />
<br />
== Stock Tooling ==<br />
<br />
In order to keep a small stock of cutters for general use, the CNC Router needs to have a means of generating money. Because there is no material provided for use with the CNC Router there is no way to bring in any funds for such things. Therefore, we ask that if you use one of the communal cutters please put 50p into the CNC Router Honesty Box. This will go towards funding for replenishing stock and also for the replacement of the sacrificial bed once it gets worn out.<br />
<br />
There will likely be 1 or two of each of the following cutters available for use, however please do not count on this being the case:<br />
<br />
* 2.5mm square cutter - single flute<br />
* 1/8" square cutter - single flute<br />
* 1/8" ball cutter - 2 flute<br />
<br />
* 6mm square cutter - 2 flute<br />
* 6mm ball cutter - 2 flute<br />
<br />
* engraver 0.2 30deg 1/8" 30mm length (8 of)<br />
* engraver 0.8 30deg 1/8" 30mm length (2 of)<br />
<br />
* 22mm 2 flute straight <br />
* 90deg x 32mm VBit<br />
<br />
<br />
Some Suppliers are listed below:<br />
<br />
== Feeds & Speeds ==<br />
<br />
What are feeds and speeds? Why are they important?<br />
<br />
[http://www.youtube.com/watch?v=ip2jm_6aUyk&feature=c4-overview&list=UUivA7_KLKWo43tFcCkFvydw Milling machine tutorial - cutter selection, speeds and feeds]<br />
<br />
[http://en.wikipedia.org/wiki/Speeds_and_feeds Wikipedia - Speeds and feeds]<br />
<br />
The phrase speeds and feeds (or feeds and speeds) refers to two separate velocities in machine tool practice, cutting speed and feed rate. They are often considered as a pair because of their combined effect on the cutting process. Each, however, can also be considered and analyzed in its own right.<br />
<br />
Cutting speed (also called surface speed or simply speed) is the speed difference (relative velocity) between the cutting tool and the surface of the workpiece it is operating on. It is expressed in units of distance along the workpiece surface per unit of time, typically surface feet per minute (sfm) or meters per minute (m/min). Feed rate (also often styled as a solid compound, feedrate, or called simply feed) is the relative velocity at which the cutter is advanced along the workpiece; its vector is perpendicular to the vector of cutting speed. Feed rate units depend on the motion of the tool and workpiece; when the workpiece rotates (e.g., in turning and boring), the units are almost always distance per spindle revolution (inches per revolution [in/rev or ipr] or millimeters per revolution [mm/rev]). When the workpiece does not rotate (e.g., in milling), the units are typically distance per time (inches per minute [in/min or ipm] or millimeters per minute [mm/min]), although distance per revolution or per cutter tooth are also sometimes used.<br />
<br />
===Spindle speed quick reference===<br />
<br />
{| class="wikitable"<br />
!|<br />
!|400Hz <br />
!|350Hz <br />
!|300Hz <br />
!|250Hz <br />
!|200Hz <br />
!|150Hz <br />
|-<br />
!|RPM<br />
|24000 <br />
|21000 <br />
|18000 <br />
|15000 <br />
|12000 <br />
|9000 <br />
|-<br />
|}<br />
<br />
===Feed rate quick reference===<br />
<br />
{| class="wikitable" <br />
!|100% <br />
!|75% <br />
!|66% <br />
!|50% <br />
!|33% <br />
!|25% <br />
|-<br />
!|6000<br />
|4500<br />
|3960<br />
|3000<br />
|1980<br />
|1500<br />
|-<br />
!|5000<br />
|3750<br />
|3300<br />
|2500<br />
|1650<br />
|1250<br />
|-<br />
!|4000<br />
|3000<br />
|2640<br />
|2000<br />
|1320<br />
|1000<br />
|-<br />
!|3000 <br />
|2250 <br />
|1980 <br />
|1500 <br />
|990 <br />
|750 <br />
|-<br />
!|2500 <br />
|1875 <br />
|1650 <br />
|1250 <br />
|825 <br />
|625 <br />
|-<br />
!|2000 <br />
|1500 <br />
|1320 <br />
|1000 <br />
|660 <br />
|500 <br />
|-<br />
!|1500 <br />
|1125 <br />
|990 <br />
|750 <br />
|495 <br />
|375 <br />
|-<br />
!|1000 <br />
|750 <br />
|660 <br />
|500 <br />
|330 <br />
|250 <br />
|-<br />
!|500 <br />
|375 <br />
|330 <br />
|250 <br />
|165 <br />
|125 <br />
|-<br />
|}<br />
<br />
=== Sample feed rates ===<br />
<br />
For working out feeds and speeds, recommend http://www.cnccookbook.com/CCGWizard.<br />
<br />
The feeds and speeds below have been tested on our machine. The 3mm cutters were single flute carbide. 2 flute HSS cutters may require different settings to avoid breakages.<br />
<br />
{| class="wikitable"<br />
!|MDF <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep <br />
|-<br />
!|3mm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|-<br />
!|6mm <br />
|3000/15Krpm <br />
|2000/13Krpm <br />
|1500/11Krpm <br />
|-<br />
!|22mm <br />
|3000/5000rpm <br />
|3000/5000rpm <br />
|1500/4Krpm<br />
|-<br />
|}<br />
<br />
{| class="wikitable"<br />
!|Plywood <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep<br />
|-<br />
!|3mm <br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|-<br />
!|6mm <br />
|3000/15Krpm <br />
|1500/15Krpm <br />
|1000/11Krpm <br />
|-<br />
!|22mm <br />
|3000/5Krpm <br />
|3000/5Krpm <br />
|1500/4Krpm <br />
|-<br />
|}<br />
<br />
== Tips & Tricks ==<br />
<br />
= Maintenance =<br />
<br />
The maintenance of the CNC Router is carried out by the Owners, with some basic maintenance being carried out by Users on every job.<br />
<br />
== Maintenance Schedule ==<br />
Every job<br />
* Vacuum cutting dust from bed and around machine<br />
* Sand down high points created on sacrificial bed by cutting/screwing<br />
<br />
As required, by users<br />
* Empty extraction bin <br />
<br />
Monthly<br />
* Inspect extraction hoses for splits/ wear<br />
* Clean and oil guide rails<br />
* Check level and condition of cooling water and replace as necessary<br />
* Inspect sacrificial bed, re-skim or replace as required<br />
<br />
== Maintenance Log ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
3/7/13: Lower spindle clamp bolts replaced with longer stainless ones, holes through tapped as original ones had stripped.<br />
<br />
== Maintenance Shopping List ==<br />
<br />
* Cutters<br />
* Sacrificial Bed (1.2m x 1.2m 12mm MDF)<br />
<br />
= Further Information =<br />
<br />
== Installation ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
<gallery><br />
File:Photo_1.JPG<br />
File:WP_20130509_005.jpg<br />
File:CNC_Router_controller_1.jpg<br />
File:CNC_Router_controller_2.jpg<br />
</gallery><br />
<br />
== Purchase ==<br />
Full Purchase, Delivery and Installation (£?????)<br />
<br />
== Notes ==<br />
<br />
http://www.shopbottools.com/mProducts/prSstandard.htm</div>Perfectphasehttp://wiki.makespace.org/Equipment/CNC_RouterEquipment/CNC Router2013-08-13T23:12:14Z<p>Perfectphase: /* Router Bits */</p>
<hr />
<div>{{RedTool}}<br />
<br />
[[Equipment|Equipment]] / CNC Router<br />
<br />
[[File:WP_20130509_005.jpg|thumb|460px|right|CNC Router]]<br />
<br />
<br />
== Summary ==<br />
<br />
A CNC router is a computer controlled shaping machine. These are related to the hand held router. Instead of hand held routing, the tool paths can be controlled via computer numerical control. It is a computer-controlled machine for cutting various hard materials, such as wood, composites, aluminum, steel, plastics, and foams. It is one of many kinds of tools that have CNC variants. A CNC router is very similar in concept to a CNC milling machine. The CNC router is controlled by a computer. Coordinates are uploaded into the machine controller from a separate CAD program<br />
<br />
* Capacity: 1200 x 1200 x 120mm<br />
* Rate (X,Y): 6000mm/min (Max) 5000mm/min (Working)<br />
* Rate (Z): 30mm/sec<br />
* Spindle Speed: 4500 to 24000rpm<br />
* Mechanical Precision: 0.01mm<br />
* Spindle Power: 1.5KW Variable Speed, Water-cooled<br />
* Blade Diameter: min 3.175mm, max 12.7mm <br />
* Order Format: HPGL, G code, u00, mmg, plt <br />
* Control System: DSP with USB connection <br />
<br />
Here are some examples we've made on the CNC router (please add a photo of yours any time you do a job!) <br />
<br />
<gallery><br />
File:WP_20130509_004.jpg<br />
File:WP_20130624_017.jpg<br />
File:WP_20130625_001.jpg<br />
</gallery><br />
<br />
= Using the CNC Router =<br />
== Owners ==<br />
<br />
The Owners are those who have volunteered to be in charge of the equipment, organising maintenance, training others to use it, and generally being a point of contact. The current Owners of the CNC Router are:<br />
<br />
* Stephen Woolhead<br />
* Chris Abri<br />
* Mark Mellors<br />
* Dave Ansell<br />
* David Bebb<br />
* Simon Stirley<br />
<br />
If you have any questions, problems or concerns around the CNC router, please use the mailing list thread:<br />
* [https://groups.google.com/d/topic/cammakespace/rkchD7VqM2c/discussion Log : CNC Router]<br />
<br />
== Training ==<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>YOU CAN ONLY USE THE CNC ROUTER IF YOU HAVE BEEN TRAINED</b><br><br />
and have been added to the [[Equipment/CNC_Router/Training#Trained_Users|Trained Users]] list by one of the Owners<br />
</div><br />
<br />
To get trained on the CNC router and be added to the qualified user list, you will need to arrange for a training session with one of the Owners. <br />
<br />
If you'd like to arrange training, please see:<br />
* [[Equipment/CNC_Router/Training|CNC Router Training]]<br />
<br />
== Health and Safety ==<br />
<br />
The CNC Router is a potentially dangerous piece of equipment which must only be operated by members who have received appropriate training and who take due care. The top things to always remember when using the CNC Router are:<br />
* '''ONLY USE THE CNC ROUTER IF YOU ARE ON THE LIST OF TRAINED USERS'''<br />
* '''NEVER LEAVE THE CNC ROUTER RUNNING UNATTENDED'''<br />
<br />
As a trained user, you should be very aware of the following risks and how to deal with them:<br />
<br />
'''FIRE''' - Cutting with the wrong settings could result in the material igniting.<br />
<br />
'''TRAPPING''' - Stand clear of the machine while in motion.<br />
<br />
'''DUST''' - Ensure extraction system is working.<br />
<br />
'''NOISE''' - Ensure that you wear the correct PPE when working with the machine for prolonged periods.<br />
<br />
== Instructions ==<br />
<br />
[http://wiki.makespace.org/File:MPC6610_CNC_Router_Manual_v1.0-En.pdf Router Manual]<br />
<br />
[[Equipment/CNC_Router/Hand_Controller|Hand Controller Look-up Guide]]<br />
<br />
===Setting the Z Origin Using the Z0 Sensor===<br />
''A tool that has an extremely narrow tip may break when it touches the tool sensor depending on which tool is to be used.''<br />
<br />
1. Secure the workpiece on the bed, and place the Z0 sensor at the place where you want to set the Z origin on the workpiece. Face the surface of the Z0 sensor without the magnet facing upward.<br />
<br />
[[image:Mill_z0.PNG]]<br />
<br />
2. Use the handset to move the tool to the position above the sensor.<br />
<br />
3. On the handset press OK + 8(Z-0). The tool slowly descend until it contacts the sensor. When the tool rises and stops, the setting operation is complete. <br />
<br />
Note: It is important the tool is electrically conductive from tip to shaft, and the sensor is clean. Failure to check will cause damage to the tool and sensor.<br />
<br />
4. Remove the sensor from the workpiece to a location where it will not interfere with future cutting operations.<br />
<br />
==Software==<br />
<br />
The standard software is Vectric's line of CAM software:<br />
<br />
===VCarvePro===<br />
<br />
[[image:Vcarvepro.png]]<br />
<br />
VCarve Pro provides a powerful but intuitive software solution for 2D design and calculation of 2D and 2.5D toolpaths for cutting parts on a CNC Router. <br />
<br />
The software can import 2D designs from other programs but also includes a full set of drawing and editing tools with advanced layout options such as True-Shape Nesting. The toolpath options cover all typical 2D routing operations such as Profiling, Pocketing, Auto-Inlays and Drilling as well as 2.5D strategies such as V-Carving, Prism carving, Fluting and even a decorative Texturing strategy. Each toolpath includes appropriate options to customize the settings and provide a high level of control for different types of operation. In addition all toolpaths can be previewed to show just how the part will look when it is actually cut, this allows instant feedback to allow toolpaths to be further optimized. <br />
<br />
'''Details''': http://www.vectric.com/products/vcarve-pro.htm<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/vcarve-pro<br />
<br />
===Cut3D===<br />
<br />
[[image:Vectric-cut3d.jpg|266px]]<br />
<br />
Cut3D is a dedicated toolpath engine for CNC machining 3D models that have been designed using a 3D CAD or Graphics design product such as AutoCAD, Rhino3D, 3D Studio etc. or scanned using a laser or touch probe device. Cut3D's exceptionally easy to use interface leads you step-by-step through the process of loading a model, setting the size, interactively placing tabs to hold the job in place, calculating single, double or four sided roughing and finishing toolpaths, previewing the results and finally saving the CNC code to run on your machine.<br />
<br />
3D Models that are too large / thick to machine because of gantry height, cutter length or limited material thickness can be 'Sliced' into separate pieces. Each slice can then be machined and the complete job assembled. <br />
<br />
'''Details''': http://www.vectric.com/products/cut3d.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/cut3d<br />
<br />
===PhotoVCarve===<br />
<br />
[[image:Vectric-photovcarve.gif|266px]]<br />
<br />
PhotoVCarve creates lines of grooves that vary in width and depth to represent the detail in a photograph or image. The quality of the finished result is very dependant upon a high level of contrast between the material surface and the machined grooves. This information is very important to remember when cutting designs using the PhotoVCarve software. <br />
<br />
PhotoVCarve machines dark areas in a photograph with wide groove and the lighter areas to have narrower ones. The software automatically calculates the toolpaths based on the cutter selected and maximum depth of groove required. <br />
<br />
'''Details''': http://www.vectric.com/products/photovcarve.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/photovcarve<br />
<br />
== Tooling ==<br />
<br />
=== Router Bits ===<br />
<br />
Router bits (or cutters) are the most common type of cutter, they have two or more vertical cutting edges. These are good general purpose cutters that can be found in most DIY shops. They are the same type that you would use in a manual hand held router.<br />
<br />
<gallery><br />
File:WP_20130813_025.jpg<br />
File:WP_20130813_025.jpg<br />
File:WP_20130814_002.jpg<br />
File:WP_20130814_003.jpg<br />
</gallery><br />
<br />
It is important to notice that the cutters are on the edge of the body only, they do not extend to the centre of the cutter. This means the cutter CAN NOT BE USED AS A DRILL. An holes that are made by these sorts of cutters must be made by ramping the cutter to the correct depth in a sloping or spiral motion.<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>NEVER USE ROUTER BITS THAT HAVE BEARINGS.</b> These types of cutters are designed for manual routers where you can feel the feed back of the bearing in contact with the material being cut. A CNC device has no such feedback and will press the bearing into the material has hard as it can until something gives, i.e. the cutter breaks or much worse the spindle breaks. People found using these types of cutters on the CNC router will be BANNED! Just use the version without the bearing.<br />
<br />
<gallery><br />
File:WP_20130813_018.jpg<br />
</gallery><br />
<br />
The cutting edges should always be the lowest part of the cutter.<br />
</div><br />
<br />
=== End mills ===<br />
<br />
'''Up Cut and Down Cut'''<br />
<br />
Router end mills have two variants, up cut (left) and down cut (right); there is a third type, compression, but they are quite rare.<br />
<br />
<gallery><br />
File:WP_20130813_015.jpg<br />
</gallery><br />
<br />
Most cutters are up cut, which have the cutting service on the top of the flutes and as they rotate lift the chips up and away from the material being cut.<br />
<br />
Down cut cutters have the cutting edge on the bottom of the flutes and push chips down towards the material being cut. This has the advantage of pressing the material being cut into the bed of the machine; this is especially useful for thin plastics. The other advantage is the top surface shows far less breakout and splintering, this is a big advantage for materials like laminates.<br />
<br />
On image on the left has been cut with an up-cut end mill and the image on the right a down-cut.<br />
<br />
<gallery><br />
File:WP_20130813_005.jpg<br />
File:WP_20130813_007.jpg<br />
</gallery><br />
<br />
NOTE: There is a very big disadvantage to down cut end mills, and that is that they do not clear there chips effectively in blind holes. This means they need larger ramping moves to get to the correct cutting depth and if used in pockets without enough clearance, the friction can lead to burning or melting of the material being cut.<br />
<br />
Another down side to down-cut cutters, is that when cutting pockets, the bottom surface will not be as clean as that made with an up-cut cutter, which will do a far better job of clearing the waste chips that rub between the cutter and the material with a down-cut.<br />
<br />
== Stock Tooling ==<br />
<br />
In order to keep a small stock of cutters for general use, the CNC Router needs to have a means of generating money. Because there is no material provided for use with the CNC Router there is no way to bring in any funds for such things. Therefore, we ask that if you use one of the communal cutters please put 50p into the CNC Router Honesty Box. This will go towards funding for replenishing stock and also for the replacement of the sacrificial bed once it gets worn out.<br />
<br />
There will likely be 1 or two of each of the following cutters available for use, however please do not count on this being the case:<br />
<br />
* 2.5mm square cutter - single flute<br />
* 1/8" square cutter - single flute<br />
* 1/8" ball cutter - 2 flute<br />
<br />
* 6mm square cutter - 2 flute<br />
* 6mm ball cutter - 2 flute<br />
<br />
* engraver 0.2 30deg 1/8" 30mm length (8 of)<br />
* engraver 0.8 30deg 1/8" 30mm length (2 of)<br />
<br />
* 22mm 2 flute straight <br />
* 90deg x 32mm VBit<br />
<br />
<br />
Some Suppliers are listed below:<br />
<br />
== Feeds & Speeds ==<br />
<br />
What are feeds and speeds? Why are they important?<br />
<br />
[http://www.youtube.com/watch?v=ip2jm_6aUyk&feature=c4-overview&list=UUivA7_KLKWo43tFcCkFvydw Milling machine tutorial - cutter selection, speeds and feeds]<br />
<br />
[http://en.wikipedia.org/wiki/Speeds_and_feeds Wikipedia - Speeds and feeds]<br />
<br />
The phrase speeds and feeds (or feeds and speeds) refers to two separate velocities in machine tool practice, cutting speed and feed rate. They are often considered as a pair because of their combined effect on the cutting process. Each, however, can also be considered and analyzed in its own right.<br />
<br />
Cutting speed (also called surface speed or simply speed) is the speed difference (relative velocity) between the cutting tool and the surface of the workpiece it is operating on. It is expressed in units of distance along the workpiece surface per unit of time, typically surface feet per minute (sfm) or meters per minute (m/min). Feed rate (also often styled as a solid compound, feedrate, or called simply feed) is the relative velocity at which the cutter is advanced along the workpiece; its vector is perpendicular to the vector of cutting speed. Feed rate units depend on the motion of the tool and workpiece; when the workpiece rotates (e.g., in turning and boring), the units are almost always distance per spindle revolution (inches per revolution [in/rev or ipr] or millimeters per revolution [mm/rev]). When the workpiece does not rotate (e.g., in milling), the units are typically distance per time (inches per minute [in/min or ipm] or millimeters per minute [mm/min]), although distance per revolution or per cutter tooth are also sometimes used.<br />
<br />
===Spindle speed quick reference===<br />
<br />
{| class="wikitable"<br />
!|<br />
!|400Hz <br />
!|350Hz <br />
!|300Hz <br />
!|250Hz <br />
!|200Hz <br />
!|150Hz <br />
|-<br />
!|RPM<br />
|24000 <br />
|21000 <br />
|18000 <br />
|15000 <br />
|12000 <br />
|9000 <br />
|-<br />
|}<br />
<br />
===Feed rate quick reference===<br />
<br />
{| class="wikitable" <br />
!|100% <br />
!|75% <br />
!|66% <br />
!|50% <br />
!|33% <br />
!|25% <br />
|-<br />
!|6000<br />
|4500<br />
|3960<br />
|3000<br />
|1980<br />
|1500<br />
|-<br />
!|5000<br />
|3750<br />
|3300<br />
|2500<br />
|1650<br />
|1250<br />
|-<br />
!|4000<br />
|3000<br />
|2640<br />
|2000<br />
|1320<br />
|1000<br />
|-<br />
!|3000 <br />
|2250 <br />
|1980 <br />
|1500 <br />
|990 <br />
|750 <br />
|-<br />
!|2500 <br />
|1875 <br />
|1650 <br />
|1250 <br />
|825 <br />
|625 <br />
|-<br />
!|2000 <br />
|1500 <br />
|1320 <br />
|1000 <br />
|660 <br />
|500 <br />
|-<br />
!|1500 <br />
|1125 <br />
|990 <br />
|750 <br />
|495 <br />
|375 <br />
|-<br />
!|1000 <br />
|750 <br />
|660 <br />
|500 <br />
|330 <br />
|250 <br />
|-<br />
!|500 <br />
|375 <br />
|330 <br />
|250 <br />
|165 <br />
|125 <br />
|-<br />
|}<br />
<br />
=== Sample feed rates ===<br />
<br />
For working out feeds and speeds, recommend http://www.cnccookbook.com/CCGWizard.<br />
<br />
The feeds and speeds below have been tested on our machine. The 3mm cutters were single flute carbide. 2 flute HSS cutters may require different settings to avoid breakages.<br />
<br />
{| class="wikitable"<br />
!|MDF <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep <br />
|-<br />
!|3mm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|-<br />
!|6mm <br />
|3000/15Krpm <br />
|2000/13Krpm <br />
|1500/11Krpm <br />
|-<br />
!|22mm <br />
|3000/5000rpm <br />
|3000/5000rpm <br />
|1500/4Krpm<br />
|-<br />
|}<br />
<br />
{| class="wikitable"<br />
!|Plywood <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep<br />
|-<br />
!|3mm <br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|-<br />
!|6mm <br />
|3000/15Krpm <br />
|1500/15Krpm <br />
|1000/11Krpm <br />
|-<br />
!|22mm <br />
|3000/5Krpm <br />
|3000/5Krpm <br />
|1500/4Krpm <br />
|-<br />
|}<br />
<br />
== Tips & Tricks ==<br />
<br />
= Maintenance =<br />
<br />
The maintenance of the CNC Router is carried out by the Owners, with some basic maintenance being carried out by Users on every job.<br />
<br />
== Maintenance Schedule ==<br />
Every job<br />
* Vacuum cutting dust from bed and around machine<br />
* Sand down high points created on sacrificial bed by cutting/screwing<br />
<br />
As required, by users<br />
* Empty extraction bin <br />
<br />
Monthly<br />
* Inspect extraction hoses for splits/ wear<br />
* Clean and oil guide rails<br />
* Check level and condition of cooling water and replace as necessary<br />
* Inspect sacrificial bed, re-skim or replace as required<br />
<br />
== Maintenance Log ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
3/7/13: Lower spindle clamp bolts replaced with longer stainless ones, holes through tapped as original ones had stripped.<br />
<br />
== Maintenance Shopping List ==<br />
<br />
* Cutters<br />
* Sacrificial Bed (1.2m x 1.2m 12mm MDF)<br />
<br />
= Further Information =<br />
<br />
== Installation ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
<gallery><br />
File:Photo_1.JPG<br />
File:WP_20130509_005.jpg<br />
File:CNC_Router_controller_1.jpg<br />
File:CNC_Router_controller_2.jpg<br />
</gallery><br />
<br />
== Purchase ==<br />
Full Purchase, Delivery and Installation (£?????)<br />
<br />
== Notes ==<br />
<br />
http://www.shopbottools.com/mProducts/prSstandard.htm</div>Perfectphasehttp://wiki.makespace.org/Equipment/CNC_RouterEquipment/CNC Router2013-08-13T23:11:10Z<p>Perfectphase: /* Router Bits */</p>
<hr />
<div>{{RedTool}}<br />
<br />
[[Equipment|Equipment]] / CNC Router<br />
<br />
[[File:WP_20130509_005.jpg|thumb|460px|right|CNC Router]]<br />
<br />
<br />
== Summary ==<br />
<br />
A CNC router is a computer controlled shaping machine. These are related to the hand held router. Instead of hand held routing, the tool paths can be controlled via computer numerical control. It is a computer-controlled machine for cutting various hard materials, such as wood, composites, aluminum, steel, plastics, and foams. It is one of many kinds of tools that have CNC variants. A CNC router is very similar in concept to a CNC milling machine. The CNC router is controlled by a computer. Coordinates are uploaded into the machine controller from a separate CAD program<br />
<br />
* Capacity: 1200 x 1200 x 120mm<br />
* Rate (X,Y): 6000mm/min (Max) 5000mm/min (Working)<br />
* Rate (Z): 30mm/sec<br />
* Spindle Speed: 4500 to 24000rpm<br />
* Mechanical Precision: 0.01mm<br />
* Spindle Power: 1.5KW Variable Speed, Water-cooled<br />
* Blade Diameter: min 3.175mm, max 12.7mm <br />
* Order Format: HPGL, G code, u00, mmg, plt <br />
* Control System: DSP with USB connection <br />
<br />
Here are some examples we've made on the CNC router (please add a photo of yours any time you do a job!) <br />
<br />
<gallery><br />
File:WP_20130509_004.jpg<br />
File:WP_20130624_017.jpg<br />
File:WP_20130625_001.jpg<br />
</gallery><br />
<br />
= Using the CNC Router =<br />
== Owners ==<br />
<br />
The Owners are those who have volunteered to be in charge of the equipment, organising maintenance, training others to use it, and generally being a point of contact. The current Owners of the CNC Router are:<br />
<br />
* Stephen Woolhead<br />
* Chris Abri<br />
* Mark Mellors<br />
* Dave Ansell<br />
* David Bebb<br />
* Simon Stirley<br />
<br />
If you have any questions, problems or concerns around the CNC router, please use the mailing list thread:<br />
* [https://groups.google.com/d/topic/cammakespace/rkchD7VqM2c/discussion Log : CNC Router]<br />
<br />
== Training ==<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>YOU CAN ONLY USE THE CNC ROUTER IF YOU HAVE BEEN TRAINED</b><br><br />
and have been added to the [[Equipment/CNC_Router/Training#Trained_Users|Trained Users]] list by one of the Owners<br />
</div><br />
<br />
To get trained on the CNC router and be added to the qualified user list, you will need to arrange for a training session with one of the Owners. <br />
<br />
If you'd like to arrange training, please see:<br />
* [[Equipment/CNC_Router/Training|CNC Router Training]]<br />
<br />
== Health and Safety ==<br />
<br />
The CNC Router is a potentially dangerous piece of equipment which must only be operated by members who have received appropriate training and who take due care. The top things to always remember when using the CNC Router are:<br />
* '''ONLY USE THE CNC ROUTER IF YOU ARE ON THE LIST OF TRAINED USERS'''<br />
* '''NEVER LEAVE THE CNC ROUTER RUNNING UNATTENDED'''<br />
<br />
As a trained user, you should be very aware of the following risks and how to deal with them:<br />
<br />
'''FIRE''' - Cutting with the wrong settings could result in the material igniting.<br />
<br />
'''TRAPPING''' - Stand clear of the machine while in motion.<br />
<br />
'''DUST''' - Ensure extraction system is working.<br />
<br />
'''NOISE''' - Ensure that you wear the correct PPE when working with the machine for prolonged periods.<br />
<br />
== Instructions ==<br />
<br />
[http://wiki.makespace.org/File:MPC6610_CNC_Router_Manual_v1.0-En.pdf Router Manual]<br />
<br />
[[Equipment/CNC_Router/Hand_Controller|Hand Controller Look-up Guide]]<br />
<br />
===Setting the Z Origin Using the Z0 Sensor===<br />
''A tool that has an extremely narrow tip may break when it touches the tool sensor depending on which tool is to be used.''<br />
<br />
1. Secure the workpiece on the bed, and place the Z0 sensor at the place where you want to set the Z origin on the workpiece. Face the surface of the Z0 sensor without the magnet facing upward.<br />
<br />
[[image:Mill_z0.PNG]]<br />
<br />
2. Use the handset to move the tool to the position above the sensor.<br />
<br />
3. On the handset press OK + 8(Z-0). The tool slowly descend until it contacts the sensor. When the tool rises and stops, the setting operation is complete. <br />
<br />
Note: It is important the tool is electrically conductive from tip to shaft, and the sensor is clean. Failure to check will cause damage to the tool and sensor.<br />
<br />
4. Remove the sensor from the workpiece to a location where it will not interfere with future cutting operations.<br />
<br />
==Software==<br />
<br />
The standard software is Vectric's line of CAM software:<br />
<br />
===VCarvePro===<br />
<br />
[[image:Vcarvepro.png]]<br />
<br />
VCarve Pro provides a powerful but intuitive software solution for 2D design and calculation of 2D and 2.5D toolpaths for cutting parts on a CNC Router. <br />
<br />
The software can import 2D designs from other programs but also includes a full set of drawing and editing tools with advanced layout options such as True-Shape Nesting. The toolpath options cover all typical 2D routing operations such as Profiling, Pocketing, Auto-Inlays and Drilling as well as 2.5D strategies such as V-Carving, Prism carving, Fluting and even a decorative Texturing strategy. Each toolpath includes appropriate options to customize the settings and provide a high level of control for different types of operation. In addition all toolpaths can be previewed to show just how the part will look when it is actually cut, this allows instant feedback to allow toolpaths to be further optimized. <br />
<br />
'''Details''': http://www.vectric.com/products/vcarve-pro.htm<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/vcarve-pro<br />
<br />
===Cut3D===<br />
<br />
[[image:Vectric-cut3d.jpg|266px]]<br />
<br />
Cut3D is a dedicated toolpath engine for CNC machining 3D models that have been designed using a 3D CAD or Graphics design product such as AutoCAD, Rhino3D, 3D Studio etc. or scanned using a laser or touch probe device. Cut3D's exceptionally easy to use interface leads you step-by-step through the process of loading a model, setting the size, interactively placing tabs to hold the job in place, calculating single, double or four sided roughing and finishing toolpaths, previewing the results and finally saving the CNC code to run on your machine.<br />
<br />
3D Models that are too large / thick to machine because of gantry height, cutter length or limited material thickness can be 'Sliced' into separate pieces. Each slice can then be machined and the complete job assembled. <br />
<br />
'''Details''': http://www.vectric.com/products/cut3d.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/cut3d<br />
<br />
===PhotoVCarve===<br />
<br />
[[image:Vectric-photovcarve.gif|266px]]<br />
<br />
PhotoVCarve creates lines of grooves that vary in width and depth to represent the detail in a photograph or image. The quality of the finished result is very dependant upon a high level of contrast between the material surface and the machined grooves. This information is very important to remember when cutting designs using the PhotoVCarve software. <br />
<br />
PhotoVCarve machines dark areas in a photograph with wide groove and the lighter areas to have narrower ones. The software automatically calculates the toolpaths based on the cutter selected and maximum depth of groove required. <br />
<br />
'''Details''': http://www.vectric.com/products/photovcarve.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/photovcarve<br />
<br />
== Tooling ==<br />
<br />
=== Router Bits ===<br />
<br />
Router bits (or cutters) are the most common type of cutter, they have two or more vertical cutting edges. These are good general purpose cutters that can be found in most DIY shops. They are the same type that you would use in a manual hand held router.<br />
<br />
<gallery><br />
File:WP_20130813_025.jpg<br />
File:WP_20130813_025.jpg<br />
File:WP_20130814_002.jpg<br />
File:WP_20130814_003.jpg<br />
</gallery><br />
<br />
It is important to notice that the cutters are on the edge of the body only, they do not extend to the centre of the cutter. This means the cutter CAN NOT BE USED AS A DRILL. An holes that are made by these sorts of cutters must be made by ramping the cutter to the correct depth in a sloping or spiral motion.<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>NEVER USE ROUTER BITS THAT HAVE BEARINGS.</b> These types of cutters are designed for manual routers where you can feel the feed back of the bearing in contact with the material being cut. A CNC device as no such feedback and will press the bearing into the material has hard as it can until something gives, i.e. the cutter breaks or much worse the spindle breaks. People found using these types of cutters on the CNC router will be BANNED! Just use the version without the bearing.<br />
<br />
<gallery><br />
File:WP_20130813_018.jpg<br />
</gallery><br />
<br />
The cutting edges should always be the lowest part of the cutter.<br />
</div><br />
<br />
=== End mills ===<br />
<br />
'''Up Cut and Down Cut'''<br />
<br />
Router end mills have two variants, up cut (left) and down cut (right); there is a third type, compression, but they are quite rare.<br />
<br />
<gallery><br />
File:WP_20130813_015.jpg<br />
</gallery><br />
<br />
Most cutters are up cut, which have the cutting service on the top of the flutes and as they rotate lift the chips up and away from the material being cut.<br />
<br />
Down cut cutters have the cutting edge on the bottom of the flutes and push chips down towards the material being cut. This has the advantage of pressing the material being cut into the bed of the machine; this is especially useful for thin plastics. The other advantage is the top surface shows far less breakout and splintering, this is a big advantage for materials like laminates.<br />
<br />
On image on the left has been cut with an up-cut end mill and the image on the right a down-cut.<br />
<br />
<gallery><br />
File:WP_20130813_005.jpg<br />
File:WP_20130813_007.jpg<br />
</gallery><br />
<br />
NOTE: There is a very big disadvantage to down cut end mills, and that is that they do not clear there chips effectively in blind holes. This means they need larger ramping moves to get to the correct cutting depth and if used in pockets without enough clearance, the friction can lead to burning or melting of the material being cut.<br />
<br />
Another down side to down-cut cutters, is that when cutting pockets, the bottom surface will not be as clean as that made with an up-cut cutter, which will do a far better job of clearing the waste chips that rub between the cutter and the material with a down-cut.<br />
<br />
== Stock Tooling ==<br />
<br />
In order to keep a small stock of cutters for general use, the CNC Router needs to have a means of generating money. Because there is no material provided for use with the CNC Router there is no way to bring in any funds for such things. Therefore, we ask that if you use one of the communal cutters please put 50p into the CNC Router Honesty Box. This will go towards funding for replenishing stock and also for the replacement of the sacrificial bed once it gets worn out.<br />
<br />
There will likely be 1 or two of each of the following cutters available for use, however please do not count on this being the case:<br />
<br />
* 2.5mm square cutter - single flute<br />
* 1/8" square cutter - single flute<br />
* 1/8" ball cutter - 2 flute<br />
<br />
* 6mm square cutter - 2 flute<br />
* 6mm ball cutter - 2 flute<br />
<br />
* engraver 0.2 30deg 1/8" 30mm length (8 of)<br />
* engraver 0.8 30deg 1/8" 30mm length (2 of)<br />
<br />
* 22mm 2 flute straight <br />
* 90deg x 32mm VBit<br />
<br />
<br />
Some Suppliers are listed below:<br />
<br />
== Feeds & Speeds ==<br />
<br />
What are feeds and speeds? Why are they important?<br />
<br />
[http://www.youtube.com/watch?v=ip2jm_6aUyk&feature=c4-overview&list=UUivA7_KLKWo43tFcCkFvydw Milling machine tutorial - cutter selection, speeds and feeds]<br />
<br />
[http://en.wikipedia.org/wiki/Speeds_and_feeds Wikipedia - Speeds and feeds]<br />
<br />
The phrase speeds and feeds (or feeds and speeds) refers to two separate velocities in machine tool practice, cutting speed and feed rate. They are often considered as a pair because of their combined effect on the cutting process. Each, however, can also be considered and analyzed in its own right.<br />
<br />
Cutting speed (also called surface speed or simply speed) is the speed difference (relative velocity) between the cutting tool and the surface of the workpiece it is operating on. It is expressed in units of distance along the workpiece surface per unit of time, typically surface feet per minute (sfm) or meters per minute (m/min). Feed rate (also often styled as a solid compound, feedrate, or called simply feed) is the relative velocity at which the cutter is advanced along the workpiece; its vector is perpendicular to the vector of cutting speed. Feed rate units depend on the motion of the tool and workpiece; when the workpiece rotates (e.g., in turning and boring), the units are almost always distance per spindle revolution (inches per revolution [in/rev or ipr] or millimeters per revolution [mm/rev]). When the workpiece does not rotate (e.g., in milling), the units are typically distance per time (inches per minute [in/min or ipm] or millimeters per minute [mm/min]), although distance per revolution or per cutter tooth are also sometimes used.<br />
<br />
===Spindle speed quick reference===<br />
<br />
{| class="wikitable"<br />
!|<br />
!|400Hz <br />
!|350Hz <br />
!|300Hz <br />
!|250Hz <br />
!|200Hz <br />
!|150Hz <br />
|-<br />
!|RPM<br />
|24000 <br />
|21000 <br />
|18000 <br />
|15000 <br />
|12000 <br />
|9000 <br />
|-<br />
|}<br />
<br />
===Feed rate quick reference===<br />
<br />
{| class="wikitable" <br />
!|100% <br />
!|75% <br />
!|66% <br />
!|50% <br />
!|33% <br />
!|25% <br />
|-<br />
!|6000<br />
|4500<br />
|3960<br />
|3000<br />
|1980<br />
|1500<br />
|-<br />
!|5000<br />
|3750<br />
|3300<br />
|2500<br />
|1650<br />
|1250<br />
|-<br />
!|4000<br />
|3000<br />
|2640<br />
|2000<br />
|1320<br />
|1000<br />
|-<br />
!|3000 <br />
|2250 <br />
|1980 <br />
|1500 <br />
|990 <br />
|750 <br />
|-<br />
!|2500 <br />
|1875 <br />
|1650 <br />
|1250 <br />
|825 <br />
|625 <br />
|-<br />
!|2000 <br />
|1500 <br />
|1320 <br />
|1000 <br />
|660 <br />
|500 <br />
|-<br />
!|1500 <br />
|1125 <br />
|990 <br />
|750 <br />
|495 <br />
|375 <br />
|-<br />
!|1000 <br />
|750 <br />
|660 <br />
|500 <br />
|330 <br />
|250 <br />
|-<br />
!|500 <br />
|375 <br />
|330 <br />
|250 <br />
|165 <br />
|125 <br />
|-<br />
|}<br />
<br />
=== Sample feed rates ===<br />
<br />
For working out feeds and speeds, recommend http://www.cnccookbook.com/CCGWizard.<br />
<br />
The feeds and speeds below have been tested on our machine. The 3mm cutters were single flute carbide. 2 flute HSS cutters may require different settings to avoid breakages.<br />
<br />
{| class="wikitable"<br />
!|MDF <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep <br />
|-<br />
!|3mm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|-<br />
!|6mm <br />
|3000/15Krpm <br />
|2000/13Krpm <br />
|1500/11Krpm <br />
|-<br />
!|22mm <br />
|3000/5000rpm <br />
|3000/5000rpm <br />
|1500/4Krpm<br />
|-<br />
|}<br />
<br />
{| class="wikitable"<br />
!|Plywood <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep<br />
|-<br />
!|3mm <br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|-<br />
!|6mm <br />
|3000/15Krpm <br />
|1500/15Krpm <br />
|1000/11Krpm <br />
|-<br />
!|22mm <br />
|3000/5Krpm <br />
|3000/5Krpm <br />
|1500/4Krpm <br />
|-<br />
|}<br />
<br />
== Tips & Tricks ==<br />
<br />
= Maintenance =<br />
<br />
The maintenance of the CNC Router is carried out by the Owners, with some basic maintenance being carried out by Users on every job.<br />
<br />
== Maintenance Schedule ==<br />
Every job<br />
* Vacuum cutting dust from bed and around machine<br />
* Sand down high points created on sacrificial bed by cutting/screwing<br />
<br />
As required, by users<br />
* Empty extraction bin <br />
<br />
Monthly<br />
* Inspect extraction hoses for splits/ wear<br />
* Clean and oil guide rails<br />
* Check level and condition of cooling water and replace as necessary<br />
* Inspect sacrificial bed, re-skim or replace as required<br />
<br />
== Maintenance Log ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
3/7/13: Lower spindle clamp bolts replaced with longer stainless ones, holes through tapped as original ones had stripped.<br />
<br />
== Maintenance Shopping List ==<br />
<br />
* Cutters<br />
* Sacrificial Bed (1.2m x 1.2m 12mm MDF)<br />
<br />
= Further Information =<br />
<br />
== Installation ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
<gallery><br />
File:Photo_1.JPG<br />
File:WP_20130509_005.jpg<br />
File:CNC_Router_controller_1.jpg<br />
File:CNC_Router_controller_2.jpg<br />
</gallery><br />
<br />
== Purchase ==<br />
Full Purchase, Delivery and Installation (£?????)<br />
<br />
== Notes ==<br />
<br />
http://www.shopbottools.com/mProducts/prSstandard.htm</div>Perfectphasehttp://wiki.makespace.org/Equipment/CNC_RouterEquipment/CNC Router2013-08-13T23:09:41Z<p>Perfectphase: /* Router Bits */</p>
<hr />
<div>{{RedTool}}<br />
<br />
[[Equipment|Equipment]] / CNC Router<br />
<br />
[[File:WP_20130509_005.jpg|thumb|460px|right|CNC Router]]<br />
<br />
<br />
== Summary ==<br />
<br />
A CNC router is a computer controlled shaping machine. These are related to the hand held router. Instead of hand held routing, the tool paths can be controlled via computer numerical control. It is a computer-controlled machine for cutting various hard materials, such as wood, composites, aluminum, steel, plastics, and foams. It is one of many kinds of tools that have CNC variants. A CNC router is very similar in concept to a CNC milling machine. The CNC router is controlled by a computer. Coordinates are uploaded into the machine controller from a separate CAD program<br />
<br />
* Capacity: 1200 x 1200 x 120mm<br />
* Rate (X,Y): 6000mm/min (Max) 5000mm/min (Working)<br />
* Rate (Z): 30mm/sec<br />
* Spindle Speed: 4500 to 24000rpm<br />
* Mechanical Precision: 0.01mm<br />
* Spindle Power: 1.5KW Variable Speed, Water-cooled<br />
* Blade Diameter: min 3.175mm, max 12.7mm <br />
* Order Format: HPGL, G code, u00, mmg, plt <br />
* Control System: DSP with USB connection <br />
<br />
Here are some examples we've made on the CNC router (please add a photo of yours any time you do a job!) <br />
<br />
<gallery><br />
File:WP_20130509_004.jpg<br />
File:WP_20130624_017.jpg<br />
File:WP_20130625_001.jpg<br />
</gallery><br />
<br />
= Using the CNC Router =<br />
== Owners ==<br />
<br />
The Owners are those who have volunteered to be in charge of the equipment, organising maintenance, training others to use it, and generally being a point of contact. The current Owners of the CNC Router are:<br />
<br />
* Stephen Woolhead<br />
* Chris Abri<br />
* Mark Mellors<br />
* Dave Ansell<br />
* David Bebb<br />
* Simon Stirley<br />
<br />
If you have any questions, problems or concerns around the CNC router, please use the mailing list thread:<br />
* [https://groups.google.com/d/topic/cammakespace/rkchD7VqM2c/discussion Log : CNC Router]<br />
<br />
== Training ==<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>YOU CAN ONLY USE THE CNC ROUTER IF YOU HAVE BEEN TRAINED</b><br><br />
and have been added to the [[Equipment/CNC_Router/Training#Trained_Users|Trained Users]] list by one of the Owners<br />
</div><br />
<br />
To get trained on the CNC router and be added to the qualified user list, you will need to arrange for a training session with one of the Owners. <br />
<br />
If you'd like to arrange training, please see:<br />
* [[Equipment/CNC_Router/Training|CNC Router Training]]<br />
<br />
== Health and Safety ==<br />
<br />
The CNC Router is a potentially dangerous piece of equipment which must only be operated by members who have received appropriate training and who take due care. The top things to always remember when using the CNC Router are:<br />
* '''ONLY USE THE CNC ROUTER IF YOU ARE ON THE LIST OF TRAINED USERS'''<br />
* '''NEVER LEAVE THE CNC ROUTER RUNNING UNATTENDED'''<br />
<br />
As a trained user, you should be very aware of the following risks and how to deal with them:<br />
<br />
'''FIRE''' - Cutting with the wrong settings could result in the material igniting.<br />
<br />
'''TRAPPING''' - Stand clear of the machine while in motion.<br />
<br />
'''DUST''' - Ensure extraction system is working.<br />
<br />
'''NOISE''' - Ensure that you wear the correct PPE when working with the machine for prolonged periods.<br />
<br />
== Instructions ==<br />
<br />
[http://wiki.makespace.org/File:MPC6610_CNC_Router_Manual_v1.0-En.pdf Router Manual]<br />
<br />
[[Equipment/CNC_Router/Hand_Controller|Hand Controller Look-up Guide]]<br />
<br />
===Setting the Z Origin Using the Z0 Sensor===<br />
''A tool that has an extremely narrow tip may break when it touches the tool sensor depending on which tool is to be used.''<br />
<br />
1. Secure the workpiece on the bed, and place the Z0 sensor at the place where you want to set the Z origin on the workpiece. Face the surface of the Z0 sensor without the magnet facing upward.<br />
<br />
[[image:Mill_z0.PNG]]<br />
<br />
2. Use the handset to move the tool to the position above the sensor.<br />
<br />
3. On the handset press OK + 8(Z-0). The tool slowly descend until it contacts the sensor. When the tool rises and stops, the setting operation is complete. <br />
<br />
Note: It is important the tool is electrically conductive from tip to shaft, and the sensor is clean. Failure to check will cause damage to the tool and sensor.<br />
<br />
4. Remove the sensor from the workpiece to a location where it will not interfere with future cutting operations.<br />
<br />
==Software==<br />
<br />
The standard software is Vectric's line of CAM software:<br />
<br />
===VCarvePro===<br />
<br />
[[image:Vcarvepro.png]]<br />
<br />
VCarve Pro provides a powerful but intuitive software solution for 2D design and calculation of 2D and 2.5D toolpaths for cutting parts on a CNC Router. <br />
<br />
The software can import 2D designs from other programs but also includes a full set of drawing and editing tools with advanced layout options such as True-Shape Nesting. The toolpath options cover all typical 2D routing operations such as Profiling, Pocketing, Auto-Inlays and Drilling as well as 2.5D strategies such as V-Carving, Prism carving, Fluting and even a decorative Texturing strategy. Each toolpath includes appropriate options to customize the settings and provide a high level of control for different types of operation. In addition all toolpaths can be previewed to show just how the part will look when it is actually cut, this allows instant feedback to allow toolpaths to be further optimized. <br />
<br />
'''Details''': http://www.vectric.com/products/vcarve-pro.htm<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/vcarve-pro<br />
<br />
===Cut3D===<br />
<br />
[[image:Vectric-cut3d.jpg|266px]]<br />
<br />
Cut3D is a dedicated toolpath engine for CNC machining 3D models that have been designed using a 3D CAD or Graphics design product such as AutoCAD, Rhino3D, 3D Studio etc. or scanned using a laser or touch probe device. Cut3D's exceptionally easy to use interface leads you step-by-step through the process of loading a model, setting the size, interactively placing tabs to hold the job in place, calculating single, double or four sided roughing and finishing toolpaths, previewing the results and finally saving the CNC code to run on your machine.<br />
<br />
3D Models that are too large / thick to machine because of gantry height, cutter length or limited material thickness can be 'Sliced' into separate pieces. Each slice can then be machined and the complete job assembled. <br />
<br />
'''Details''': http://www.vectric.com/products/cut3d.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/cut3d<br />
<br />
===PhotoVCarve===<br />
<br />
[[image:Vectric-photovcarve.gif|266px]]<br />
<br />
PhotoVCarve creates lines of grooves that vary in width and depth to represent the detail in a photograph or image. The quality of the finished result is very dependant upon a high level of contrast between the material surface and the machined grooves. This information is very important to remember when cutting designs using the PhotoVCarve software. <br />
<br />
PhotoVCarve machines dark areas in a photograph with wide groove and the lighter areas to have narrower ones. The software automatically calculates the toolpaths based on the cutter selected and maximum depth of groove required. <br />
<br />
'''Details''': http://www.vectric.com/products/photovcarve.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/photovcarve<br />
<br />
== Tooling ==<br />
<br />
=== Router Bits ===<br />
<br />
Router bits (or cutters) are the most common type of cutter, they have two or more vertical cutting edges. These are good general purpose cutters that can be found in most DIY shops. The are the same type that you would use in a manual hand held router.<br />
<br />
<gallery><br />
File:WP_20130813_025.jpg<br />
File:WP_20130813_025.jpg<br />
File:WP_20130814_002.jpg<br />
File:WP_20130814_003.jpg<br />
</gallery><br />
<br />
It is important to notice that the cutters are on the edge of the body only, they do not extend to the centre of the cutter. This means the cutter CAN NOT BE USED AS A DRILL. An holes that are made by these sorts of cutters must be made by ramping the cutter to the correct depth in a sloping or spiral motion.<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>NEVER USE ROUTER BITS THAT HAVE BEARINGS.</b> These types of cutters are designed for manual routers where you can feel the feed back of the bearing in contact with the material being cut. A CNC device as no such feedback and will press the bearing into the material has hard as it can until something gives, i.e. the cutter breaks or much worse the spindle breaks. People found using these types of cutters on the CNC router will be BANNED! Just use the version without the bearing.<br />
<br />
<gallery><br />
File:WP_20130813_018.jpg<br />
</gallery><br />
<br />
The cutting edges should always be the lowest part of the cutter.<br />
</div><br />
<br />
=== End mills ===<br />
<br />
'''Up Cut and Down Cut'''<br />
<br />
Router end mills have two variants, up cut (left) and down cut (right); there is a third type, compression, but they are quite rare.<br />
<br />
<gallery><br />
File:WP_20130813_015.jpg<br />
</gallery><br />
<br />
Most cutters are up cut, which have the cutting service on the top of the flutes and as they rotate lift the chips up and away from the material being cut.<br />
<br />
Down cut cutters have the cutting edge on the bottom of the flutes and push chips down towards the material being cut. This has the advantage of pressing the material being cut into the bed of the machine; this is especially useful for thin plastics. The other advantage is the top surface shows far less breakout and splintering, this is a big advantage for materials like laminates.<br />
<br />
On image on the left has been cut with an up-cut end mill and the image on the right a down-cut.<br />
<br />
<gallery><br />
File:WP_20130813_005.jpg<br />
File:WP_20130813_007.jpg<br />
</gallery><br />
<br />
NOTE: There is a very big disadvantage to down cut end mills, and that is that they do not clear there chips effectively in blind holes. This means they need larger ramping moves to get to the correct cutting depth and if used in pockets without enough clearance, the friction can lead to burning or melting of the material being cut.<br />
<br />
Another down side to down-cut cutters, is that when cutting pockets, the bottom surface will not be as clean as that made with an up-cut cutter, which will do a far better job of clearing the waste chips that rub between the cutter and the material with a down-cut.<br />
<br />
== Stock Tooling ==<br />
<br />
In order to keep a small stock of cutters for general use, the CNC Router needs to have a means of generating money. Because there is no material provided for use with the CNC Router there is no way to bring in any funds for such things. Therefore, we ask that if you use one of the communal cutters please put 50p into the CNC Router Honesty Box. This will go towards funding for replenishing stock and also for the replacement of the sacrificial bed once it gets worn out.<br />
<br />
There will likely be 1 or two of each of the following cutters available for use, however please do not count on this being the case:<br />
<br />
* 2.5mm square cutter - single flute<br />
* 1/8" square cutter - single flute<br />
* 1/8" ball cutter - 2 flute<br />
<br />
* 6mm square cutter - 2 flute<br />
* 6mm ball cutter - 2 flute<br />
<br />
* engraver 0.2 30deg 1/8" 30mm length (8 of)<br />
* engraver 0.8 30deg 1/8" 30mm length (2 of)<br />
<br />
* 22mm 2 flute straight <br />
* 90deg x 32mm VBit<br />
<br />
<br />
Some Suppliers are listed below:<br />
<br />
== Feeds & Speeds ==<br />
<br />
What are feeds and speeds? Why are they important?<br />
<br />
[http://www.youtube.com/watch?v=ip2jm_6aUyk&feature=c4-overview&list=UUivA7_KLKWo43tFcCkFvydw Milling machine tutorial - cutter selection, speeds and feeds]<br />
<br />
[http://en.wikipedia.org/wiki/Speeds_and_feeds Wikipedia - Speeds and feeds]<br />
<br />
The phrase speeds and feeds (or feeds and speeds) refers to two separate velocities in machine tool practice, cutting speed and feed rate. They are often considered as a pair because of their combined effect on the cutting process. Each, however, can also be considered and analyzed in its own right.<br />
<br />
Cutting speed (also called surface speed or simply speed) is the speed difference (relative velocity) between the cutting tool and the surface of the workpiece it is operating on. It is expressed in units of distance along the workpiece surface per unit of time, typically surface feet per minute (sfm) or meters per minute (m/min). Feed rate (also often styled as a solid compound, feedrate, or called simply feed) is the relative velocity at which the cutter is advanced along the workpiece; its vector is perpendicular to the vector of cutting speed. Feed rate units depend on the motion of the tool and workpiece; when the workpiece rotates (e.g., in turning and boring), the units are almost always distance per spindle revolution (inches per revolution [in/rev or ipr] or millimeters per revolution [mm/rev]). When the workpiece does not rotate (e.g., in milling), the units are typically distance per time (inches per minute [in/min or ipm] or millimeters per minute [mm/min]), although distance per revolution or per cutter tooth are also sometimes used.<br />
<br />
===Spindle speed quick reference===<br />
<br />
{| class="wikitable"<br />
!|<br />
!|400Hz <br />
!|350Hz <br />
!|300Hz <br />
!|250Hz <br />
!|200Hz <br />
!|150Hz <br />
|-<br />
!|RPM<br />
|24000 <br />
|21000 <br />
|18000 <br />
|15000 <br />
|12000 <br />
|9000 <br />
|-<br />
|}<br />
<br />
===Feed rate quick reference===<br />
<br />
{| class="wikitable" <br />
!|100% <br />
!|75% <br />
!|66% <br />
!|50% <br />
!|33% <br />
!|25% <br />
|-<br />
!|6000<br />
|4500<br />
|3960<br />
|3000<br />
|1980<br />
|1500<br />
|-<br />
!|5000<br />
|3750<br />
|3300<br />
|2500<br />
|1650<br />
|1250<br />
|-<br />
!|4000<br />
|3000<br />
|2640<br />
|2000<br />
|1320<br />
|1000<br />
|-<br />
!|3000 <br />
|2250 <br />
|1980 <br />
|1500 <br />
|990 <br />
|750 <br />
|-<br />
!|2500 <br />
|1875 <br />
|1650 <br />
|1250 <br />
|825 <br />
|625 <br />
|-<br />
!|2000 <br />
|1500 <br />
|1320 <br />
|1000 <br />
|660 <br />
|500 <br />
|-<br />
!|1500 <br />
|1125 <br />
|990 <br />
|750 <br />
|495 <br />
|375 <br />
|-<br />
!|1000 <br />
|750 <br />
|660 <br />
|500 <br />
|330 <br />
|250 <br />
|-<br />
!|500 <br />
|375 <br />
|330 <br />
|250 <br />
|165 <br />
|125 <br />
|-<br />
|}<br />
<br />
=== Sample feed rates ===<br />
<br />
For working out feeds and speeds, recommend http://www.cnccookbook.com/CCGWizard.<br />
<br />
The feeds and speeds below have been tested on our machine. The 3mm cutters were single flute carbide. 2 flute HSS cutters may require different settings to avoid breakages.<br />
<br />
{| class="wikitable"<br />
!|MDF <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep <br />
|-<br />
!|3mm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|-<br />
!|6mm <br />
|3000/15Krpm <br />
|2000/13Krpm <br />
|1500/11Krpm <br />
|-<br />
!|22mm <br />
|3000/5000rpm <br />
|3000/5000rpm <br />
|1500/4Krpm<br />
|-<br />
|}<br />
<br />
{| class="wikitable"<br />
!|Plywood <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep<br />
|-<br />
!|3mm <br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|-<br />
!|6mm <br />
|3000/15Krpm <br />
|1500/15Krpm <br />
|1000/11Krpm <br />
|-<br />
!|22mm <br />
|3000/5Krpm <br />
|3000/5Krpm <br />
|1500/4Krpm <br />
|-<br />
|}<br />
<br />
== Tips & Tricks ==<br />
<br />
= Maintenance =<br />
<br />
The maintenance of the CNC Router is carried out by the Owners, with some basic maintenance being carried out by Users on every job.<br />
<br />
== Maintenance Schedule ==<br />
Every job<br />
* Vacuum cutting dust from bed and around machine<br />
* Sand down high points created on sacrificial bed by cutting/screwing<br />
<br />
As required, by users<br />
* Empty extraction bin <br />
<br />
Monthly<br />
* Inspect extraction hoses for splits/ wear<br />
* Clean and oil guide rails<br />
* Check level and condition of cooling water and replace as necessary<br />
* Inspect sacrificial bed, re-skim or replace as required<br />
<br />
== Maintenance Log ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
3/7/13: Lower spindle clamp bolts replaced with longer stainless ones, holes through tapped as original ones had stripped.<br />
<br />
== Maintenance Shopping List ==<br />
<br />
* Cutters<br />
* Sacrificial Bed (1.2m x 1.2m 12mm MDF)<br />
<br />
= Further Information =<br />
<br />
== Installation ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
<gallery><br />
File:Photo_1.JPG<br />
File:WP_20130509_005.jpg<br />
File:CNC_Router_controller_1.jpg<br />
File:CNC_Router_controller_2.jpg<br />
</gallery><br />
<br />
== Purchase ==<br />
Full Purchase, Delivery and Installation (£?????)<br />
<br />
== Notes ==<br />
<br />
http://www.shopbottools.com/mProducts/prSstandard.htm</div>Perfectphasehttp://wiki.makespace.org/File:WP_20130814_003.jpgFile:WP 20130814 003.jpg2013-08-13T23:09:31Z<p>Perfectphase: </p>
<hr />
<div></div>Perfectphasehttp://wiki.makespace.org/File:WP_20130814_002.jpgFile:WP 20130814 002.jpg2013-08-13T23:08:31Z<p>Perfectphase: </p>
<hr />
<div></div>Perfectphasehttp://wiki.makespace.org/Equipment/CNC_RouterEquipment/CNC Router2013-08-13T23:01:04Z<p>Perfectphase: /* Router Bits */</p>
<hr />
<div>{{RedTool}}<br />
<br />
[[Equipment|Equipment]] / CNC Router<br />
<br />
[[File:WP_20130509_005.jpg|thumb|460px|right|CNC Router]]<br />
<br />
<br />
== Summary ==<br />
<br />
A CNC router is a computer controlled shaping machine. These are related to the hand held router. Instead of hand held routing, the tool paths can be controlled via computer numerical control. It is a computer-controlled machine for cutting various hard materials, such as wood, composites, aluminum, steel, plastics, and foams. It is one of many kinds of tools that have CNC variants. A CNC router is very similar in concept to a CNC milling machine. The CNC router is controlled by a computer. Coordinates are uploaded into the machine controller from a separate CAD program<br />
<br />
* Capacity: 1200 x 1200 x 120mm<br />
* Rate (X,Y): 6000mm/min (Max) 5000mm/min (Working)<br />
* Rate (Z): 30mm/sec<br />
* Spindle Speed: 4500 to 24000rpm<br />
* Mechanical Precision: 0.01mm<br />
* Spindle Power: 1.5KW Variable Speed, Water-cooled<br />
* Blade Diameter: min 3.175mm, max 12.7mm <br />
* Order Format: HPGL, G code, u00, mmg, plt <br />
* Control System: DSP with USB connection <br />
<br />
Here are some examples we've made on the CNC router (please add a photo of yours any time you do a job!) <br />
<br />
<gallery><br />
File:WP_20130509_004.jpg<br />
File:WP_20130624_017.jpg<br />
File:WP_20130625_001.jpg<br />
</gallery><br />
<br />
= Using the CNC Router =<br />
== Owners ==<br />
<br />
The Owners are those who have volunteered to be in charge of the equipment, organising maintenance, training others to use it, and generally being a point of contact. The current Owners of the CNC Router are:<br />
<br />
* Stephen Woolhead<br />
* Chris Abri<br />
* Mark Mellors<br />
* Dave Ansell<br />
* David Bebb<br />
* Simon Stirley<br />
<br />
If you have any questions, problems or concerns around the CNC router, please use the mailing list thread:<br />
* [https://groups.google.com/d/topic/cammakespace/rkchD7VqM2c/discussion Log : CNC Router]<br />
<br />
== Training ==<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>YOU CAN ONLY USE THE CNC ROUTER IF YOU HAVE BEEN TRAINED</b><br><br />
and have been added to the [[Equipment/CNC_Router/Training#Trained_Users|Trained Users]] list by one of the Owners<br />
</div><br />
<br />
To get trained on the CNC router and be added to the qualified user list, you will need to arrange for a training session with one of the Owners. <br />
<br />
If you'd like to arrange training, please see:<br />
* [[Equipment/CNC_Router/Training|CNC Router Training]]<br />
<br />
== Health and Safety ==<br />
<br />
The CNC Router is a potentially dangerous piece of equipment which must only be operated by members who have received appropriate training and who take due care. The top things to always remember when using the CNC Router are:<br />
* '''ONLY USE THE CNC ROUTER IF YOU ARE ON THE LIST OF TRAINED USERS'''<br />
* '''NEVER LEAVE THE CNC ROUTER RUNNING UNATTENDED'''<br />
<br />
As a trained user, you should be very aware of the following risks and how to deal with them:<br />
<br />
'''FIRE''' - Cutting with the wrong settings could result in the material igniting.<br />
<br />
'''TRAPPING''' - Stand clear of the machine while in motion.<br />
<br />
'''DUST''' - Ensure extraction system is working.<br />
<br />
'''NOISE''' - Ensure that you wear the correct PPE when working with the machine for prolonged periods.<br />
<br />
== Instructions ==<br />
<br />
[http://wiki.makespace.org/File:MPC6610_CNC_Router_Manual_v1.0-En.pdf Router Manual]<br />
<br />
[[Equipment/CNC_Router/Hand_Controller|Hand Controller Look-up Guide]]<br />
<br />
===Setting the Z Origin Using the Z0 Sensor===<br />
''A tool that has an extremely narrow tip may break when it touches the tool sensor depending on which tool is to be used.''<br />
<br />
1. Secure the workpiece on the bed, and place the Z0 sensor at the place where you want to set the Z origin on the workpiece. Face the surface of the Z0 sensor without the magnet facing upward.<br />
<br />
[[image:Mill_z0.PNG]]<br />
<br />
2. Use the handset to move the tool to the position above the sensor.<br />
<br />
3. On the handset press OK + 8(Z-0). The tool slowly descend until it contacts the sensor. When the tool rises and stops, the setting operation is complete. <br />
<br />
Note: It is important the tool is electrically conductive from tip to shaft, and the sensor is clean. Failure to check will cause damage to the tool and sensor.<br />
<br />
4. Remove the sensor from the workpiece to a location where it will not interfere with future cutting operations.<br />
<br />
==Software==<br />
<br />
The standard software is Vectric's line of CAM software:<br />
<br />
===VCarvePro===<br />
<br />
[[image:Vcarvepro.png]]<br />
<br />
VCarve Pro provides a powerful but intuitive software solution for 2D design and calculation of 2D and 2.5D toolpaths for cutting parts on a CNC Router. <br />
<br />
The software can import 2D designs from other programs but also includes a full set of drawing and editing tools with advanced layout options such as True-Shape Nesting. The toolpath options cover all typical 2D routing operations such as Profiling, Pocketing, Auto-Inlays and Drilling as well as 2.5D strategies such as V-Carving, Prism carving, Fluting and even a decorative Texturing strategy. Each toolpath includes appropriate options to customize the settings and provide a high level of control for different types of operation. In addition all toolpaths can be previewed to show just how the part will look when it is actually cut, this allows instant feedback to allow toolpaths to be further optimized. <br />
<br />
'''Details''': http://www.vectric.com/products/vcarve-pro.htm<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/vcarve-pro<br />
<br />
===Cut3D===<br />
<br />
[[image:Vectric-cut3d.jpg|266px]]<br />
<br />
Cut3D is a dedicated toolpath engine for CNC machining 3D models that have been designed using a 3D CAD or Graphics design product such as AutoCAD, Rhino3D, 3D Studio etc. or scanned using a laser or touch probe device. Cut3D's exceptionally easy to use interface leads you step-by-step through the process of loading a model, setting the size, interactively placing tabs to hold the job in place, calculating single, double or four sided roughing and finishing toolpaths, previewing the results and finally saving the CNC code to run on your machine.<br />
<br />
3D Models that are too large / thick to machine because of gantry height, cutter length or limited material thickness can be 'Sliced' into separate pieces. Each slice can then be machined and the complete job assembled. <br />
<br />
'''Details''': http://www.vectric.com/products/cut3d.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/cut3d<br />
<br />
===PhotoVCarve===<br />
<br />
[[image:Vectric-photovcarve.gif|266px]]<br />
<br />
PhotoVCarve creates lines of grooves that vary in width and depth to represent the detail in a photograph or image. The quality of the finished result is very dependant upon a high level of contrast between the material surface and the machined grooves. This information is very important to remember when cutting designs using the PhotoVCarve software. <br />
<br />
PhotoVCarve machines dark areas in a photograph with wide groove and the lighter areas to have narrower ones. The software automatically calculates the toolpaths based on the cutter selected and maximum depth of groove required. <br />
<br />
'''Details''': http://www.vectric.com/products/photovcarve.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/photovcarve<br />
<br />
== Tooling ==<br />
<br />
=== Router Bits ===<br />
<br />
Router bits (or cutters) are the most common type of cutter, they have two or more vertical cutting edges. These are good general purpose cutters that can be found in most DIY shops. The are the same type that you would use in a manual hand held router.<br />
<br />
<gallery><br />
File:WP_20130813_025.jpg<br />
File:WP_20130813_025.jpg<br />
</gallery><br />
<br />
It is important to notice that the cutters are on the edge of the body only, they do not extend to the centre of the cutter. This means the cutter CAN NOT BE USED AS A DRILL. An holes that are made by these sorts of cutters must be made by ramping the cutter to the correct depth in a sloping or spiral motion.<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>NEVER USE ROUTER BITS THAT HAVE BEARINGS.</b> These types of cutters are designed for manual routers where you can feel the feed back of the bearing in contact with the material being cut. A CNC device as no such feedback and will press the bearing into the material has hard as it can until something gives, i.e. the cutter breaks or much worse the spindle breaks. People found using these types of cutters on the CNC router will be BANNED! Just use the version without the bearing.<br />
<br />
<gallery><br />
File:WP_20130813_018.jpg<br />
</gallery><br />
<br />
The cutting edges should always be the lowest part of the cutter.<br />
</div><br />
<br />
=== End mills ===<br />
<br />
'''Up Cut and Down Cut'''<br />
<br />
Router end mills have two variants, up cut (left) and down cut (right); there is a third type, compression, but they are quite rare.<br />
<br />
<gallery><br />
File:WP_20130813_015.jpg<br />
</gallery><br />
<br />
Most cutters are up cut, which have the cutting service on the top of the flutes and as they rotate lift the chips up and away from the material being cut.<br />
<br />
Down cut cutters have the cutting edge on the bottom of the flutes and push chips down towards the material being cut. This has the advantage of pressing the material being cut into the bed of the machine; this is especially useful for thin plastics. The other advantage is the top surface shows far less breakout and splintering, this is a big advantage for materials like laminates.<br />
<br />
On image on the left has been cut with an up-cut end mill and the image on the right a down-cut.<br />
<br />
<gallery><br />
File:WP_20130813_005.jpg<br />
File:WP_20130813_007.jpg<br />
</gallery><br />
<br />
NOTE: There is a very big disadvantage to down cut end mills, and that is that they do not clear there chips effectively in blind holes. This means they need larger ramping moves to get to the correct cutting depth and if used in pockets without enough clearance, the friction can lead to burning or melting of the material being cut.<br />
<br />
Another down side to down-cut cutters, is that when cutting pockets, the bottom surface will not be as clean as that made with an up-cut cutter, which will do a far better job of clearing the waste chips that rub between the cutter and the material with a down-cut.<br />
<br />
== Stock Tooling ==<br />
<br />
In order to keep a small stock of cutters for general use, the CNC Router needs to have a means of generating money. Because there is no material provided for use with the CNC Router there is no way to bring in any funds for such things. Therefore, we ask that if you use one of the communal cutters please put 50p into the CNC Router Honesty Box. This will go towards funding for replenishing stock and also for the replacement of the sacrificial bed once it gets worn out.<br />
<br />
There will likely be 1 or two of each of the following cutters available for use, however please do not count on this being the case:<br />
<br />
* 2.5mm square cutter - single flute<br />
* 1/8" square cutter - single flute<br />
* 1/8" ball cutter - 2 flute<br />
<br />
* 6mm square cutter - 2 flute<br />
* 6mm ball cutter - 2 flute<br />
<br />
* engraver 0.2 30deg 1/8" 30mm length (8 of)<br />
* engraver 0.8 30deg 1/8" 30mm length (2 of)<br />
<br />
* 22mm 2 flute straight <br />
* 90deg x 32mm VBit<br />
<br />
<br />
Some Suppliers are listed below:<br />
<br />
== Feeds & Speeds ==<br />
<br />
What are feeds and speeds? Why are they important?<br />
<br />
[http://www.youtube.com/watch?v=ip2jm_6aUyk&feature=c4-overview&list=UUivA7_KLKWo43tFcCkFvydw Milling machine tutorial - cutter selection, speeds and feeds]<br />
<br />
[http://en.wikipedia.org/wiki/Speeds_and_feeds Wikipedia - Speeds and feeds]<br />
<br />
The phrase speeds and feeds (or feeds and speeds) refers to two separate velocities in machine tool practice, cutting speed and feed rate. They are often considered as a pair because of their combined effect on the cutting process. Each, however, can also be considered and analyzed in its own right.<br />
<br />
Cutting speed (also called surface speed or simply speed) is the speed difference (relative velocity) between the cutting tool and the surface of the workpiece it is operating on. It is expressed in units of distance along the workpiece surface per unit of time, typically surface feet per minute (sfm) or meters per minute (m/min). Feed rate (also often styled as a solid compound, feedrate, or called simply feed) is the relative velocity at which the cutter is advanced along the workpiece; its vector is perpendicular to the vector of cutting speed. Feed rate units depend on the motion of the tool and workpiece; when the workpiece rotates (e.g., in turning and boring), the units are almost always distance per spindle revolution (inches per revolution [in/rev or ipr] or millimeters per revolution [mm/rev]). When the workpiece does not rotate (e.g., in milling), the units are typically distance per time (inches per minute [in/min or ipm] or millimeters per minute [mm/min]), although distance per revolution or per cutter tooth are also sometimes used.<br />
<br />
===Spindle speed quick reference===<br />
<br />
{| class="wikitable"<br />
!|<br />
!|400Hz <br />
!|350Hz <br />
!|300Hz <br />
!|250Hz <br />
!|200Hz <br />
!|150Hz <br />
|-<br />
!|RPM<br />
|24000 <br />
|21000 <br />
|18000 <br />
|15000 <br />
|12000 <br />
|9000 <br />
|-<br />
|}<br />
<br />
===Feed rate quick reference===<br />
<br />
{| class="wikitable" <br />
!|100% <br />
!|75% <br />
!|66% <br />
!|50% <br />
!|33% <br />
!|25% <br />
|-<br />
!|6000<br />
|4500<br />
|3960<br />
|3000<br />
|1980<br />
|1500<br />
|-<br />
!|5000<br />
|3750<br />
|3300<br />
|2500<br />
|1650<br />
|1250<br />
|-<br />
!|4000<br />
|3000<br />
|2640<br />
|2000<br />
|1320<br />
|1000<br />
|-<br />
!|3000 <br />
|2250 <br />
|1980 <br />
|1500 <br />
|990 <br />
|750 <br />
|-<br />
!|2500 <br />
|1875 <br />
|1650 <br />
|1250 <br />
|825 <br />
|625 <br />
|-<br />
!|2000 <br />
|1500 <br />
|1320 <br />
|1000 <br />
|660 <br />
|500 <br />
|-<br />
!|1500 <br />
|1125 <br />
|990 <br />
|750 <br />
|495 <br />
|375 <br />
|-<br />
!|1000 <br />
|750 <br />
|660 <br />
|500 <br />
|330 <br />
|250 <br />
|-<br />
!|500 <br />
|375 <br />
|330 <br />
|250 <br />
|165 <br />
|125 <br />
|-<br />
|}<br />
<br />
=== Sample feed rates ===<br />
<br />
For working out feeds and speeds, recommend http://www.cnccookbook.com/CCGWizard.<br />
<br />
The feeds and speeds below have been tested on our machine. The 3mm cutters were single flute carbide. 2 flute HSS cutters may require different settings to avoid breakages.<br />
<br />
{| class="wikitable"<br />
!|MDF <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep <br />
|-<br />
!|3mm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|-<br />
!|6mm <br />
|3000/15Krpm <br />
|2000/13Krpm <br />
|1500/11Krpm <br />
|-<br />
!|22mm <br />
|3000/5000rpm <br />
|3000/5000rpm <br />
|1500/4Krpm<br />
|-<br />
|}<br />
<br />
{| class="wikitable"<br />
!|Plywood <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep<br />
|-<br />
!|3mm <br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|-<br />
!|6mm <br />
|3000/15Krpm <br />
|1500/15Krpm <br />
|1000/11Krpm <br />
|-<br />
!|22mm <br />
|3000/5Krpm <br />
|3000/5Krpm <br />
|1500/4Krpm <br />
|-<br />
|}<br />
<br />
== Tips & Tricks ==<br />
<br />
= Maintenance =<br />
<br />
The maintenance of the CNC Router is carried out by the Owners, with some basic maintenance being carried out by Users on every job.<br />
<br />
== Maintenance Schedule ==<br />
Every job<br />
* Vacuum cutting dust from bed and around machine<br />
* Sand down high points created on sacrificial bed by cutting/screwing<br />
<br />
As required, by users<br />
* Empty extraction bin <br />
<br />
Monthly<br />
* Inspect extraction hoses for splits/ wear<br />
* Clean and oil guide rails<br />
* Check level and condition of cooling water and replace as necessary<br />
* Inspect sacrificial bed, re-skim or replace as required<br />
<br />
== Maintenance Log ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
3/7/13: Lower spindle clamp bolts replaced with longer stainless ones, holes through tapped as original ones had stripped.<br />
<br />
== Maintenance Shopping List ==<br />
<br />
* Cutters<br />
* Sacrificial Bed (1.2m x 1.2m 12mm MDF)<br />
<br />
= Further Information =<br />
<br />
== Installation ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
<gallery><br />
File:Photo_1.JPG<br />
File:WP_20130509_005.jpg<br />
File:CNC_Router_controller_1.jpg<br />
File:CNC_Router_controller_2.jpg<br />
</gallery><br />
<br />
== Purchase ==<br />
Full Purchase, Delivery and Installation (£?????)<br />
<br />
== Notes ==<br />
<br />
http://www.shopbottools.com/mProducts/prSstandard.htm</div>Perfectphasehttp://wiki.makespace.org/Equipment/CNC_RouterEquipment/CNC Router2013-08-13T23:00:25Z<p>Perfectphase: /* Router Bits */</p>
<hr />
<div>{{RedTool}}<br />
<br />
[[Equipment|Equipment]] / CNC Router<br />
<br />
[[File:WP_20130509_005.jpg|thumb|460px|right|CNC Router]]<br />
<br />
<br />
== Summary ==<br />
<br />
A CNC router is a computer controlled shaping machine. These are related to the hand held router. Instead of hand held routing, the tool paths can be controlled via computer numerical control. It is a computer-controlled machine for cutting various hard materials, such as wood, composites, aluminum, steel, plastics, and foams. It is one of many kinds of tools that have CNC variants. A CNC router is very similar in concept to a CNC milling machine. The CNC router is controlled by a computer. Coordinates are uploaded into the machine controller from a separate CAD program<br />
<br />
* Capacity: 1200 x 1200 x 120mm<br />
* Rate (X,Y): 6000mm/min (Max) 5000mm/min (Working)<br />
* Rate (Z): 30mm/sec<br />
* Spindle Speed: 4500 to 24000rpm<br />
* Mechanical Precision: 0.01mm<br />
* Spindle Power: 1.5KW Variable Speed, Water-cooled<br />
* Blade Diameter: min 3.175mm, max 12.7mm <br />
* Order Format: HPGL, G code, u00, mmg, plt <br />
* Control System: DSP with USB connection <br />
<br />
Here are some examples we've made on the CNC router (please add a photo of yours any time you do a job!) <br />
<br />
<gallery><br />
File:WP_20130509_004.jpg<br />
File:WP_20130624_017.jpg<br />
File:WP_20130625_001.jpg<br />
</gallery><br />
<br />
= Using the CNC Router =<br />
== Owners ==<br />
<br />
The Owners are those who have volunteered to be in charge of the equipment, organising maintenance, training others to use it, and generally being a point of contact. The current Owners of the CNC Router are:<br />
<br />
* Stephen Woolhead<br />
* Chris Abri<br />
* Mark Mellors<br />
* Dave Ansell<br />
* David Bebb<br />
* Simon Stirley<br />
<br />
If you have any questions, problems or concerns around the CNC router, please use the mailing list thread:<br />
* [https://groups.google.com/d/topic/cammakespace/rkchD7VqM2c/discussion Log : CNC Router]<br />
<br />
== Training ==<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>YOU CAN ONLY USE THE CNC ROUTER IF YOU HAVE BEEN TRAINED</b><br><br />
and have been added to the [[Equipment/CNC_Router/Training#Trained_Users|Trained Users]] list by one of the Owners<br />
</div><br />
<br />
To get trained on the CNC router and be added to the qualified user list, you will need to arrange for a training session with one of the Owners. <br />
<br />
If you'd like to arrange training, please see:<br />
* [[Equipment/CNC_Router/Training|CNC Router Training]]<br />
<br />
== Health and Safety ==<br />
<br />
The CNC Router is a potentially dangerous piece of equipment which must only be operated by members who have received appropriate training and who take due care. The top things to always remember when using the CNC Router are:<br />
* '''ONLY USE THE CNC ROUTER IF YOU ARE ON THE LIST OF TRAINED USERS'''<br />
* '''NEVER LEAVE THE CNC ROUTER RUNNING UNATTENDED'''<br />
<br />
As a trained user, you should be very aware of the following risks and how to deal with them:<br />
<br />
'''FIRE''' - Cutting with the wrong settings could result in the material igniting.<br />
<br />
'''TRAPPING''' - Stand clear of the machine while in motion.<br />
<br />
'''DUST''' - Ensure extraction system is working.<br />
<br />
'''NOISE''' - Ensure that you wear the correct PPE when working with the machine for prolonged periods.<br />
<br />
== Instructions ==<br />
<br />
[http://wiki.makespace.org/File:MPC6610_CNC_Router_Manual_v1.0-En.pdf Router Manual]<br />
<br />
[[Equipment/CNC_Router/Hand_Controller|Hand Controller Look-up Guide]]<br />
<br />
===Setting the Z Origin Using the Z0 Sensor===<br />
''A tool that has an extremely narrow tip may break when it touches the tool sensor depending on which tool is to be used.''<br />
<br />
1. Secure the workpiece on the bed, and place the Z0 sensor at the place where you want to set the Z origin on the workpiece. Face the surface of the Z0 sensor without the magnet facing upward.<br />
<br />
[[image:Mill_z0.PNG]]<br />
<br />
2. Use the handset to move the tool to the position above the sensor.<br />
<br />
3. On the handset press OK + 8(Z-0). The tool slowly descend until it contacts the sensor. When the tool rises and stops, the setting operation is complete. <br />
<br />
Note: It is important the tool is electrically conductive from tip to shaft, and the sensor is clean. Failure to check will cause damage to the tool and sensor.<br />
<br />
4. Remove the sensor from the workpiece to a location where it will not interfere with future cutting operations.<br />
<br />
==Software==<br />
<br />
The standard software is Vectric's line of CAM software:<br />
<br />
===VCarvePro===<br />
<br />
[[image:Vcarvepro.png]]<br />
<br />
VCarve Pro provides a powerful but intuitive software solution for 2D design and calculation of 2D and 2.5D toolpaths for cutting parts on a CNC Router. <br />
<br />
The software can import 2D designs from other programs but also includes a full set of drawing and editing tools with advanced layout options such as True-Shape Nesting. The toolpath options cover all typical 2D routing operations such as Profiling, Pocketing, Auto-Inlays and Drilling as well as 2.5D strategies such as V-Carving, Prism carving, Fluting and even a decorative Texturing strategy. Each toolpath includes appropriate options to customize the settings and provide a high level of control for different types of operation. In addition all toolpaths can be previewed to show just how the part will look when it is actually cut, this allows instant feedback to allow toolpaths to be further optimized. <br />
<br />
'''Details''': http://www.vectric.com/products/vcarve-pro.htm<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/vcarve-pro<br />
<br />
===Cut3D===<br />
<br />
[[image:Vectric-cut3d.jpg|266px]]<br />
<br />
Cut3D is a dedicated toolpath engine for CNC machining 3D models that have been designed using a 3D CAD or Graphics design product such as AutoCAD, Rhino3D, 3D Studio etc. or scanned using a laser or touch probe device. Cut3D's exceptionally easy to use interface leads you step-by-step through the process of loading a model, setting the size, interactively placing tabs to hold the job in place, calculating single, double or four sided roughing and finishing toolpaths, previewing the results and finally saving the CNC code to run on your machine.<br />
<br />
3D Models that are too large / thick to machine because of gantry height, cutter length or limited material thickness can be 'Sliced' into separate pieces. Each slice can then be machined and the complete job assembled. <br />
<br />
'''Details''': http://www.vectric.com/products/cut3d.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/cut3d<br />
<br />
===PhotoVCarve===<br />
<br />
[[image:Vectric-photovcarve.gif|266px]]<br />
<br />
PhotoVCarve creates lines of grooves that vary in width and depth to represent the detail in a photograph or image. The quality of the finished result is very dependant upon a high level of contrast between the material surface and the machined grooves. This information is very important to remember when cutting designs using the PhotoVCarve software. <br />
<br />
PhotoVCarve machines dark areas in a photograph with wide groove and the lighter areas to have narrower ones. The software automatically calculates the toolpaths based on the cutter selected and maximum depth of groove required. <br />
<br />
'''Details''': http://www.vectric.com/products/photovcarve.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/photovcarve<br />
<br />
== Tooling ==<br />
<br />
=== Router Bits ===<br />
<br />
Router bits (or cutters) are the most common type of cutter, they have two or more vertical cutting edges. These are good general purpose cutters that can be found in most DIY shops. The are the same type that you would use in a manual hand held router.<br />
<br />
<gallery><br />
File:WP_20130813_025.jpg<br />
File:WP_20130813_025.jpg<br />
</gallery><br />
<br />
It is important to notice that the cutters are on the edge of the body only, they do not extend to the centre of the cutter. This means the cutter CAN NOT BE USED AS A DRILL. An holes that are made by these sorts of cutters must be made by ramping the cutter to the correct depth in a sloping or spiral motion.<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
NEVER USE ROUTER BITS THAT HAVE BEARINGS. These types of cutters are designed for manual routers where you can feel the feed back of the bearing in contact with the material being cut. A CNC device as no such feedback and will press the bearing into the material has hard as it can until something gives, i.e. the cutter breaks or much worse the spindle breaks. People found using these types of cutters on the CNC router will be BANNED! Just use the version without the bearing.<br />
<br />
<gallery><br />
File:WP_20130813_018.jpg<br />
</gallery><br />
<br />
The cutting edges should always be the lowest part of the cutter.<br />
</div><br />
<br />
=== End mills ===<br />
<br />
'''Up Cut and Down Cut'''<br />
<br />
Router end mills have two variants, up cut (left) and down cut (right); there is a third type, compression, but they are quite rare.<br />
<br />
<gallery><br />
File:WP_20130813_015.jpg<br />
</gallery><br />
<br />
Most cutters are up cut, which have the cutting service on the top of the flutes and as they rotate lift the chips up and away from the material being cut.<br />
<br />
Down cut cutters have the cutting edge on the bottom of the flutes and push chips down towards the material being cut. This has the advantage of pressing the material being cut into the bed of the machine; this is especially useful for thin plastics. The other advantage is the top surface shows far less breakout and splintering, this is a big advantage for materials like laminates.<br />
<br />
On image on the left has been cut with an up-cut end mill and the image on the right a down-cut.<br />
<br />
<gallery><br />
File:WP_20130813_005.jpg<br />
File:WP_20130813_007.jpg<br />
</gallery><br />
<br />
NOTE: There is a very big disadvantage to down cut end mills, and that is that they do not clear there chips effectively in blind holes. This means they need larger ramping moves to get to the correct cutting depth and if used in pockets without enough clearance, the friction can lead to burning or melting of the material being cut.<br />
<br />
Another down side to down-cut cutters, is that when cutting pockets, the bottom surface will not be as clean as that made with an up-cut cutter, which will do a far better job of clearing the waste chips that rub between the cutter and the material with a down-cut.<br />
<br />
== Stock Tooling ==<br />
<br />
In order to keep a small stock of cutters for general use, the CNC Router needs to have a means of generating money. Because there is no material provided for use with the CNC Router there is no way to bring in any funds for such things. Therefore, we ask that if you use one of the communal cutters please put 50p into the CNC Router Honesty Box. This will go towards funding for replenishing stock and also for the replacement of the sacrificial bed once it gets worn out.<br />
<br />
There will likely be 1 or two of each of the following cutters available for use, however please do not count on this being the case:<br />
<br />
* 2.5mm square cutter - single flute<br />
* 1/8" square cutter - single flute<br />
* 1/8" ball cutter - 2 flute<br />
<br />
* 6mm square cutter - 2 flute<br />
* 6mm ball cutter - 2 flute<br />
<br />
* engraver 0.2 30deg 1/8" 30mm length (8 of)<br />
* engraver 0.8 30deg 1/8" 30mm length (2 of)<br />
<br />
* 22mm 2 flute straight <br />
* 90deg x 32mm VBit<br />
<br />
<br />
Some Suppliers are listed below:<br />
<br />
== Feeds & Speeds ==<br />
<br />
What are feeds and speeds? Why are they important?<br />
<br />
[http://www.youtube.com/watch?v=ip2jm_6aUyk&feature=c4-overview&list=UUivA7_KLKWo43tFcCkFvydw Milling machine tutorial - cutter selection, speeds and feeds]<br />
<br />
[http://en.wikipedia.org/wiki/Speeds_and_feeds Wikipedia - Speeds and feeds]<br />
<br />
The phrase speeds and feeds (or feeds and speeds) refers to two separate velocities in machine tool practice, cutting speed and feed rate. They are often considered as a pair because of their combined effect on the cutting process. Each, however, can also be considered and analyzed in its own right.<br />
<br />
Cutting speed (also called surface speed or simply speed) is the speed difference (relative velocity) between the cutting tool and the surface of the workpiece it is operating on. It is expressed in units of distance along the workpiece surface per unit of time, typically surface feet per minute (sfm) or meters per minute (m/min). Feed rate (also often styled as a solid compound, feedrate, or called simply feed) is the relative velocity at which the cutter is advanced along the workpiece; its vector is perpendicular to the vector of cutting speed. Feed rate units depend on the motion of the tool and workpiece; when the workpiece rotates (e.g., in turning and boring), the units are almost always distance per spindle revolution (inches per revolution [in/rev or ipr] or millimeters per revolution [mm/rev]). When the workpiece does not rotate (e.g., in milling), the units are typically distance per time (inches per minute [in/min or ipm] or millimeters per minute [mm/min]), although distance per revolution or per cutter tooth are also sometimes used.<br />
<br />
===Spindle speed quick reference===<br />
<br />
{| class="wikitable"<br />
!|<br />
!|400Hz <br />
!|350Hz <br />
!|300Hz <br />
!|250Hz <br />
!|200Hz <br />
!|150Hz <br />
|-<br />
!|RPM<br />
|24000 <br />
|21000 <br />
|18000 <br />
|15000 <br />
|12000 <br />
|9000 <br />
|-<br />
|}<br />
<br />
===Feed rate quick reference===<br />
<br />
{| class="wikitable" <br />
!|100% <br />
!|75% <br />
!|66% <br />
!|50% <br />
!|33% <br />
!|25% <br />
|-<br />
!|6000<br />
|4500<br />
|3960<br />
|3000<br />
|1980<br />
|1500<br />
|-<br />
!|5000<br />
|3750<br />
|3300<br />
|2500<br />
|1650<br />
|1250<br />
|-<br />
!|4000<br />
|3000<br />
|2640<br />
|2000<br />
|1320<br />
|1000<br />
|-<br />
!|3000 <br />
|2250 <br />
|1980 <br />
|1500 <br />
|990 <br />
|750 <br />
|-<br />
!|2500 <br />
|1875 <br />
|1650 <br />
|1250 <br />
|825 <br />
|625 <br />
|-<br />
!|2000 <br />
|1500 <br />
|1320 <br />
|1000 <br />
|660 <br />
|500 <br />
|-<br />
!|1500 <br />
|1125 <br />
|990 <br />
|750 <br />
|495 <br />
|375 <br />
|-<br />
!|1000 <br />
|750 <br />
|660 <br />
|500 <br />
|330 <br />
|250 <br />
|-<br />
!|500 <br />
|375 <br />
|330 <br />
|250 <br />
|165 <br />
|125 <br />
|-<br />
|}<br />
<br />
=== Sample feed rates ===<br />
<br />
For working out feeds and speeds, recommend http://www.cnccookbook.com/CCGWizard.<br />
<br />
The feeds and speeds below have been tested on our machine. The 3mm cutters were single flute carbide. 2 flute HSS cutters may require different settings to avoid breakages.<br />
<br />
{| class="wikitable"<br />
!|MDF <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep <br />
|-<br />
!|3mm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|-<br />
!|6mm <br />
|3000/15Krpm <br />
|2000/13Krpm <br />
|1500/11Krpm <br />
|-<br />
!|22mm <br />
|3000/5000rpm <br />
|3000/5000rpm <br />
|1500/4Krpm<br />
|-<br />
|}<br />
<br />
{| class="wikitable"<br />
!|Plywood <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep<br />
|-<br />
!|3mm <br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|-<br />
!|6mm <br />
|3000/15Krpm <br />
|1500/15Krpm <br />
|1000/11Krpm <br />
|-<br />
!|22mm <br />
|3000/5Krpm <br />
|3000/5Krpm <br />
|1500/4Krpm <br />
|-<br />
|}<br />
<br />
== Tips & Tricks ==<br />
<br />
= Maintenance =<br />
<br />
The maintenance of the CNC Router is carried out by the Owners, with some basic maintenance being carried out by Users on every job.<br />
<br />
== Maintenance Schedule ==<br />
Every job<br />
* Vacuum cutting dust from bed and around machine<br />
* Sand down high points created on sacrificial bed by cutting/screwing<br />
<br />
As required, by users<br />
* Empty extraction bin <br />
<br />
Monthly<br />
* Inspect extraction hoses for splits/ wear<br />
* Clean and oil guide rails<br />
* Check level and condition of cooling water and replace as necessary<br />
* Inspect sacrificial bed, re-skim or replace as required<br />
<br />
== Maintenance Log ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
3/7/13: Lower spindle clamp bolts replaced with longer stainless ones, holes through tapped as original ones had stripped.<br />
<br />
== Maintenance Shopping List ==<br />
<br />
* Cutters<br />
* Sacrificial Bed (1.2m x 1.2m 12mm MDF)<br />
<br />
= Further Information =<br />
<br />
== Installation ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
<gallery><br />
File:Photo_1.JPG<br />
File:WP_20130509_005.jpg<br />
File:CNC_Router_controller_1.jpg<br />
File:CNC_Router_controller_2.jpg<br />
</gallery><br />
<br />
== Purchase ==<br />
Full Purchase, Delivery and Installation (£?????)<br />
<br />
== Notes ==<br />
<br />
http://www.shopbottools.com/mProducts/prSstandard.htm</div>Perfectphasehttp://wiki.makespace.org/Equipment/CNC_RouterEquipment/CNC Router2013-08-13T22:59:14Z<p>Perfectphase: /* Router Bits */</p>
<hr />
<div>{{RedTool}}<br />
<br />
[[Equipment|Equipment]] / CNC Router<br />
<br />
[[File:WP_20130509_005.jpg|thumb|460px|right|CNC Router]]<br />
<br />
<br />
== Summary ==<br />
<br />
A CNC router is a computer controlled shaping machine. These are related to the hand held router. Instead of hand held routing, the tool paths can be controlled via computer numerical control. It is a computer-controlled machine for cutting various hard materials, such as wood, composites, aluminum, steel, plastics, and foams. It is one of many kinds of tools that have CNC variants. A CNC router is very similar in concept to a CNC milling machine. The CNC router is controlled by a computer. Coordinates are uploaded into the machine controller from a separate CAD program<br />
<br />
* Capacity: 1200 x 1200 x 120mm<br />
* Rate (X,Y): 6000mm/min (Max) 5000mm/min (Working)<br />
* Rate (Z): 30mm/sec<br />
* Spindle Speed: 4500 to 24000rpm<br />
* Mechanical Precision: 0.01mm<br />
* Spindle Power: 1.5KW Variable Speed, Water-cooled<br />
* Blade Diameter: min 3.175mm, max 12.7mm <br />
* Order Format: HPGL, G code, u00, mmg, plt <br />
* Control System: DSP with USB connection <br />
<br />
Here are some examples we've made on the CNC router (please add a photo of yours any time you do a job!) <br />
<br />
<gallery><br />
File:WP_20130509_004.jpg<br />
File:WP_20130624_017.jpg<br />
File:WP_20130625_001.jpg<br />
</gallery><br />
<br />
= Using the CNC Router =<br />
== Owners ==<br />
<br />
The Owners are those who have volunteered to be in charge of the equipment, organising maintenance, training others to use it, and generally being a point of contact. The current Owners of the CNC Router are:<br />
<br />
* Stephen Woolhead<br />
* Chris Abri<br />
* Mark Mellors<br />
* Dave Ansell<br />
* David Bebb<br />
* Simon Stirley<br />
<br />
If you have any questions, problems or concerns around the CNC router, please use the mailing list thread:<br />
* [https://groups.google.com/d/topic/cammakespace/rkchD7VqM2c/discussion Log : CNC Router]<br />
<br />
== Training ==<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>YOU CAN ONLY USE THE CNC ROUTER IF YOU HAVE BEEN TRAINED</b><br><br />
and have been added to the [[Equipment/CNC_Router/Training#Trained_Users|Trained Users]] list by one of the Owners<br />
</div><br />
<br />
To get trained on the CNC router and be added to the qualified user list, you will need to arrange for a training session with one of the Owners. <br />
<br />
If you'd like to arrange training, please see:<br />
* [[Equipment/CNC_Router/Training|CNC Router Training]]<br />
<br />
== Health and Safety ==<br />
<br />
The CNC Router is a potentially dangerous piece of equipment which must only be operated by members who have received appropriate training and who take due care. The top things to always remember when using the CNC Router are:<br />
* '''ONLY USE THE CNC ROUTER IF YOU ARE ON THE LIST OF TRAINED USERS'''<br />
* '''NEVER LEAVE THE CNC ROUTER RUNNING UNATTENDED'''<br />
<br />
As a trained user, you should be very aware of the following risks and how to deal with them:<br />
<br />
'''FIRE''' - Cutting with the wrong settings could result in the material igniting.<br />
<br />
'''TRAPPING''' - Stand clear of the machine while in motion.<br />
<br />
'''DUST''' - Ensure extraction system is working.<br />
<br />
'''NOISE''' - Ensure that you wear the correct PPE when working with the machine for prolonged periods.<br />
<br />
== Instructions ==<br />
<br />
[http://wiki.makespace.org/File:MPC6610_CNC_Router_Manual_v1.0-En.pdf Router Manual]<br />
<br />
[[Equipment/CNC_Router/Hand_Controller|Hand Controller Look-up Guide]]<br />
<br />
===Setting the Z Origin Using the Z0 Sensor===<br />
''A tool that has an extremely narrow tip may break when it touches the tool sensor depending on which tool is to be used.''<br />
<br />
1. Secure the workpiece on the bed, and place the Z0 sensor at the place where you want to set the Z origin on the workpiece. Face the surface of the Z0 sensor without the magnet facing upward.<br />
<br />
[[image:Mill_z0.PNG]]<br />
<br />
2. Use the handset to move the tool to the position above the sensor.<br />
<br />
3. On the handset press OK + 8(Z-0). The tool slowly descend until it contacts the sensor. When the tool rises and stops, the setting operation is complete. <br />
<br />
Note: It is important the tool is electrically conductive from tip to shaft, and the sensor is clean. Failure to check will cause damage to the tool and sensor.<br />
<br />
4. Remove the sensor from the workpiece to a location where it will not interfere with future cutting operations.<br />
<br />
==Software==<br />
<br />
The standard software is Vectric's line of CAM software:<br />
<br />
===VCarvePro===<br />
<br />
[[image:Vcarvepro.png]]<br />
<br />
VCarve Pro provides a powerful but intuitive software solution for 2D design and calculation of 2D and 2.5D toolpaths for cutting parts on a CNC Router. <br />
<br />
The software can import 2D designs from other programs but also includes a full set of drawing and editing tools with advanced layout options such as True-Shape Nesting. The toolpath options cover all typical 2D routing operations such as Profiling, Pocketing, Auto-Inlays and Drilling as well as 2.5D strategies such as V-Carving, Prism carving, Fluting and even a decorative Texturing strategy. Each toolpath includes appropriate options to customize the settings and provide a high level of control for different types of operation. In addition all toolpaths can be previewed to show just how the part will look when it is actually cut, this allows instant feedback to allow toolpaths to be further optimized. <br />
<br />
'''Details''': http://www.vectric.com/products/vcarve-pro.htm<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/vcarve-pro<br />
<br />
===Cut3D===<br />
<br />
[[image:Vectric-cut3d.jpg|266px]]<br />
<br />
Cut3D is a dedicated toolpath engine for CNC machining 3D models that have been designed using a 3D CAD or Graphics design product such as AutoCAD, Rhino3D, 3D Studio etc. or scanned using a laser or touch probe device. Cut3D's exceptionally easy to use interface leads you step-by-step through the process of loading a model, setting the size, interactively placing tabs to hold the job in place, calculating single, double or four sided roughing and finishing toolpaths, previewing the results and finally saving the CNC code to run on your machine.<br />
<br />
3D Models that are too large / thick to machine because of gantry height, cutter length or limited material thickness can be 'Sliced' into separate pieces. Each slice can then be machined and the complete job assembled. <br />
<br />
'''Details''': http://www.vectric.com/products/cut3d.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/cut3d<br />
<br />
===PhotoVCarve===<br />
<br />
[[image:Vectric-photovcarve.gif|266px]]<br />
<br />
PhotoVCarve creates lines of grooves that vary in width and depth to represent the detail in a photograph or image. The quality of the finished result is very dependant upon a high level of contrast between the material surface and the machined grooves. This information is very important to remember when cutting designs using the PhotoVCarve software. <br />
<br />
PhotoVCarve machines dark areas in a photograph with wide groove and the lighter areas to have narrower ones. The software automatically calculates the toolpaths based on the cutter selected and maximum depth of groove required. <br />
<br />
'''Details''': http://www.vectric.com/products/photovcarve.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/photovcarve<br />
<br />
== Tooling ==<br />
<br />
=== Router Bits ===<br />
<br />
Router bits (or cutters) are the most common type of cutter, they have two or more vertical cutting edges. These are good general purpose cutters that can be found in most DIY shops. The are the same type that you would use in a manual hand held router.<br />
<br />
<gallery><br />
File:WP_20130813_025.jpg<br />
File:WP_20130813_025.jpg<br />
</gallery><br />
<br />
It is important to notice that the cutters are on the edge of the body only, they do not extend to the centre of the cutter. This means the cutter CAN NOT BE USED AS A DRILL. An holes that are made by these sorts of cutters must be made by ramping the cutter to the correct depth in a sloping or spiral motion.<br />
<br />
NEVER USE ROUTER BITS THAT HAVE BEARINGS. These types of cutters are designed for manual routers where you can feel the feed back of the bearing in contact with the material being cut. A CNC device as no such feedback and will press the bearing into the material has hard as it can until something gives, i.e. the cutter breaks or much worse the spindle breaks. People found using these types of cutters on the CNC router will be BANNED! Just use the version without the bearing.<br />
<br />
<gallery><br />
File:WP_20130813_018.jpg<br />
</gallery><br />
<br />
The cutting edges should always be the lowest part of the cutter.<br />
<br />
=== End mills ===<br />
<br />
'''Up Cut and Down Cut'''<br />
<br />
Router end mills have two variants, up cut (left) and down cut (right); there is a third type, compression, but they are quite rare.<br />
<br />
<gallery><br />
File:WP_20130813_015.jpg<br />
</gallery><br />
<br />
Most cutters are up cut, which have the cutting service on the top of the flutes and as they rotate lift the chips up and away from the material being cut.<br />
<br />
Down cut cutters have the cutting edge on the bottom of the flutes and push chips down towards the material being cut. This has the advantage of pressing the material being cut into the bed of the machine; this is especially useful for thin plastics. The other advantage is the top surface shows far less breakout and splintering, this is a big advantage for materials like laminates.<br />
<br />
On image on the left has been cut with an up-cut end mill and the image on the right a down-cut.<br />
<br />
<gallery><br />
File:WP_20130813_005.jpg<br />
File:WP_20130813_007.jpg<br />
</gallery><br />
<br />
NOTE: There is a very big disadvantage to down cut end mills, and that is that they do not clear there chips effectively in blind holes. This means they need larger ramping moves to get to the correct cutting depth and if used in pockets without enough clearance, the friction can lead to burning or melting of the material being cut.<br />
<br />
Another down side to down-cut cutters, is that when cutting pockets, the bottom surface will not be as clean as that made with an up-cut cutter, which will do a far better job of clearing the waste chips that rub between the cutter and the material with a down-cut.<br />
<br />
== Stock Tooling ==<br />
<br />
In order to keep a small stock of cutters for general use, the CNC Router needs to have a means of generating money. Because there is no material provided for use with the CNC Router there is no way to bring in any funds for such things. Therefore, we ask that if you use one of the communal cutters please put 50p into the CNC Router Honesty Box. This will go towards funding for replenishing stock and also for the replacement of the sacrificial bed once it gets worn out.<br />
<br />
There will likely be 1 or two of each of the following cutters available for use, however please do not count on this being the case:<br />
<br />
* 2.5mm square cutter - single flute<br />
* 1/8" square cutter - single flute<br />
* 1/8" ball cutter - 2 flute<br />
<br />
* 6mm square cutter - 2 flute<br />
* 6mm ball cutter - 2 flute<br />
<br />
* engraver 0.2 30deg 1/8" 30mm length (8 of)<br />
* engraver 0.8 30deg 1/8" 30mm length (2 of)<br />
<br />
* 22mm 2 flute straight <br />
* 90deg x 32mm VBit<br />
<br />
<br />
Some Suppliers are listed below:<br />
<br />
== Feeds & Speeds ==<br />
<br />
What are feeds and speeds? Why are they important?<br />
<br />
[http://www.youtube.com/watch?v=ip2jm_6aUyk&feature=c4-overview&list=UUivA7_KLKWo43tFcCkFvydw Milling machine tutorial - cutter selection, speeds and feeds]<br />
<br />
[http://en.wikipedia.org/wiki/Speeds_and_feeds Wikipedia - Speeds and feeds]<br />
<br />
The phrase speeds and feeds (or feeds and speeds) refers to two separate velocities in machine tool practice, cutting speed and feed rate. They are often considered as a pair because of their combined effect on the cutting process. Each, however, can also be considered and analyzed in its own right.<br />
<br />
Cutting speed (also called surface speed or simply speed) is the speed difference (relative velocity) between the cutting tool and the surface of the workpiece it is operating on. It is expressed in units of distance along the workpiece surface per unit of time, typically surface feet per minute (sfm) or meters per minute (m/min). Feed rate (also often styled as a solid compound, feedrate, or called simply feed) is the relative velocity at which the cutter is advanced along the workpiece; its vector is perpendicular to the vector of cutting speed. Feed rate units depend on the motion of the tool and workpiece; when the workpiece rotates (e.g., in turning and boring), the units are almost always distance per spindle revolution (inches per revolution [in/rev or ipr] or millimeters per revolution [mm/rev]). When the workpiece does not rotate (e.g., in milling), the units are typically distance per time (inches per minute [in/min or ipm] or millimeters per minute [mm/min]), although distance per revolution or per cutter tooth are also sometimes used.<br />
<br />
===Spindle speed quick reference===<br />
<br />
{| class="wikitable"<br />
!|<br />
!|400Hz <br />
!|350Hz <br />
!|300Hz <br />
!|250Hz <br />
!|200Hz <br />
!|150Hz <br />
|-<br />
!|RPM<br />
|24000 <br />
|21000 <br />
|18000 <br />
|15000 <br />
|12000 <br />
|9000 <br />
|-<br />
|}<br />
<br />
===Feed rate quick reference===<br />
<br />
{| class="wikitable" <br />
!|100% <br />
!|75% <br />
!|66% <br />
!|50% <br />
!|33% <br />
!|25% <br />
|-<br />
!|6000<br />
|4500<br />
|3960<br />
|3000<br />
|1980<br />
|1500<br />
|-<br />
!|5000<br />
|3750<br />
|3300<br />
|2500<br />
|1650<br />
|1250<br />
|-<br />
!|4000<br />
|3000<br />
|2640<br />
|2000<br />
|1320<br />
|1000<br />
|-<br />
!|3000 <br />
|2250 <br />
|1980 <br />
|1500 <br />
|990 <br />
|750 <br />
|-<br />
!|2500 <br />
|1875 <br />
|1650 <br />
|1250 <br />
|825 <br />
|625 <br />
|-<br />
!|2000 <br />
|1500 <br />
|1320 <br />
|1000 <br />
|660 <br />
|500 <br />
|-<br />
!|1500 <br />
|1125 <br />
|990 <br />
|750 <br />
|495 <br />
|375 <br />
|-<br />
!|1000 <br />
|750 <br />
|660 <br />
|500 <br />
|330 <br />
|250 <br />
|-<br />
!|500 <br />
|375 <br />
|330 <br />
|250 <br />
|165 <br />
|125 <br />
|-<br />
|}<br />
<br />
=== Sample feed rates ===<br />
<br />
For working out feeds and speeds, recommend http://www.cnccookbook.com/CCGWizard.<br />
<br />
The feeds and speeds below have been tested on our machine. The 3mm cutters were single flute carbide. 2 flute HSS cutters may require different settings to avoid breakages.<br />
<br />
{| class="wikitable"<br />
!|MDF <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep <br />
|-<br />
!|3mm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|-<br />
!|6mm <br />
|3000/15Krpm <br />
|2000/13Krpm <br />
|1500/11Krpm <br />
|-<br />
!|22mm <br />
|3000/5000rpm <br />
|3000/5000rpm <br />
|1500/4Krpm<br />
|-<br />
|}<br />
<br />
{| class="wikitable"<br />
!|Plywood <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep<br />
|-<br />
!|3mm <br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|-<br />
!|6mm <br />
|3000/15Krpm <br />
|1500/15Krpm <br />
|1000/11Krpm <br />
|-<br />
!|22mm <br />
|3000/5Krpm <br />
|3000/5Krpm <br />
|1500/4Krpm <br />
|-<br />
|}<br />
<br />
== Tips & Tricks ==<br />
<br />
= Maintenance =<br />
<br />
The maintenance of the CNC Router is carried out by the Owners, with some basic maintenance being carried out by Users on every job.<br />
<br />
== Maintenance Schedule ==<br />
Every job<br />
* Vacuum cutting dust from bed and around machine<br />
* Sand down high points created on sacrificial bed by cutting/screwing<br />
<br />
As required, by users<br />
* Empty extraction bin <br />
<br />
Monthly<br />
* Inspect extraction hoses for splits/ wear<br />
* Clean and oil guide rails<br />
* Check level and condition of cooling water and replace as necessary<br />
* Inspect sacrificial bed, re-skim or replace as required<br />
<br />
== Maintenance Log ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
3/7/13: Lower spindle clamp bolts replaced with longer stainless ones, holes through tapped as original ones had stripped.<br />
<br />
== Maintenance Shopping List ==<br />
<br />
* Cutters<br />
* Sacrificial Bed (1.2m x 1.2m 12mm MDF)<br />
<br />
= Further Information =<br />
<br />
== Installation ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
<gallery><br />
File:Photo_1.JPG<br />
File:WP_20130509_005.jpg<br />
File:CNC_Router_controller_1.jpg<br />
File:CNC_Router_controller_2.jpg<br />
</gallery><br />
<br />
== Purchase ==<br />
Full Purchase, Delivery and Installation (£?????)<br />
<br />
== Notes ==<br />
<br />
http://www.shopbottools.com/mProducts/prSstandard.htm</div>Perfectphasehttp://wiki.makespace.org/File:WP_20130813_018.jpgFile:WP 20130813 018.jpg2013-08-13T22:58:37Z<p>Perfectphase: </p>
<hr />
<div></div>Perfectphasehttp://wiki.makespace.org/Equipment/CNC_RouterEquipment/CNC Router2013-08-13T22:54:17Z<p>Perfectphase: /* Tooling */</p>
<hr />
<div>{{RedTool}}<br />
<br />
[[Equipment|Equipment]] / CNC Router<br />
<br />
[[File:WP_20130509_005.jpg|thumb|460px|right|CNC Router]]<br />
<br />
<br />
== Summary ==<br />
<br />
A CNC router is a computer controlled shaping machine. These are related to the hand held router. Instead of hand held routing, the tool paths can be controlled via computer numerical control. It is a computer-controlled machine for cutting various hard materials, such as wood, composites, aluminum, steel, plastics, and foams. It is one of many kinds of tools that have CNC variants. A CNC router is very similar in concept to a CNC milling machine. The CNC router is controlled by a computer. Coordinates are uploaded into the machine controller from a separate CAD program<br />
<br />
* Capacity: 1200 x 1200 x 120mm<br />
* Rate (X,Y): 6000mm/min (Max) 5000mm/min (Working)<br />
* Rate (Z): 30mm/sec<br />
* Spindle Speed: 4500 to 24000rpm<br />
* Mechanical Precision: 0.01mm<br />
* Spindle Power: 1.5KW Variable Speed, Water-cooled<br />
* Blade Diameter: min 3.175mm, max 12.7mm <br />
* Order Format: HPGL, G code, u00, mmg, plt <br />
* Control System: DSP with USB connection <br />
<br />
Here are some examples we've made on the CNC router (please add a photo of yours any time you do a job!) <br />
<br />
<gallery><br />
File:WP_20130509_004.jpg<br />
File:WP_20130624_017.jpg<br />
File:WP_20130625_001.jpg<br />
</gallery><br />
<br />
= Using the CNC Router =<br />
== Owners ==<br />
<br />
The Owners are those who have volunteered to be in charge of the equipment, organising maintenance, training others to use it, and generally being a point of contact. The current Owners of the CNC Router are:<br />
<br />
* Stephen Woolhead<br />
* Chris Abri<br />
* Mark Mellors<br />
* Dave Ansell<br />
* David Bebb<br />
* Simon Stirley<br />
<br />
If you have any questions, problems or concerns around the CNC router, please use the mailing list thread:<br />
* [https://groups.google.com/d/topic/cammakespace/rkchD7VqM2c/discussion Log : CNC Router]<br />
<br />
== Training ==<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>YOU CAN ONLY USE THE CNC ROUTER IF YOU HAVE BEEN TRAINED</b><br><br />
and have been added to the [[Equipment/CNC_Router/Training#Trained_Users|Trained Users]] list by one of the Owners<br />
</div><br />
<br />
To get trained on the CNC router and be added to the qualified user list, you will need to arrange for a training session with one of the Owners. <br />
<br />
If you'd like to arrange training, please see:<br />
* [[Equipment/CNC_Router/Training|CNC Router Training]]<br />
<br />
== Health and Safety ==<br />
<br />
The CNC Router is a potentially dangerous piece of equipment which must only be operated by members who have received appropriate training and who take due care. The top things to always remember when using the CNC Router are:<br />
* '''ONLY USE THE CNC ROUTER IF YOU ARE ON THE LIST OF TRAINED USERS'''<br />
* '''NEVER LEAVE THE CNC ROUTER RUNNING UNATTENDED'''<br />
<br />
As a trained user, you should be very aware of the following risks and how to deal with them:<br />
<br />
'''FIRE''' - Cutting with the wrong settings could result in the material igniting.<br />
<br />
'''TRAPPING''' - Stand clear of the machine while in motion.<br />
<br />
'''DUST''' - Ensure extraction system is working.<br />
<br />
'''NOISE''' - Ensure that you wear the correct PPE when working with the machine for prolonged periods.<br />
<br />
== Instructions ==<br />
<br />
[http://wiki.makespace.org/File:MPC6610_CNC_Router_Manual_v1.0-En.pdf Router Manual]<br />
<br />
[[Equipment/CNC_Router/Hand_Controller|Hand Controller Look-up Guide]]<br />
<br />
===Setting the Z Origin Using the Z0 Sensor===<br />
''A tool that has an extremely narrow tip may break when it touches the tool sensor depending on which tool is to be used.''<br />
<br />
1. Secure the workpiece on the bed, and place the Z0 sensor at the place where you want to set the Z origin on the workpiece. Face the surface of the Z0 sensor without the magnet facing upward.<br />
<br />
[[image:Mill_z0.PNG]]<br />
<br />
2. Use the handset to move the tool to the position above the sensor.<br />
<br />
3. On the handset press OK + 8(Z-0). The tool slowly descend until it contacts the sensor. When the tool rises and stops, the setting operation is complete. <br />
<br />
Note: It is important the tool is electrically conductive from tip to shaft, and the sensor is clean. Failure to check will cause damage to the tool and sensor.<br />
<br />
4. Remove the sensor from the workpiece to a location where it will not interfere with future cutting operations.<br />
<br />
==Software==<br />
<br />
The standard software is Vectric's line of CAM software:<br />
<br />
===VCarvePro===<br />
<br />
[[image:Vcarvepro.png]]<br />
<br />
VCarve Pro provides a powerful but intuitive software solution for 2D design and calculation of 2D and 2.5D toolpaths for cutting parts on a CNC Router. <br />
<br />
The software can import 2D designs from other programs but also includes a full set of drawing and editing tools with advanced layout options such as True-Shape Nesting. The toolpath options cover all typical 2D routing operations such as Profiling, Pocketing, Auto-Inlays and Drilling as well as 2.5D strategies such as V-Carving, Prism carving, Fluting and even a decorative Texturing strategy. Each toolpath includes appropriate options to customize the settings and provide a high level of control for different types of operation. In addition all toolpaths can be previewed to show just how the part will look when it is actually cut, this allows instant feedback to allow toolpaths to be further optimized. <br />
<br />
'''Details''': http://www.vectric.com/products/vcarve-pro.htm<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/vcarve-pro<br />
<br />
===Cut3D===<br />
<br />
[[image:Vectric-cut3d.jpg|266px]]<br />
<br />
Cut3D is a dedicated toolpath engine for CNC machining 3D models that have been designed using a 3D CAD or Graphics design product such as AutoCAD, Rhino3D, 3D Studio etc. or scanned using a laser or touch probe device. Cut3D's exceptionally easy to use interface leads you step-by-step through the process of loading a model, setting the size, interactively placing tabs to hold the job in place, calculating single, double or four sided roughing and finishing toolpaths, previewing the results and finally saving the CNC code to run on your machine.<br />
<br />
3D Models that are too large / thick to machine because of gantry height, cutter length or limited material thickness can be 'Sliced' into separate pieces. Each slice can then be machined and the complete job assembled. <br />
<br />
'''Details''': http://www.vectric.com/products/cut3d.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/cut3d<br />
<br />
===PhotoVCarve===<br />
<br />
[[image:Vectric-photovcarve.gif|266px]]<br />
<br />
PhotoVCarve creates lines of grooves that vary in width and depth to represent the detail in a photograph or image. The quality of the finished result is very dependant upon a high level of contrast between the material surface and the machined grooves. This information is very important to remember when cutting designs using the PhotoVCarve software. <br />
<br />
PhotoVCarve machines dark areas in a photograph with wide groove and the lighter areas to have narrower ones. The software automatically calculates the toolpaths based on the cutter selected and maximum depth of groove required. <br />
<br />
'''Details''': http://www.vectric.com/products/photovcarve.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/photovcarve<br />
<br />
== Tooling ==<br />
<br />
=== Router Bits ===<br />
<br />
Router bits (or cutters) are the most common type of cutter, they have two or more vertical cutting edges. These are good general purpose cutters that can be found in most DIY shops. The are the same type that you would use in a manual hand held router.<br />
<br />
<gallery><br />
File:WP_20130813_025.jpg<br />
File:WP_20130813_025.jpg<br />
</gallery><br />
<br />
It is important to notice that the cutters are on the edge of the body only, they do not extend to the centre of the cutter. This means the cutter CAN NOT BE USED AS A DRILL. An holes that are made by these sorts of cutters must be made by ramping the cutter to the correct depth in a sloping or spiral motion.<br />
<br />
NEVER USE ROUTER BITS THAT HAVE BEARINGS<br />
<br />
<br />
=== End mills ===<br />
<br />
'''Up Cut and Down Cut'''<br />
<br />
Router end mills have two variants, up cut (left) and down cut (right); there is a third type, compression, but they are quite rare.<br />
<br />
<gallery><br />
File:WP_20130813_015.jpg<br />
</gallery><br />
<br />
Most cutters are up cut, which have the cutting service on the top of the flutes and as they rotate lift the chips up and away from the material being cut.<br />
<br />
Down cut cutters have the cutting edge on the bottom of the flutes and push chips down towards the material being cut. This has the advantage of pressing the material being cut into the bed of the machine; this is especially useful for thin plastics. The other advantage is the top surface shows far less breakout and splintering, this is a big advantage for materials like laminates.<br />
<br />
On image on the left has been cut with an up-cut end mill and the image on the right a down-cut.<br />
<br />
<gallery><br />
File:WP_20130813_005.jpg<br />
File:WP_20130813_007.jpg<br />
</gallery><br />
<br />
NOTE: There is a very big disadvantage to down cut end mills, and that is that they do not clear there chips effectively in blind holes. This means they need larger ramping moves to get to the correct cutting depth and if used in pockets without enough clearance, the friction can lead to burning or melting of the material being cut.<br />
<br />
Another down side to down-cut cutters, is that when cutting pockets, the bottom surface will not be as clean as that made with an up-cut cutter, which will do a far better job of clearing the waste chips that rub between the cutter and the material with a down-cut.<br />
<br />
== Stock Tooling ==<br />
<br />
In order to keep a small stock of cutters for general use, the CNC Router needs to have a means of generating money. Because there is no material provided for use with the CNC Router there is no way to bring in any funds for such things. Therefore, we ask that if you use one of the communal cutters please put 50p into the CNC Router Honesty Box. This will go towards funding for replenishing stock and also for the replacement of the sacrificial bed once it gets worn out.<br />
<br />
There will likely be 1 or two of each of the following cutters available for use, however please do not count on this being the case:<br />
<br />
* 2.5mm square cutter - single flute<br />
* 1/8" square cutter - single flute<br />
* 1/8" ball cutter - 2 flute<br />
<br />
* 6mm square cutter - 2 flute<br />
* 6mm ball cutter - 2 flute<br />
<br />
* engraver 0.2 30deg 1/8" 30mm length (8 of)<br />
* engraver 0.8 30deg 1/8" 30mm length (2 of)<br />
<br />
* 22mm 2 flute straight <br />
* 90deg x 32mm VBit<br />
<br />
<br />
Some Suppliers are listed below:<br />
<br />
== Feeds & Speeds ==<br />
<br />
What are feeds and speeds? Why are they important?<br />
<br />
[http://www.youtube.com/watch?v=ip2jm_6aUyk&feature=c4-overview&list=UUivA7_KLKWo43tFcCkFvydw Milling machine tutorial - cutter selection, speeds and feeds]<br />
<br />
[http://en.wikipedia.org/wiki/Speeds_and_feeds Wikipedia - Speeds and feeds]<br />
<br />
The phrase speeds and feeds (or feeds and speeds) refers to two separate velocities in machine tool practice, cutting speed and feed rate. They are often considered as a pair because of their combined effect on the cutting process. Each, however, can also be considered and analyzed in its own right.<br />
<br />
Cutting speed (also called surface speed or simply speed) is the speed difference (relative velocity) between the cutting tool and the surface of the workpiece it is operating on. It is expressed in units of distance along the workpiece surface per unit of time, typically surface feet per minute (sfm) or meters per minute (m/min). Feed rate (also often styled as a solid compound, feedrate, or called simply feed) is the relative velocity at which the cutter is advanced along the workpiece; its vector is perpendicular to the vector of cutting speed. Feed rate units depend on the motion of the tool and workpiece; when the workpiece rotates (e.g., in turning and boring), the units are almost always distance per spindle revolution (inches per revolution [in/rev or ipr] or millimeters per revolution [mm/rev]). When the workpiece does not rotate (e.g., in milling), the units are typically distance per time (inches per minute [in/min or ipm] or millimeters per minute [mm/min]), although distance per revolution or per cutter tooth are also sometimes used.<br />
<br />
===Spindle speed quick reference===<br />
<br />
{| class="wikitable"<br />
!|<br />
!|400Hz <br />
!|350Hz <br />
!|300Hz <br />
!|250Hz <br />
!|200Hz <br />
!|150Hz <br />
|-<br />
!|RPM<br />
|24000 <br />
|21000 <br />
|18000 <br />
|15000 <br />
|12000 <br />
|9000 <br />
|-<br />
|}<br />
<br />
===Feed rate quick reference===<br />
<br />
{| class="wikitable" <br />
!|100% <br />
!|75% <br />
!|66% <br />
!|50% <br />
!|33% <br />
!|25% <br />
|-<br />
!|6000<br />
|4500<br />
|3960<br />
|3000<br />
|1980<br />
|1500<br />
|-<br />
!|5000<br />
|3750<br />
|3300<br />
|2500<br />
|1650<br />
|1250<br />
|-<br />
!|4000<br />
|3000<br />
|2640<br />
|2000<br />
|1320<br />
|1000<br />
|-<br />
!|3000 <br />
|2250 <br />
|1980 <br />
|1500 <br />
|990 <br />
|750 <br />
|-<br />
!|2500 <br />
|1875 <br />
|1650 <br />
|1250 <br />
|825 <br />
|625 <br />
|-<br />
!|2000 <br />
|1500 <br />
|1320 <br />
|1000 <br />
|660 <br />
|500 <br />
|-<br />
!|1500 <br />
|1125 <br />
|990 <br />
|750 <br />
|495 <br />
|375 <br />
|-<br />
!|1000 <br />
|750 <br />
|660 <br />
|500 <br />
|330 <br />
|250 <br />
|-<br />
!|500 <br />
|375 <br />
|330 <br />
|250 <br />
|165 <br />
|125 <br />
|-<br />
|}<br />
<br />
=== Sample feed rates ===<br />
<br />
For working out feeds and speeds, recommend http://www.cnccookbook.com/CCGWizard.<br />
<br />
The feeds and speeds below have been tested on our machine. The 3mm cutters were single flute carbide. 2 flute HSS cutters may require different settings to avoid breakages.<br />
<br />
{| class="wikitable"<br />
!|MDF <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep <br />
|-<br />
!|3mm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|-<br />
!|6mm <br />
|3000/15Krpm <br />
|2000/13Krpm <br />
|1500/11Krpm <br />
|-<br />
!|22mm <br />
|3000/5000rpm <br />
|3000/5000rpm <br />
|1500/4Krpm<br />
|-<br />
|}<br />
<br />
{| class="wikitable"<br />
!|Plywood <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep<br />
|-<br />
!|3mm <br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|-<br />
!|6mm <br />
|3000/15Krpm <br />
|1500/15Krpm <br />
|1000/11Krpm <br />
|-<br />
!|22mm <br />
|3000/5Krpm <br />
|3000/5Krpm <br />
|1500/4Krpm <br />
|-<br />
|}<br />
<br />
== Tips & Tricks ==<br />
<br />
= Maintenance =<br />
<br />
The maintenance of the CNC Router is carried out by the Owners, with some basic maintenance being carried out by Users on every job.<br />
<br />
== Maintenance Schedule ==<br />
Every job<br />
* Vacuum cutting dust from bed and around machine<br />
* Sand down high points created on sacrificial bed by cutting/screwing<br />
<br />
As required, by users<br />
* Empty extraction bin <br />
<br />
Monthly<br />
* Inspect extraction hoses for splits/ wear<br />
* Clean and oil guide rails<br />
* Check level and condition of cooling water and replace as necessary<br />
* Inspect sacrificial bed, re-skim or replace as required<br />
<br />
== Maintenance Log ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
3/7/13: Lower spindle clamp bolts replaced with longer stainless ones, holes through tapped as original ones had stripped.<br />
<br />
== Maintenance Shopping List ==<br />
<br />
* Cutters<br />
* Sacrificial Bed (1.2m x 1.2m 12mm MDF)<br />
<br />
= Further Information =<br />
<br />
== Installation ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
<gallery><br />
File:Photo_1.JPG<br />
File:WP_20130509_005.jpg<br />
File:CNC_Router_controller_1.jpg<br />
File:CNC_Router_controller_2.jpg<br />
</gallery><br />
<br />
== Purchase ==<br />
Full Purchase, Delivery and Installation (£?????)<br />
<br />
== Notes ==<br />
<br />
http://www.shopbottools.com/mProducts/prSstandard.htm</div>Perfectphasehttp://wiki.makespace.org/File:WP_20130813_025.jpgFile:WP 20130813 025.jpg2013-08-13T22:44:19Z<p>Perfectphase: </p>
<hr />
<div></div>Perfectphasehttp://wiki.makespace.org/File:WP_20130813_023.jpgFile:WP 20130813 023.jpg2013-08-13T22:41:20Z<p>Perfectphase: </p>
<hr />
<div></div>Perfectphasehttp://wiki.makespace.org/Equipment/CNC_RouterEquipment/CNC Router2013-08-13T22:32:15Z<p>Perfectphase: /* End mills */</p>
<hr />
<div>{{RedTool}}<br />
<br />
[[Equipment|Equipment]] / CNC Router<br />
<br />
[[File:WP_20130509_005.jpg|thumb|460px|right|CNC Router]]<br />
<br />
<br />
== Summary ==<br />
<br />
A CNC router is a computer controlled shaping machine. These are related to the hand held router. Instead of hand held routing, the tool paths can be controlled via computer numerical control. It is a computer-controlled machine for cutting various hard materials, such as wood, composites, aluminum, steel, plastics, and foams. It is one of many kinds of tools that have CNC variants. A CNC router is very similar in concept to a CNC milling machine. The CNC router is controlled by a computer. Coordinates are uploaded into the machine controller from a separate CAD program<br />
<br />
* Capacity: 1200 x 1200 x 120mm<br />
* Rate (X,Y): 6000mm/min (Max) 5000mm/min (Working)<br />
* Rate (Z): 30mm/sec<br />
* Spindle Speed: 4500 to 24000rpm<br />
* Mechanical Precision: 0.01mm<br />
* Spindle Power: 1.5KW Variable Speed, Water-cooled<br />
* Blade Diameter: min 3.175mm, max 12.7mm <br />
* Order Format: HPGL, G code, u00, mmg, plt <br />
* Control System: DSP with USB connection <br />
<br />
Here are some examples we've made on the CNC router (please add a photo of yours any time you do a job!) <br />
<br />
<gallery><br />
File:WP_20130509_004.jpg<br />
File:WP_20130624_017.jpg<br />
File:WP_20130625_001.jpg<br />
</gallery><br />
<br />
= Using the CNC Router =<br />
== Owners ==<br />
<br />
The Owners are those who have volunteered to be in charge of the equipment, organising maintenance, training others to use it, and generally being a point of contact. The current Owners of the CNC Router are:<br />
<br />
* Stephen Woolhead<br />
* Chris Abri<br />
* Mark Mellors<br />
* Dave Ansell<br />
* David Bebb<br />
* Simon Stirley<br />
<br />
If you have any questions, problems or concerns around the CNC router, please use the mailing list thread:<br />
* [https://groups.google.com/d/topic/cammakespace/rkchD7VqM2c/discussion Log : CNC Router]<br />
<br />
== Training ==<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>YOU CAN ONLY USE THE CNC ROUTER IF YOU HAVE BEEN TRAINED</b><br><br />
and have been added to the [[Equipment/CNC_Router/Training#Trained_Users|Trained Users]] list by one of the Owners<br />
</div><br />
<br />
To get trained on the CNC router and be added to the qualified user list, you will need to arrange for a training session with one of the Owners. <br />
<br />
If you'd like to arrange training, please see:<br />
* [[Equipment/CNC_Router/Training|CNC Router Training]]<br />
<br />
== Health and Safety ==<br />
<br />
The CNC Router is a potentially dangerous piece of equipment which must only be operated by members who have received appropriate training and who take due care. The top things to always remember when using the CNC Router are:<br />
* '''ONLY USE THE CNC ROUTER IF YOU ARE ON THE LIST OF TRAINED USERS'''<br />
* '''NEVER LEAVE THE CNC ROUTER RUNNING UNATTENDED'''<br />
<br />
As a trained user, you should be very aware of the following risks and how to deal with them:<br />
<br />
'''FIRE''' - Cutting with the wrong settings could result in the material igniting.<br />
<br />
'''TRAPPING''' - Stand clear of the machine while in motion.<br />
<br />
'''DUST''' - Ensure extraction system is working.<br />
<br />
'''NOISE''' - Ensure that you wear the correct PPE when working with the machine for prolonged periods.<br />
<br />
== Instructions ==<br />
<br />
[http://wiki.makespace.org/File:MPC6610_CNC_Router_Manual_v1.0-En.pdf Router Manual]<br />
<br />
[[Equipment/CNC_Router/Hand_Controller|Hand Controller Look-up Guide]]<br />
<br />
===Setting the Z Origin Using the Z0 Sensor===<br />
''A tool that has an extremely narrow tip may break when it touches the tool sensor depending on which tool is to be used.''<br />
<br />
1. Secure the workpiece on the bed, and place the Z0 sensor at the place where you want to set the Z origin on the workpiece. Face the surface of the Z0 sensor without the magnet facing upward.<br />
<br />
[[image:Mill_z0.PNG]]<br />
<br />
2. Use the handset to move the tool to the position above the sensor.<br />
<br />
3. On the handset press OK + 8(Z-0). The tool slowly descend until it contacts the sensor. When the tool rises and stops, the setting operation is complete. <br />
<br />
Note: It is important the tool is electrically conductive from tip to shaft, and the sensor is clean. Failure to check will cause damage to the tool and sensor.<br />
<br />
4. Remove the sensor from the workpiece to a location where it will not interfere with future cutting operations.<br />
<br />
==Software==<br />
<br />
The standard software is Vectric's line of CAM software:<br />
<br />
===VCarvePro===<br />
<br />
[[image:Vcarvepro.png]]<br />
<br />
VCarve Pro provides a powerful but intuitive software solution for 2D design and calculation of 2D and 2.5D toolpaths for cutting parts on a CNC Router. <br />
<br />
The software can import 2D designs from other programs but also includes a full set of drawing and editing tools with advanced layout options such as True-Shape Nesting. The toolpath options cover all typical 2D routing operations such as Profiling, Pocketing, Auto-Inlays and Drilling as well as 2.5D strategies such as V-Carving, Prism carving, Fluting and even a decorative Texturing strategy. Each toolpath includes appropriate options to customize the settings and provide a high level of control for different types of operation. In addition all toolpaths can be previewed to show just how the part will look when it is actually cut, this allows instant feedback to allow toolpaths to be further optimized. <br />
<br />
'''Details''': http://www.vectric.com/products/vcarve-pro.htm<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/vcarve-pro<br />
<br />
===Cut3D===<br />
<br />
[[image:Vectric-cut3d.jpg|266px]]<br />
<br />
Cut3D is a dedicated toolpath engine for CNC machining 3D models that have been designed using a 3D CAD or Graphics design product such as AutoCAD, Rhino3D, 3D Studio etc. or scanned using a laser or touch probe device. Cut3D's exceptionally easy to use interface leads you step-by-step through the process of loading a model, setting the size, interactively placing tabs to hold the job in place, calculating single, double or four sided roughing and finishing toolpaths, previewing the results and finally saving the CNC code to run on your machine.<br />
<br />
3D Models that are too large / thick to machine because of gantry height, cutter length or limited material thickness can be 'Sliced' into separate pieces. Each slice can then be machined and the complete job assembled. <br />
<br />
'''Details''': http://www.vectric.com/products/cut3d.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/cut3d<br />
<br />
===PhotoVCarve===<br />
<br />
[[image:Vectric-photovcarve.gif|266px]]<br />
<br />
PhotoVCarve creates lines of grooves that vary in width and depth to represent the detail in a photograph or image. The quality of the finished result is very dependant upon a high level of contrast between the material surface and the machined grooves. This information is very important to remember when cutting designs using the PhotoVCarve software. <br />
<br />
PhotoVCarve machines dark areas in a photograph with wide groove and the lighter areas to have narrower ones. The software automatically calculates the toolpaths based on the cutter selected and maximum depth of groove required. <br />
<br />
'''Details''': http://www.vectric.com/products/photovcarve.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/photovcarve<br />
<br />
== Tooling ==<br />
<br />
=== End mills ===<br />
<br />
'''Up Cut and Down Cut'''<br />
<br />
Router end mills have two variants, up cut (left) and down cut (right); there is a third type, compression, but they are quite rare.<br />
<br />
<gallery><br />
File:WP_20130813_015.jpg<br />
</gallery><br />
<br />
Most cutters are up cut, which have the cutting service on the top of the flutes and as they rotate lift the chips up and away from the material being cut.<br />
<br />
Down cut cutters have the cutting edge on the bottom of the flutes and push chips down towards the material being cut. This has the advantage of pressing the material being cut into the bed of the machine; this is especially useful for thin plastics. The other advantage is the top surface shows far less breakout and splintering, this is a big advantage for materials like laminates.<br />
<br />
On image on the left has been cut with an up-cut end mill and the image on the right a down-cut.<br />
<br />
<gallery><br />
File:WP_20130813_005.jpg<br />
File:WP_20130813_007.jpg<br />
</gallery><br />
<br />
NOTE: There is a very big disadvantage to down cut end mills, and that is that they do not clear there chips effectively in blind holes. This means they need larger ramping moves to get to the correct cutting depth and if used in pockets without enough clearance, the friction can lead to burning or melting of the material being cut.<br />
<br />
Another down side to down-cut cutters, is that when cutting pockets, the bottom surface will not be as clean as that made with an up-cut cutter, which will do a far better job of clearing the waste chips that rub between the cutter and the material with a down-cut.<br />
<br />
== Stock Tooling ==<br />
<br />
In order to keep a small stock of cutters for general use, the CNC Router needs to have a means of generating money. Because there is no material provided for use with the CNC Router there is no way to bring in any funds for such things. Therefore, we ask that if you use one of the communal cutters please put 50p into the CNC Router Honesty Box. This will go towards funding for replenishing stock and also for the replacement of the sacrificial bed once it gets worn out.<br />
<br />
There will likely be 1 or two of each of the following cutters available for use, however please do not count on this being the case:<br />
<br />
* 2.5mm square cutter - single flute<br />
* 1/8" square cutter - single flute<br />
* 1/8" ball cutter - 2 flute<br />
<br />
* 6mm square cutter - 2 flute<br />
* 6mm ball cutter - 2 flute<br />
<br />
* engraver 0.2 30deg 1/8" 30mm length (8 of)<br />
* engraver 0.8 30deg 1/8" 30mm length (2 of)<br />
<br />
* 22mm 2 flute straight <br />
* 90deg x 32mm VBit<br />
<br />
<br />
Some Suppliers are listed below:<br />
<br />
== Feeds & Speeds ==<br />
<br />
What are feeds and speeds? Why are they important?<br />
<br />
[http://www.youtube.com/watch?v=ip2jm_6aUyk&feature=c4-overview&list=UUivA7_KLKWo43tFcCkFvydw Milling machine tutorial - cutter selection, speeds and feeds]<br />
<br />
[http://en.wikipedia.org/wiki/Speeds_and_feeds Wikipedia - Speeds and feeds]<br />
<br />
The phrase speeds and feeds (or feeds and speeds) refers to two separate velocities in machine tool practice, cutting speed and feed rate. They are often considered as a pair because of their combined effect on the cutting process. Each, however, can also be considered and analyzed in its own right.<br />
<br />
Cutting speed (also called surface speed or simply speed) is the speed difference (relative velocity) between the cutting tool and the surface of the workpiece it is operating on. It is expressed in units of distance along the workpiece surface per unit of time, typically surface feet per minute (sfm) or meters per minute (m/min). Feed rate (also often styled as a solid compound, feedrate, or called simply feed) is the relative velocity at which the cutter is advanced along the workpiece; its vector is perpendicular to the vector of cutting speed. Feed rate units depend on the motion of the tool and workpiece; when the workpiece rotates (e.g., in turning and boring), the units are almost always distance per spindle revolution (inches per revolution [in/rev or ipr] or millimeters per revolution [mm/rev]). When the workpiece does not rotate (e.g., in milling), the units are typically distance per time (inches per minute [in/min or ipm] or millimeters per minute [mm/min]), although distance per revolution or per cutter tooth are also sometimes used.<br />
<br />
===Spindle speed quick reference===<br />
<br />
{| class="wikitable"<br />
!|<br />
!|400Hz <br />
!|350Hz <br />
!|300Hz <br />
!|250Hz <br />
!|200Hz <br />
!|150Hz <br />
|-<br />
!|RPM<br />
|24000 <br />
|21000 <br />
|18000 <br />
|15000 <br />
|12000 <br />
|9000 <br />
|-<br />
|}<br />
<br />
===Feed rate quick reference===<br />
<br />
{| class="wikitable" <br />
!|100% <br />
!|75% <br />
!|66% <br />
!|50% <br />
!|33% <br />
!|25% <br />
|-<br />
!|6000<br />
|4500<br />
|3960<br />
|3000<br />
|1980<br />
|1500<br />
|-<br />
!|5000<br />
|3750<br />
|3300<br />
|2500<br />
|1650<br />
|1250<br />
|-<br />
!|4000<br />
|3000<br />
|2640<br />
|2000<br />
|1320<br />
|1000<br />
|-<br />
!|3000 <br />
|2250 <br />
|1980 <br />
|1500 <br />
|990 <br />
|750 <br />
|-<br />
!|2500 <br />
|1875 <br />
|1650 <br />
|1250 <br />
|825 <br />
|625 <br />
|-<br />
!|2000 <br />
|1500 <br />
|1320 <br />
|1000 <br />
|660 <br />
|500 <br />
|-<br />
!|1500 <br />
|1125 <br />
|990 <br />
|750 <br />
|495 <br />
|375 <br />
|-<br />
!|1000 <br />
|750 <br />
|660 <br />
|500 <br />
|330 <br />
|250 <br />
|-<br />
!|500 <br />
|375 <br />
|330 <br />
|250 <br />
|165 <br />
|125 <br />
|-<br />
|}<br />
<br />
=== Sample feed rates ===<br />
<br />
For working out feeds and speeds, recommend http://www.cnccookbook.com/CCGWizard.<br />
<br />
The feeds and speeds below have been tested on our machine. The 3mm cutters were single flute carbide. 2 flute HSS cutters may require different settings to avoid breakages.<br />
<br />
{| class="wikitable"<br />
!|MDF <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep <br />
|-<br />
!|3mm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|-<br />
!|6mm <br />
|3000/15Krpm <br />
|2000/13Krpm <br />
|1500/11Krpm <br />
|-<br />
!|22mm <br />
|3000/5000rpm <br />
|3000/5000rpm <br />
|1500/4Krpm<br />
|-<br />
|}<br />
<br />
{| class="wikitable"<br />
!|Plywood <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep<br />
|-<br />
!|3mm <br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|-<br />
!|6mm <br />
|3000/15Krpm <br />
|1500/15Krpm <br />
|1000/11Krpm <br />
|-<br />
!|22mm <br />
|3000/5Krpm <br />
|3000/5Krpm <br />
|1500/4Krpm <br />
|-<br />
|}<br />
<br />
== Tips & Tricks ==<br />
<br />
= Maintenance =<br />
<br />
The maintenance of the CNC Router is carried out by the Owners, with some basic maintenance being carried out by Users on every job.<br />
<br />
== Maintenance Schedule ==<br />
Every job<br />
* Vacuum cutting dust from bed and around machine<br />
* Sand down high points created on sacrificial bed by cutting/screwing<br />
<br />
As required, by users<br />
* Empty extraction bin <br />
<br />
Monthly<br />
* Inspect extraction hoses for splits/ wear<br />
* Clean and oil guide rails<br />
* Check level and condition of cooling water and replace as necessary<br />
* Inspect sacrificial bed, re-skim or replace as required<br />
<br />
== Maintenance Log ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
3/7/13: Lower spindle clamp bolts replaced with longer stainless ones, holes through tapped as original ones had stripped.<br />
<br />
== Maintenance Shopping List ==<br />
<br />
* Cutters<br />
* Sacrificial Bed (1.2m x 1.2m 12mm MDF)<br />
<br />
= Further Information =<br />
<br />
== Installation ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
<gallery><br />
File:Photo_1.JPG<br />
File:WP_20130509_005.jpg<br />
File:CNC_Router_controller_1.jpg<br />
File:CNC_Router_controller_2.jpg<br />
</gallery><br />
<br />
== Purchase ==<br />
Full Purchase, Delivery and Installation (£?????)<br />
<br />
== Notes ==<br />
<br />
http://www.shopbottools.com/mProducts/prSstandard.htm</div>Perfectphasehttp://wiki.makespace.org/Equipment/CNC_RouterEquipment/CNC Router2013-08-13T22:26:45Z<p>Perfectphase: /* End mills */</p>
<hr />
<div>{{RedTool}}<br />
<br />
[[Equipment|Equipment]] / CNC Router<br />
<br />
[[File:WP_20130509_005.jpg|thumb|460px|right|CNC Router]]<br />
<br />
<br />
== Summary ==<br />
<br />
A CNC router is a computer controlled shaping machine. These are related to the hand held router. Instead of hand held routing, the tool paths can be controlled via computer numerical control. It is a computer-controlled machine for cutting various hard materials, such as wood, composites, aluminum, steel, plastics, and foams. It is one of many kinds of tools that have CNC variants. A CNC router is very similar in concept to a CNC milling machine. The CNC router is controlled by a computer. Coordinates are uploaded into the machine controller from a separate CAD program<br />
<br />
* Capacity: 1200 x 1200 x 120mm<br />
* Rate (X,Y): 6000mm/min (Max) 5000mm/min (Working)<br />
* Rate (Z): 30mm/sec<br />
* Spindle Speed: 4500 to 24000rpm<br />
* Mechanical Precision: 0.01mm<br />
* Spindle Power: 1.5KW Variable Speed, Water-cooled<br />
* Blade Diameter: min 3.175mm, max 12.7mm <br />
* Order Format: HPGL, G code, u00, mmg, plt <br />
* Control System: DSP with USB connection <br />
<br />
Here are some examples we've made on the CNC router (please add a photo of yours any time you do a job!) <br />
<br />
<gallery><br />
File:WP_20130509_004.jpg<br />
File:WP_20130624_017.jpg<br />
File:WP_20130625_001.jpg<br />
</gallery><br />
<br />
= Using the CNC Router =<br />
== Owners ==<br />
<br />
The Owners are those who have volunteered to be in charge of the equipment, organising maintenance, training others to use it, and generally being a point of contact. The current Owners of the CNC Router are:<br />
<br />
* Stephen Woolhead<br />
* Chris Abri<br />
* Mark Mellors<br />
* Dave Ansell<br />
* David Bebb<br />
* Simon Stirley<br />
<br />
If you have any questions, problems or concerns around the CNC router, please use the mailing list thread:<br />
* [https://groups.google.com/d/topic/cammakespace/rkchD7VqM2c/discussion Log : CNC Router]<br />
<br />
== Training ==<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>YOU CAN ONLY USE THE CNC ROUTER IF YOU HAVE BEEN TRAINED</b><br><br />
and have been added to the [[Equipment/CNC_Router/Training#Trained_Users|Trained Users]] list by one of the Owners<br />
</div><br />
<br />
To get trained on the CNC router and be added to the qualified user list, you will need to arrange for a training session with one of the Owners. <br />
<br />
If you'd like to arrange training, please see:<br />
* [[Equipment/CNC_Router/Training|CNC Router Training]]<br />
<br />
== Health and Safety ==<br />
<br />
The CNC Router is a potentially dangerous piece of equipment which must only be operated by members who have received appropriate training and who take due care. The top things to always remember when using the CNC Router are:<br />
* '''ONLY USE THE CNC ROUTER IF YOU ARE ON THE LIST OF TRAINED USERS'''<br />
* '''NEVER LEAVE THE CNC ROUTER RUNNING UNATTENDED'''<br />
<br />
As a trained user, you should be very aware of the following risks and how to deal with them:<br />
<br />
'''FIRE''' - Cutting with the wrong settings could result in the material igniting.<br />
<br />
'''TRAPPING''' - Stand clear of the machine while in motion.<br />
<br />
'''DUST''' - Ensure extraction system is working.<br />
<br />
'''NOISE''' - Ensure that you wear the correct PPE when working with the machine for prolonged periods.<br />
<br />
== Instructions ==<br />
<br />
[http://wiki.makespace.org/File:MPC6610_CNC_Router_Manual_v1.0-En.pdf Router Manual]<br />
<br />
[[Equipment/CNC_Router/Hand_Controller|Hand Controller Look-up Guide]]<br />
<br />
===Setting the Z Origin Using the Z0 Sensor===<br />
''A tool that has an extremely narrow tip may break when it touches the tool sensor depending on which tool is to be used.''<br />
<br />
1. Secure the workpiece on the bed, and place the Z0 sensor at the place where you want to set the Z origin on the workpiece. Face the surface of the Z0 sensor without the magnet facing upward.<br />
<br />
[[image:Mill_z0.PNG]]<br />
<br />
2. Use the handset to move the tool to the position above the sensor.<br />
<br />
3. On the handset press OK + 8(Z-0). The tool slowly descend until it contacts the sensor. When the tool rises and stops, the setting operation is complete. <br />
<br />
Note: It is important the tool is electrically conductive from tip to shaft, and the sensor is clean. Failure to check will cause damage to the tool and sensor.<br />
<br />
4. Remove the sensor from the workpiece to a location where it will not interfere with future cutting operations.<br />
<br />
==Software==<br />
<br />
The standard software is Vectric's line of CAM software:<br />
<br />
===VCarvePro===<br />
<br />
[[image:Vcarvepro.png]]<br />
<br />
VCarve Pro provides a powerful but intuitive software solution for 2D design and calculation of 2D and 2.5D toolpaths for cutting parts on a CNC Router. <br />
<br />
The software can import 2D designs from other programs but also includes a full set of drawing and editing tools with advanced layout options such as True-Shape Nesting. The toolpath options cover all typical 2D routing operations such as Profiling, Pocketing, Auto-Inlays and Drilling as well as 2.5D strategies such as V-Carving, Prism carving, Fluting and even a decorative Texturing strategy. Each toolpath includes appropriate options to customize the settings and provide a high level of control for different types of operation. In addition all toolpaths can be previewed to show just how the part will look when it is actually cut, this allows instant feedback to allow toolpaths to be further optimized. <br />
<br />
'''Details''': http://www.vectric.com/products/vcarve-pro.htm<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/vcarve-pro<br />
<br />
===Cut3D===<br />
<br />
[[image:Vectric-cut3d.jpg|266px]]<br />
<br />
Cut3D is a dedicated toolpath engine for CNC machining 3D models that have been designed using a 3D CAD or Graphics design product such as AutoCAD, Rhino3D, 3D Studio etc. or scanned using a laser or touch probe device. Cut3D's exceptionally easy to use interface leads you step-by-step through the process of loading a model, setting the size, interactively placing tabs to hold the job in place, calculating single, double or four sided roughing and finishing toolpaths, previewing the results and finally saving the CNC code to run on your machine.<br />
<br />
3D Models that are too large / thick to machine because of gantry height, cutter length or limited material thickness can be 'Sliced' into separate pieces. Each slice can then be machined and the complete job assembled. <br />
<br />
'''Details''': http://www.vectric.com/products/cut3d.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/cut3d<br />
<br />
===PhotoVCarve===<br />
<br />
[[image:Vectric-photovcarve.gif|266px]]<br />
<br />
PhotoVCarve creates lines of grooves that vary in width and depth to represent the detail in a photograph or image. The quality of the finished result is very dependant upon a high level of contrast between the material surface and the machined grooves. This information is very important to remember when cutting designs using the PhotoVCarve software. <br />
<br />
PhotoVCarve machines dark areas in a photograph with wide groove and the lighter areas to have narrower ones. The software automatically calculates the toolpaths based on the cutter selected and maximum depth of groove required. <br />
<br />
'''Details''': http://www.vectric.com/products/photovcarve.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/photovcarve<br />
<br />
== Tooling ==<br />
<br />
=== End mills ===<br />
<br />
'''Up Cut and Down Cut'''<br />
<br />
Router end mills have two variants, up cut (left) and down cut (right)<br />
<br />
<gallery><br />
File:WP_20130813_015.jpg<br />
</gallery><br />
<br />
Most cutters are up cut, which have the cutting service on the top of the flutes and as they rotate lift the chips up and away from the material being cut.<br />
<br />
Down cut cutters have the cutting edge on the bottom of the flutes and push chips down towards the material being cut. This has the advantage of pressing the material being cut into the bed of the machine; this is especially useful for thin plastics. The other advantage is the top surface shows far less breakout and splintering, this is a big advantage for materials like laminates.<br />
<br />
On image on the left has been cut with an up-cut end mill and the image on the right a down-cut.<br />
<br />
<gallery><br />
File:WP_20130813_005.jpg<br />
File:WP_20130813_007.jpg<br />
</gallery><br />
<br />
NOTE: There is a very big disadvantage to down cut end mills, and that is that they do not clear there chips effectively in blind holes. This means they need larger ramping moves to get to the correct cutting depth and if used in pockets without enough clearance, the friction can lead to burning or melting of the material being cut.<br />
<br />
Another down side to down-cut cutters, is that when cutting pockets, the bottom surface will not be as clean as that made with an up-cut cutter, which will do a far better job of clearing the waste chips that rub between the cutter and the material with a down-cut.<br />
<br />
== Stock Tooling ==<br />
<br />
In order to keep a small stock of cutters for general use, the CNC Router needs to have a means of generating money. Because there is no material provided for use with the CNC Router there is no way to bring in any funds for such things. Therefore, we ask that if you use one of the communal cutters please put 50p into the CNC Router Honesty Box. This will go towards funding for replenishing stock and also for the replacement of the sacrificial bed once it gets worn out.<br />
<br />
There will likely be 1 or two of each of the following cutters available for use, however please do not count on this being the case:<br />
<br />
* 2.5mm square cutter - single flute<br />
* 1/8" square cutter - single flute<br />
* 1/8" ball cutter - 2 flute<br />
<br />
* 6mm square cutter - 2 flute<br />
* 6mm ball cutter - 2 flute<br />
<br />
* engraver 0.2 30deg 1/8" 30mm length (8 of)<br />
* engraver 0.8 30deg 1/8" 30mm length (2 of)<br />
<br />
* 22mm 2 flute straight <br />
* 90deg x 32mm VBit<br />
<br />
<br />
Some Suppliers are listed below:<br />
<br />
== Feeds & Speeds ==<br />
<br />
What are feeds and speeds? Why are they important?<br />
<br />
[http://www.youtube.com/watch?v=ip2jm_6aUyk&feature=c4-overview&list=UUivA7_KLKWo43tFcCkFvydw Milling machine tutorial - cutter selection, speeds and feeds]<br />
<br />
[http://en.wikipedia.org/wiki/Speeds_and_feeds Wikipedia - Speeds and feeds]<br />
<br />
The phrase speeds and feeds (or feeds and speeds) refers to two separate velocities in machine tool practice, cutting speed and feed rate. They are often considered as a pair because of their combined effect on the cutting process. Each, however, can also be considered and analyzed in its own right.<br />
<br />
Cutting speed (also called surface speed or simply speed) is the speed difference (relative velocity) between the cutting tool and the surface of the workpiece it is operating on. It is expressed in units of distance along the workpiece surface per unit of time, typically surface feet per minute (sfm) or meters per minute (m/min). Feed rate (also often styled as a solid compound, feedrate, or called simply feed) is the relative velocity at which the cutter is advanced along the workpiece; its vector is perpendicular to the vector of cutting speed. Feed rate units depend on the motion of the tool and workpiece; when the workpiece rotates (e.g., in turning and boring), the units are almost always distance per spindle revolution (inches per revolution [in/rev or ipr] or millimeters per revolution [mm/rev]). When the workpiece does not rotate (e.g., in milling), the units are typically distance per time (inches per minute [in/min or ipm] or millimeters per minute [mm/min]), although distance per revolution or per cutter tooth are also sometimes used.<br />
<br />
===Spindle speed quick reference===<br />
<br />
{| class="wikitable"<br />
!|<br />
!|400Hz <br />
!|350Hz <br />
!|300Hz <br />
!|250Hz <br />
!|200Hz <br />
!|150Hz <br />
|-<br />
!|RPM<br />
|24000 <br />
|21000 <br />
|18000 <br />
|15000 <br />
|12000 <br />
|9000 <br />
|-<br />
|}<br />
<br />
===Feed rate quick reference===<br />
<br />
{| class="wikitable" <br />
!|100% <br />
!|75% <br />
!|66% <br />
!|50% <br />
!|33% <br />
!|25% <br />
|-<br />
!|6000<br />
|4500<br />
|3960<br />
|3000<br />
|1980<br />
|1500<br />
|-<br />
!|5000<br />
|3750<br />
|3300<br />
|2500<br />
|1650<br />
|1250<br />
|-<br />
!|4000<br />
|3000<br />
|2640<br />
|2000<br />
|1320<br />
|1000<br />
|-<br />
!|3000 <br />
|2250 <br />
|1980 <br />
|1500 <br />
|990 <br />
|750 <br />
|-<br />
!|2500 <br />
|1875 <br />
|1650 <br />
|1250 <br />
|825 <br />
|625 <br />
|-<br />
!|2000 <br />
|1500 <br />
|1320 <br />
|1000 <br />
|660 <br />
|500 <br />
|-<br />
!|1500 <br />
|1125 <br />
|990 <br />
|750 <br />
|495 <br />
|375 <br />
|-<br />
!|1000 <br />
|750 <br />
|660 <br />
|500 <br />
|330 <br />
|250 <br />
|-<br />
!|500 <br />
|375 <br />
|330 <br />
|250 <br />
|165 <br />
|125 <br />
|-<br />
|}<br />
<br />
=== Sample feed rates ===<br />
<br />
For working out feeds and speeds, recommend http://www.cnccookbook.com/CCGWizard.<br />
<br />
The feeds and speeds below have been tested on our machine. The 3mm cutters were single flute carbide. 2 flute HSS cutters may require different settings to avoid breakages.<br />
<br />
{| class="wikitable"<br />
!|MDF <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep <br />
|-<br />
!|3mm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|-<br />
!|6mm <br />
|3000/15Krpm <br />
|2000/13Krpm <br />
|1500/11Krpm <br />
|-<br />
!|22mm <br />
|3000/5000rpm <br />
|3000/5000rpm <br />
|1500/4Krpm<br />
|-<br />
|}<br />
<br />
{| class="wikitable"<br />
!|Plywood <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep<br />
|-<br />
!|3mm <br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|-<br />
!|6mm <br />
|3000/15Krpm <br />
|1500/15Krpm <br />
|1000/11Krpm <br />
|-<br />
!|22mm <br />
|3000/5Krpm <br />
|3000/5Krpm <br />
|1500/4Krpm <br />
|-<br />
|}<br />
<br />
== Tips & Tricks ==<br />
<br />
= Maintenance =<br />
<br />
The maintenance of the CNC Router is carried out by the Owners, with some basic maintenance being carried out by Users on every job.<br />
<br />
== Maintenance Schedule ==<br />
Every job<br />
* Vacuum cutting dust from bed and around machine<br />
* Sand down high points created on sacrificial bed by cutting/screwing<br />
<br />
As required, by users<br />
* Empty extraction bin <br />
<br />
Monthly<br />
* Inspect extraction hoses for splits/ wear<br />
* Clean and oil guide rails<br />
* Check level and condition of cooling water and replace as necessary<br />
* Inspect sacrificial bed, re-skim or replace as required<br />
<br />
== Maintenance Log ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
3/7/13: Lower spindle clamp bolts replaced with longer stainless ones, holes through tapped as original ones had stripped.<br />
<br />
== Maintenance Shopping List ==<br />
<br />
* Cutters<br />
* Sacrificial Bed (1.2m x 1.2m 12mm MDF)<br />
<br />
= Further Information =<br />
<br />
== Installation ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
<gallery><br />
File:Photo_1.JPG<br />
File:WP_20130509_005.jpg<br />
File:CNC_Router_controller_1.jpg<br />
File:CNC_Router_controller_2.jpg<br />
</gallery><br />
<br />
== Purchase ==<br />
Full Purchase, Delivery and Installation (£?????)<br />
<br />
== Notes ==<br />
<br />
http://www.shopbottools.com/mProducts/prSstandard.htm</div>Perfectphasehttp://wiki.makespace.org/Equipment/CNC_RouterEquipment/CNC Router2013-08-13T22:17:51Z<p>Perfectphase: /* End mills */</p>
<hr />
<div>{{RedTool}}<br />
<br />
[[Equipment|Equipment]] / CNC Router<br />
<br />
[[File:WP_20130509_005.jpg|thumb|460px|right|CNC Router]]<br />
<br />
<br />
== Summary ==<br />
<br />
A CNC router is a computer controlled shaping machine. These are related to the hand held router. Instead of hand held routing, the tool paths can be controlled via computer numerical control. It is a computer-controlled machine for cutting various hard materials, such as wood, composites, aluminum, steel, plastics, and foams. It is one of many kinds of tools that have CNC variants. A CNC router is very similar in concept to a CNC milling machine. The CNC router is controlled by a computer. Coordinates are uploaded into the machine controller from a separate CAD program<br />
<br />
* Capacity: 1200 x 1200 x 120mm<br />
* Rate (X,Y): 6000mm/min (Max) 5000mm/min (Working)<br />
* Rate (Z): 30mm/sec<br />
* Spindle Speed: 4500 to 24000rpm<br />
* Mechanical Precision: 0.01mm<br />
* Spindle Power: 1.5KW Variable Speed, Water-cooled<br />
* Blade Diameter: min 3.175mm, max 12.7mm <br />
* Order Format: HPGL, G code, u00, mmg, plt <br />
* Control System: DSP with USB connection <br />
<br />
Here are some examples we've made on the CNC router (please add a photo of yours any time you do a job!) <br />
<br />
<gallery><br />
File:WP_20130509_004.jpg<br />
File:WP_20130624_017.jpg<br />
File:WP_20130625_001.jpg<br />
</gallery><br />
<br />
= Using the CNC Router =<br />
== Owners ==<br />
<br />
The Owners are those who have volunteered to be in charge of the equipment, organising maintenance, training others to use it, and generally being a point of contact. The current Owners of the CNC Router are:<br />
<br />
* Stephen Woolhead<br />
* Chris Abri<br />
* Mark Mellors<br />
* Dave Ansell<br />
* David Bebb<br />
* Simon Stirley<br />
<br />
If you have any questions, problems or concerns around the CNC router, please use the mailing list thread:<br />
* [https://groups.google.com/d/topic/cammakespace/rkchD7VqM2c/discussion Log : CNC Router]<br />
<br />
== Training ==<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>YOU CAN ONLY USE THE CNC ROUTER IF YOU HAVE BEEN TRAINED</b><br><br />
and have been added to the [[Equipment/CNC_Router/Training#Trained_Users|Trained Users]] list by one of the Owners<br />
</div><br />
<br />
To get trained on the CNC router and be added to the qualified user list, you will need to arrange for a training session with one of the Owners. <br />
<br />
If you'd like to arrange training, please see:<br />
* [[Equipment/CNC_Router/Training|CNC Router Training]]<br />
<br />
== Health and Safety ==<br />
<br />
The CNC Router is a potentially dangerous piece of equipment which must only be operated by members who have received appropriate training and who take due care. The top things to always remember when using the CNC Router are:<br />
* '''ONLY USE THE CNC ROUTER IF YOU ARE ON THE LIST OF TRAINED USERS'''<br />
* '''NEVER LEAVE THE CNC ROUTER RUNNING UNATTENDED'''<br />
<br />
As a trained user, you should be very aware of the following risks and how to deal with them:<br />
<br />
'''FIRE''' - Cutting with the wrong settings could result in the material igniting.<br />
<br />
'''TRAPPING''' - Stand clear of the machine while in motion.<br />
<br />
'''DUST''' - Ensure extraction system is working.<br />
<br />
'''NOISE''' - Ensure that you wear the correct PPE when working with the machine for prolonged periods.<br />
<br />
== Instructions ==<br />
<br />
[http://wiki.makespace.org/File:MPC6610_CNC_Router_Manual_v1.0-En.pdf Router Manual]<br />
<br />
[[Equipment/CNC_Router/Hand_Controller|Hand Controller Look-up Guide]]<br />
<br />
===Setting the Z Origin Using the Z0 Sensor===<br />
''A tool that has an extremely narrow tip may break when it touches the tool sensor depending on which tool is to be used.''<br />
<br />
1. Secure the workpiece on the bed, and place the Z0 sensor at the place where you want to set the Z origin on the workpiece. Face the surface of the Z0 sensor without the magnet facing upward.<br />
<br />
[[image:Mill_z0.PNG]]<br />
<br />
2. Use the handset to move the tool to the position above the sensor.<br />
<br />
3. On the handset press OK + 8(Z-0). The tool slowly descend until it contacts the sensor. When the tool rises and stops, the setting operation is complete. <br />
<br />
Note: It is important the tool is electrically conductive from tip to shaft, and the sensor is clean. Failure to check will cause damage to the tool and sensor.<br />
<br />
4. Remove the sensor from the workpiece to a location where it will not interfere with future cutting operations.<br />
<br />
==Software==<br />
<br />
The standard software is Vectric's line of CAM software:<br />
<br />
===VCarvePro===<br />
<br />
[[image:Vcarvepro.png]]<br />
<br />
VCarve Pro provides a powerful but intuitive software solution for 2D design and calculation of 2D and 2.5D toolpaths for cutting parts on a CNC Router. <br />
<br />
The software can import 2D designs from other programs but also includes a full set of drawing and editing tools with advanced layout options such as True-Shape Nesting. The toolpath options cover all typical 2D routing operations such as Profiling, Pocketing, Auto-Inlays and Drilling as well as 2.5D strategies such as V-Carving, Prism carving, Fluting and even a decorative Texturing strategy. Each toolpath includes appropriate options to customize the settings and provide a high level of control for different types of operation. In addition all toolpaths can be previewed to show just how the part will look when it is actually cut, this allows instant feedback to allow toolpaths to be further optimized. <br />
<br />
'''Details''': http://www.vectric.com/products/vcarve-pro.htm<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/vcarve-pro<br />
<br />
===Cut3D===<br />
<br />
[[image:Vectric-cut3d.jpg|266px]]<br />
<br />
Cut3D is a dedicated toolpath engine for CNC machining 3D models that have been designed using a 3D CAD or Graphics design product such as AutoCAD, Rhino3D, 3D Studio etc. or scanned using a laser or touch probe device. Cut3D's exceptionally easy to use interface leads you step-by-step through the process of loading a model, setting the size, interactively placing tabs to hold the job in place, calculating single, double or four sided roughing and finishing toolpaths, previewing the results and finally saving the CNC code to run on your machine.<br />
<br />
3D Models that are too large / thick to machine because of gantry height, cutter length or limited material thickness can be 'Sliced' into separate pieces. Each slice can then be machined and the complete job assembled. <br />
<br />
'''Details''': http://www.vectric.com/products/cut3d.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/cut3d<br />
<br />
===PhotoVCarve===<br />
<br />
[[image:Vectric-photovcarve.gif|266px]]<br />
<br />
PhotoVCarve creates lines of grooves that vary in width and depth to represent the detail in a photograph or image. The quality of the finished result is very dependant upon a high level of contrast between the material surface and the machined grooves. This information is very important to remember when cutting designs using the PhotoVCarve software. <br />
<br />
PhotoVCarve machines dark areas in a photograph with wide groove and the lighter areas to have narrower ones. The software automatically calculates the toolpaths based on the cutter selected and maximum depth of groove required. <br />
<br />
'''Details''': http://www.vectric.com/products/photovcarve.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/photovcarve<br />
<br />
== Tooling ==<br />
<br />
=== End mills ===<br />
<br />
'''Up Cut and Down Cut'''<br />
<br />
Router end mills have two variants, up cut (left) and down cut (right)<br />
<br />
<gallery><br />
File:WP_20130813_015.jpg<br />
</gallery><br />
<br />
Most cutters are up cut, which have the cutting service on the top of the flutes and as they rotate lift the chips up and away from the material being cut.<br />
<br />
Down cut cutters have the cutting edge on the bottom of the flutes and push chips down towards the material being cut. This has the advantage of pressing the material being cut into the bed of the machine; this is especially useful for thin plastics. The other advantage is the top surface shows far less breakout and splintering, this is a big advantage for materials like laminates.<br />
<br />
On image on the left has been cut with an up-cut end mill and the image on the right a down-cut.<br />
<br />
<gallery><br />
File:WP_20130813_005.jpg<br />
File:WP_20130813_007.jpg<br />
</gallery><br />
<br />
NOTE: There is a very big disadvantage to down cut end mills, and that is that they do not clear there chips in blind holes. This means they need larger ramping moves to get to the correct cutting depth and if used in pockets without enough clearance, the friction can lead to burning or melting of the material being cut.<br />
<br />
Another down side to down-cut cutters, is that when cutting pockets, the bottom surface will not be as clean as that made with an up-cut cutter, which will do a far better job of clearing the waste chips that rub between the cutter and the material with a down-cut.<br />
<br />
== Stock Tooling ==<br />
<br />
In order to keep a small stock of cutters for general use, the CNC Router needs to have a means of generating money. Because there is no material provided for use with the CNC Router there is no way to bring in any funds for such things. Therefore, we ask that if you use one of the communal cutters please put 50p into the CNC Router Honesty Box. This will go towards funding for replenishing stock and also for the replacement of the sacrificial bed once it gets worn out.<br />
<br />
There will likely be 1 or two of each of the following cutters available for use, however please do not count on this being the case:<br />
<br />
* 2.5mm square cutter - single flute<br />
* 1/8" square cutter - single flute<br />
* 1/8" ball cutter - 2 flute<br />
<br />
* 6mm square cutter - 2 flute<br />
* 6mm ball cutter - 2 flute<br />
<br />
* engraver 0.2 30deg 1/8" 30mm length (8 of)<br />
* engraver 0.8 30deg 1/8" 30mm length (2 of)<br />
<br />
* 22mm 2 flute straight <br />
* 90deg x 32mm VBit<br />
<br />
<br />
Some Suppliers are listed below:<br />
<br />
== Feeds & Speeds ==<br />
<br />
What are feeds and speeds? Why are they important?<br />
<br />
[http://www.youtube.com/watch?v=ip2jm_6aUyk&feature=c4-overview&list=UUivA7_KLKWo43tFcCkFvydw Milling machine tutorial - cutter selection, speeds and feeds]<br />
<br />
[http://en.wikipedia.org/wiki/Speeds_and_feeds Wikipedia - Speeds and feeds]<br />
<br />
The phrase speeds and feeds (or feeds and speeds) refers to two separate velocities in machine tool practice, cutting speed and feed rate. They are often considered as a pair because of their combined effect on the cutting process. Each, however, can also be considered and analyzed in its own right.<br />
<br />
Cutting speed (also called surface speed or simply speed) is the speed difference (relative velocity) between the cutting tool and the surface of the workpiece it is operating on. It is expressed in units of distance along the workpiece surface per unit of time, typically surface feet per minute (sfm) or meters per minute (m/min). Feed rate (also often styled as a solid compound, feedrate, or called simply feed) is the relative velocity at which the cutter is advanced along the workpiece; its vector is perpendicular to the vector of cutting speed. Feed rate units depend on the motion of the tool and workpiece; when the workpiece rotates (e.g., in turning and boring), the units are almost always distance per spindle revolution (inches per revolution [in/rev or ipr] or millimeters per revolution [mm/rev]). When the workpiece does not rotate (e.g., in milling), the units are typically distance per time (inches per minute [in/min or ipm] or millimeters per minute [mm/min]), although distance per revolution or per cutter tooth are also sometimes used.<br />
<br />
===Spindle speed quick reference===<br />
<br />
{| class="wikitable"<br />
!|<br />
!|400Hz <br />
!|350Hz <br />
!|300Hz <br />
!|250Hz <br />
!|200Hz <br />
!|150Hz <br />
|-<br />
!|RPM<br />
|24000 <br />
|21000 <br />
|18000 <br />
|15000 <br />
|12000 <br />
|9000 <br />
|-<br />
|}<br />
<br />
===Feed rate quick reference===<br />
<br />
{| class="wikitable" <br />
!|100% <br />
!|75% <br />
!|66% <br />
!|50% <br />
!|33% <br />
!|25% <br />
|-<br />
!|6000<br />
|4500<br />
|3960<br />
|3000<br />
|1980<br />
|1500<br />
|-<br />
!|5000<br />
|3750<br />
|3300<br />
|2500<br />
|1650<br />
|1250<br />
|-<br />
!|4000<br />
|3000<br />
|2640<br />
|2000<br />
|1320<br />
|1000<br />
|-<br />
!|3000 <br />
|2250 <br />
|1980 <br />
|1500 <br />
|990 <br />
|750 <br />
|-<br />
!|2500 <br />
|1875 <br />
|1650 <br />
|1250 <br />
|825 <br />
|625 <br />
|-<br />
!|2000 <br />
|1500 <br />
|1320 <br />
|1000 <br />
|660 <br />
|500 <br />
|-<br />
!|1500 <br />
|1125 <br />
|990 <br />
|750 <br />
|495 <br />
|375 <br />
|-<br />
!|1000 <br />
|750 <br />
|660 <br />
|500 <br />
|330 <br />
|250 <br />
|-<br />
!|500 <br />
|375 <br />
|330 <br />
|250 <br />
|165 <br />
|125 <br />
|-<br />
|}<br />
<br />
=== Sample feed rates ===<br />
<br />
For working out feeds and speeds, recommend http://www.cnccookbook.com/CCGWizard.<br />
<br />
The feeds and speeds below have been tested on our machine. The 3mm cutters were single flute carbide. 2 flute HSS cutters may require different settings to avoid breakages.<br />
<br />
{| class="wikitable"<br />
!|MDF <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep <br />
|-<br />
!|3mm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|-<br />
!|6mm <br />
|3000/15Krpm <br />
|2000/13Krpm <br />
|1500/11Krpm <br />
|-<br />
!|22mm <br />
|3000/5000rpm <br />
|3000/5000rpm <br />
|1500/4Krpm<br />
|-<br />
|}<br />
<br />
{| class="wikitable"<br />
!|Plywood <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep<br />
|-<br />
!|3mm <br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|-<br />
!|6mm <br />
|3000/15Krpm <br />
|1500/15Krpm <br />
|1000/11Krpm <br />
|-<br />
!|22mm <br />
|3000/5Krpm <br />
|3000/5Krpm <br />
|1500/4Krpm <br />
|-<br />
|}<br />
<br />
== Tips & Tricks ==<br />
<br />
= Maintenance =<br />
<br />
The maintenance of the CNC Router is carried out by the Owners, with some basic maintenance being carried out by Users on every job.<br />
<br />
== Maintenance Schedule ==<br />
Every job<br />
* Vacuum cutting dust from bed and around machine<br />
* Sand down high points created on sacrificial bed by cutting/screwing<br />
<br />
As required, by users<br />
* Empty extraction bin <br />
<br />
Monthly<br />
* Inspect extraction hoses for splits/ wear<br />
* Clean and oil guide rails<br />
* Check level and condition of cooling water and replace as necessary<br />
* Inspect sacrificial bed, re-skim or replace as required<br />
<br />
== Maintenance Log ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
3/7/13: Lower spindle clamp bolts replaced with longer stainless ones, holes through tapped as original ones had stripped.<br />
<br />
== Maintenance Shopping List ==<br />
<br />
* Cutters<br />
* Sacrificial Bed (1.2m x 1.2m 12mm MDF)<br />
<br />
= Further Information =<br />
<br />
== Installation ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
<gallery><br />
File:Photo_1.JPG<br />
File:WP_20130509_005.jpg<br />
File:CNC_Router_controller_1.jpg<br />
File:CNC_Router_controller_2.jpg<br />
</gallery><br />
<br />
== Purchase ==<br />
Full Purchase, Delivery and Installation (£?????)<br />
<br />
== Notes ==<br />
<br />
http://www.shopbottools.com/mProducts/prSstandard.htm</div>Perfectphasehttp://wiki.makespace.org/Equipment/CNC_RouterEquipment/CNC Router2013-08-13T22:17:40Z<p>Perfectphase: /* = End mills */</p>
<hr />
<div>{{RedTool}}<br />
<br />
[[Equipment|Equipment]] / CNC Router<br />
<br />
[[File:WP_20130509_005.jpg|thumb|460px|right|CNC Router]]<br />
<br />
<br />
== Summary ==<br />
<br />
A CNC router is a computer controlled shaping machine. These are related to the hand held router. Instead of hand held routing, the tool paths can be controlled via computer numerical control. It is a computer-controlled machine for cutting various hard materials, such as wood, composites, aluminum, steel, plastics, and foams. It is one of many kinds of tools that have CNC variants. A CNC router is very similar in concept to a CNC milling machine. The CNC router is controlled by a computer. Coordinates are uploaded into the machine controller from a separate CAD program<br />
<br />
* Capacity: 1200 x 1200 x 120mm<br />
* Rate (X,Y): 6000mm/min (Max) 5000mm/min (Working)<br />
* Rate (Z): 30mm/sec<br />
* Spindle Speed: 4500 to 24000rpm<br />
* Mechanical Precision: 0.01mm<br />
* Spindle Power: 1.5KW Variable Speed, Water-cooled<br />
* Blade Diameter: min 3.175mm, max 12.7mm <br />
* Order Format: HPGL, G code, u00, mmg, plt <br />
* Control System: DSP with USB connection <br />
<br />
Here are some examples we've made on the CNC router (please add a photo of yours any time you do a job!) <br />
<br />
<gallery><br />
File:WP_20130509_004.jpg<br />
File:WP_20130624_017.jpg<br />
File:WP_20130625_001.jpg<br />
</gallery><br />
<br />
= Using the CNC Router =<br />
== Owners ==<br />
<br />
The Owners are those who have volunteered to be in charge of the equipment, organising maintenance, training others to use it, and generally being a point of contact. The current Owners of the CNC Router are:<br />
<br />
* Stephen Woolhead<br />
* Chris Abri<br />
* Mark Mellors<br />
* Dave Ansell<br />
* David Bebb<br />
* Simon Stirley<br />
<br />
If you have any questions, problems or concerns around the CNC router, please use the mailing list thread:<br />
* [https://groups.google.com/d/topic/cammakespace/rkchD7VqM2c/discussion Log : CNC Router]<br />
<br />
== Training ==<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>YOU CAN ONLY USE THE CNC ROUTER IF YOU HAVE BEEN TRAINED</b><br><br />
and have been added to the [[Equipment/CNC_Router/Training#Trained_Users|Trained Users]] list by one of the Owners<br />
</div><br />
<br />
To get trained on the CNC router and be added to the qualified user list, you will need to arrange for a training session with one of the Owners. <br />
<br />
If you'd like to arrange training, please see:<br />
* [[Equipment/CNC_Router/Training|CNC Router Training]]<br />
<br />
== Health and Safety ==<br />
<br />
The CNC Router is a potentially dangerous piece of equipment which must only be operated by members who have received appropriate training and who take due care. The top things to always remember when using the CNC Router are:<br />
* '''ONLY USE THE CNC ROUTER IF YOU ARE ON THE LIST OF TRAINED USERS'''<br />
* '''NEVER LEAVE THE CNC ROUTER RUNNING UNATTENDED'''<br />
<br />
As a trained user, you should be very aware of the following risks and how to deal with them:<br />
<br />
'''FIRE''' - Cutting with the wrong settings could result in the material igniting.<br />
<br />
'''TRAPPING''' - Stand clear of the machine while in motion.<br />
<br />
'''DUST''' - Ensure extraction system is working.<br />
<br />
'''NOISE''' - Ensure that you wear the correct PPE when working with the machine for prolonged periods.<br />
<br />
== Instructions ==<br />
<br />
[http://wiki.makespace.org/File:MPC6610_CNC_Router_Manual_v1.0-En.pdf Router Manual]<br />
<br />
[[Equipment/CNC_Router/Hand_Controller|Hand Controller Look-up Guide]]<br />
<br />
===Setting the Z Origin Using the Z0 Sensor===<br />
''A tool that has an extremely narrow tip may break when it touches the tool sensor depending on which tool is to be used.''<br />
<br />
1. Secure the workpiece on the bed, and place the Z0 sensor at the place where you want to set the Z origin on the workpiece. Face the surface of the Z0 sensor without the magnet facing upward.<br />
<br />
[[image:Mill_z0.PNG]]<br />
<br />
2. Use the handset to move the tool to the position above the sensor.<br />
<br />
3. On the handset press OK + 8(Z-0). The tool slowly descend until it contacts the sensor. When the tool rises and stops, the setting operation is complete. <br />
<br />
Note: It is important the tool is electrically conductive from tip to shaft, and the sensor is clean. Failure to check will cause damage to the tool and sensor.<br />
<br />
4. Remove the sensor from the workpiece to a location where it will not interfere with future cutting operations.<br />
<br />
==Software==<br />
<br />
The standard software is Vectric's line of CAM software:<br />
<br />
===VCarvePro===<br />
<br />
[[image:Vcarvepro.png]]<br />
<br />
VCarve Pro provides a powerful but intuitive software solution for 2D design and calculation of 2D and 2.5D toolpaths for cutting parts on a CNC Router. <br />
<br />
The software can import 2D designs from other programs but also includes a full set of drawing and editing tools with advanced layout options such as True-Shape Nesting. The toolpath options cover all typical 2D routing operations such as Profiling, Pocketing, Auto-Inlays and Drilling as well as 2.5D strategies such as V-Carving, Prism carving, Fluting and even a decorative Texturing strategy. Each toolpath includes appropriate options to customize the settings and provide a high level of control for different types of operation. In addition all toolpaths can be previewed to show just how the part will look when it is actually cut, this allows instant feedback to allow toolpaths to be further optimized. <br />
<br />
'''Details''': http://www.vectric.com/products/vcarve-pro.htm<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/vcarve-pro<br />
<br />
===Cut3D===<br />
<br />
[[image:Vectric-cut3d.jpg|266px]]<br />
<br />
Cut3D is a dedicated toolpath engine for CNC machining 3D models that have been designed using a 3D CAD or Graphics design product such as AutoCAD, Rhino3D, 3D Studio etc. or scanned using a laser or touch probe device. Cut3D's exceptionally easy to use interface leads you step-by-step through the process of loading a model, setting the size, interactively placing tabs to hold the job in place, calculating single, double or four sided roughing and finishing toolpaths, previewing the results and finally saving the CNC code to run on your machine.<br />
<br />
3D Models that are too large / thick to machine because of gantry height, cutter length or limited material thickness can be 'Sliced' into separate pieces. Each slice can then be machined and the complete job assembled. <br />
<br />
'''Details''': http://www.vectric.com/products/cut3d.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/cut3d<br />
<br />
===PhotoVCarve===<br />
<br />
[[image:Vectric-photovcarve.gif|266px]]<br />
<br />
PhotoVCarve creates lines of grooves that vary in width and depth to represent the detail in a photograph or image. The quality of the finished result is very dependant upon a high level of contrast between the material surface and the machined grooves. This information is very important to remember when cutting designs using the PhotoVCarve software. <br />
<br />
PhotoVCarve machines dark areas in a photograph with wide groove and the lighter areas to have narrower ones. The software automatically calculates the toolpaths based on the cutter selected and maximum depth of groove required. <br />
<br />
'''Details''': http://www.vectric.com/products/photovcarve.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/photovcarve<br />
<br />
== Tooling ==<br />
<br />
=== End mills ===<br />
<br />
'''Up Cut and Down Cut'''<br />
Router end mills have two variants, up cut (left) and down cut (right)<br />
<br />
<gallery><br />
File:WP_20130813_015.jpg<br />
</gallery><br />
<br />
Most cutters are up cut, which have the cutting service on the top of the flutes and as they rotate lift the chips up and away from the material being cut.<br />
<br />
Down cut cutters have the cutting edge on the bottom of the flutes and push chips down towards the material being cut. This has the advantage of pressing the material being cut into the bed of the machine; this is especially useful for thin plastics. The other advantage is the top surface shows far less breakout and splintering, this is a big advantage for materials like laminates.<br />
<br />
On image on the left has been cut with an up-cut end mill and the image on the right a down-cut.<br />
<br />
<gallery><br />
File:WP_20130813_005.jpg<br />
File:WP_20130813_007.jpg<br />
</gallery><br />
<br />
NOTE: There is a very big disadvantage to down cut end mills, and that is that they do not clear there chips in blind holes. This means they need larger ramping moves to get to the correct cutting depth and if used in pockets without enough clearance, the friction can lead to burning or melting of the material being cut.<br />
<br />
Another down side to down-cut cutters, is that when cutting pockets, the bottom surface will not be as clean as that made with an up-cut cutter, which will do a far better job of clearing the waste chips that rub between the cutter and the material with a down-cut.<br />
<br />
== Stock Tooling ==<br />
<br />
In order to keep a small stock of cutters for general use, the CNC Router needs to have a means of generating money. Because there is no material provided for use with the CNC Router there is no way to bring in any funds for such things. Therefore, we ask that if you use one of the communal cutters please put 50p into the CNC Router Honesty Box. This will go towards funding for replenishing stock and also for the replacement of the sacrificial bed once it gets worn out.<br />
<br />
There will likely be 1 or two of each of the following cutters available for use, however please do not count on this being the case:<br />
<br />
* 2.5mm square cutter - single flute<br />
* 1/8" square cutter - single flute<br />
* 1/8" ball cutter - 2 flute<br />
<br />
* 6mm square cutter - 2 flute<br />
* 6mm ball cutter - 2 flute<br />
<br />
* engraver 0.2 30deg 1/8" 30mm length (8 of)<br />
* engraver 0.8 30deg 1/8" 30mm length (2 of)<br />
<br />
* 22mm 2 flute straight <br />
* 90deg x 32mm VBit<br />
<br />
<br />
Some Suppliers are listed below:<br />
<br />
== Feeds & Speeds ==<br />
<br />
What are feeds and speeds? Why are they important?<br />
<br />
[http://www.youtube.com/watch?v=ip2jm_6aUyk&feature=c4-overview&list=UUivA7_KLKWo43tFcCkFvydw Milling machine tutorial - cutter selection, speeds and feeds]<br />
<br />
[http://en.wikipedia.org/wiki/Speeds_and_feeds Wikipedia - Speeds and feeds]<br />
<br />
The phrase speeds and feeds (or feeds and speeds) refers to two separate velocities in machine tool practice, cutting speed and feed rate. They are often considered as a pair because of their combined effect on the cutting process. Each, however, can also be considered and analyzed in its own right.<br />
<br />
Cutting speed (also called surface speed or simply speed) is the speed difference (relative velocity) between the cutting tool and the surface of the workpiece it is operating on. It is expressed in units of distance along the workpiece surface per unit of time, typically surface feet per minute (sfm) or meters per minute (m/min). Feed rate (also often styled as a solid compound, feedrate, or called simply feed) is the relative velocity at which the cutter is advanced along the workpiece; its vector is perpendicular to the vector of cutting speed. Feed rate units depend on the motion of the tool and workpiece; when the workpiece rotates (e.g., in turning and boring), the units are almost always distance per spindle revolution (inches per revolution [in/rev or ipr] or millimeters per revolution [mm/rev]). When the workpiece does not rotate (e.g., in milling), the units are typically distance per time (inches per minute [in/min or ipm] or millimeters per minute [mm/min]), although distance per revolution or per cutter tooth are also sometimes used.<br />
<br />
===Spindle speed quick reference===<br />
<br />
{| class="wikitable"<br />
!|<br />
!|400Hz <br />
!|350Hz <br />
!|300Hz <br />
!|250Hz <br />
!|200Hz <br />
!|150Hz <br />
|-<br />
!|RPM<br />
|24000 <br />
|21000 <br />
|18000 <br />
|15000 <br />
|12000 <br />
|9000 <br />
|-<br />
|}<br />
<br />
===Feed rate quick reference===<br />
<br />
{| class="wikitable" <br />
!|100% <br />
!|75% <br />
!|66% <br />
!|50% <br />
!|33% <br />
!|25% <br />
|-<br />
!|6000<br />
|4500<br />
|3960<br />
|3000<br />
|1980<br />
|1500<br />
|-<br />
!|5000<br />
|3750<br />
|3300<br />
|2500<br />
|1650<br />
|1250<br />
|-<br />
!|4000<br />
|3000<br />
|2640<br />
|2000<br />
|1320<br />
|1000<br />
|-<br />
!|3000 <br />
|2250 <br />
|1980 <br />
|1500 <br />
|990 <br />
|750 <br />
|-<br />
!|2500 <br />
|1875 <br />
|1650 <br />
|1250 <br />
|825 <br />
|625 <br />
|-<br />
!|2000 <br />
|1500 <br />
|1320 <br />
|1000 <br />
|660 <br />
|500 <br />
|-<br />
!|1500 <br />
|1125 <br />
|990 <br />
|750 <br />
|495 <br />
|375 <br />
|-<br />
!|1000 <br />
|750 <br />
|660 <br />
|500 <br />
|330 <br />
|250 <br />
|-<br />
!|500 <br />
|375 <br />
|330 <br />
|250 <br />
|165 <br />
|125 <br />
|-<br />
|}<br />
<br />
=== Sample feed rates ===<br />
<br />
For working out feeds and speeds, recommend http://www.cnccookbook.com/CCGWizard.<br />
<br />
The feeds and speeds below have been tested on our machine. The 3mm cutters were single flute carbide. 2 flute HSS cutters may require different settings to avoid breakages.<br />
<br />
{| class="wikitable"<br />
!|MDF <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep <br />
|-<br />
!|3mm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|-<br />
!|6mm <br />
|3000/15Krpm <br />
|2000/13Krpm <br />
|1500/11Krpm <br />
|-<br />
!|22mm <br />
|3000/5000rpm <br />
|3000/5000rpm <br />
|1500/4Krpm<br />
|-<br />
|}<br />
<br />
{| class="wikitable"<br />
!|Plywood <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep<br />
|-<br />
!|3mm <br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|-<br />
!|6mm <br />
|3000/15Krpm <br />
|1500/15Krpm <br />
|1000/11Krpm <br />
|-<br />
!|22mm <br />
|3000/5Krpm <br />
|3000/5Krpm <br />
|1500/4Krpm <br />
|-<br />
|}<br />
<br />
== Tips & Tricks ==<br />
<br />
= Maintenance =<br />
<br />
The maintenance of the CNC Router is carried out by the Owners, with some basic maintenance being carried out by Users on every job.<br />
<br />
== Maintenance Schedule ==<br />
Every job<br />
* Vacuum cutting dust from bed and around machine<br />
* Sand down high points created on sacrificial bed by cutting/screwing<br />
<br />
As required, by users<br />
* Empty extraction bin <br />
<br />
Monthly<br />
* Inspect extraction hoses for splits/ wear<br />
* Clean and oil guide rails<br />
* Check level and condition of cooling water and replace as necessary<br />
* Inspect sacrificial bed, re-skim or replace as required<br />
<br />
== Maintenance Log ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
3/7/13: Lower spindle clamp bolts replaced with longer stainless ones, holes through tapped as original ones had stripped.<br />
<br />
== Maintenance Shopping List ==<br />
<br />
* Cutters<br />
* Sacrificial Bed (1.2m x 1.2m 12mm MDF)<br />
<br />
= Further Information =<br />
<br />
== Installation ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
<gallery><br />
File:Photo_1.JPG<br />
File:WP_20130509_005.jpg<br />
File:CNC_Router_controller_1.jpg<br />
File:CNC_Router_controller_2.jpg<br />
</gallery><br />
<br />
== Purchase ==<br />
Full Purchase, Delivery and Installation (£?????)<br />
<br />
== Notes ==<br />
<br />
http://www.shopbottools.com/mProducts/prSstandard.htm</div>Perfectphasehttp://wiki.makespace.org/Equipment/CNC_RouterEquipment/CNC Router2013-08-13T22:17:22Z<p>Perfectphase: /* =End mills */</p>
<hr />
<div>{{RedTool}}<br />
<br />
[[Equipment|Equipment]] / CNC Router<br />
<br />
[[File:WP_20130509_005.jpg|thumb|460px|right|CNC Router]]<br />
<br />
<br />
== Summary ==<br />
<br />
A CNC router is a computer controlled shaping machine. These are related to the hand held router. Instead of hand held routing, the tool paths can be controlled via computer numerical control. It is a computer-controlled machine for cutting various hard materials, such as wood, composites, aluminum, steel, plastics, and foams. It is one of many kinds of tools that have CNC variants. A CNC router is very similar in concept to a CNC milling machine. The CNC router is controlled by a computer. Coordinates are uploaded into the machine controller from a separate CAD program<br />
<br />
* Capacity: 1200 x 1200 x 120mm<br />
* Rate (X,Y): 6000mm/min (Max) 5000mm/min (Working)<br />
* Rate (Z): 30mm/sec<br />
* Spindle Speed: 4500 to 24000rpm<br />
* Mechanical Precision: 0.01mm<br />
* Spindle Power: 1.5KW Variable Speed, Water-cooled<br />
* Blade Diameter: min 3.175mm, max 12.7mm <br />
* Order Format: HPGL, G code, u00, mmg, plt <br />
* Control System: DSP with USB connection <br />
<br />
Here are some examples we've made on the CNC router (please add a photo of yours any time you do a job!) <br />
<br />
<gallery><br />
File:WP_20130509_004.jpg<br />
File:WP_20130624_017.jpg<br />
File:WP_20130625_001.jpg<br />
</gallery><br />
<br />
= Using the CNC Router =<br />
== Owners ==<br />
<br />
The Owners are those who have volunteered to be in charge of the equipment, organising maintenance, training others to use it, and generally being a point of contact. The current Owners of the CNC Router are:<br />
<br />
* Stephen Woolhead<br />
* Chris Abri<br />
* Mark Mellors<br />
* Dave Ansell<br />
* David Bebb<br />
* Simon Stirley<br />
<br />
If you have any questions, problems or concerns around the CNC router, please use the mailing list thread:<br />
* [https://groups.google.com/d/topic/cammakespace/rkchD7VqM2c/discussion Log : CNC Router]<br />
<br />
== Training ==<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>YOU CAN ONLY USE THE CNC ROUTER IF YOU HAVE BEEN TRAINED</b><br><br />
and have been added to the [[Equipment/CNC_Router/Training#Trained_Users|Trained Users]] list by one of the Owners<br />
</div><br />
<br />
To get trained on the CNC router and be added to the qualified user list, you will need to arrange for a training session with one of the Owners. <br />
<br />
If you'd like to arrange training, please see:<br />
* [[Equipment/CNC_Router/Training|CNC Router Training]]<br />
<br />
== Health and Safety ==<br />
<br />
The CNC Router is a potentially dangerous piece of equipment which must only be operated by members who have received appropriate training and who take due care. The top things to always remember when using the CNC Router are:<br />
* '''ONLY USE THE CNC ROUTER IF YOU ARE ON THE LIST OF TRAINED USERS'''<br />
* '''NEVER LEAVE THE CNC ROUTER RUNNING UNATTENDED'''<br />
<br />
As a trained user, you should be very aware of the following risks and how to deal with them:<br />
<br />
'''FIRE''' - Cutting with the wrong settings could result in the material igniting.<br />
<br />
'''TRAPPING''' - Stand clear of the machine while in motion.<br />
<br />
'''DUST''' - Ensure extraction system is working.<br />
<br />
'''NOISE''' - Ensure that you wear the correct PPE when working with the machine for prolonged periods.<br />
<br />
== Instructions ==<br />
<br />
[http://wiki.makespace.org/File:MPC6610_CNC_Router_Manual_v1.0-En.pdf Router Manual]<br />
<br />
[[Equipment/CNC_Router/Hand_Controller|Hand Controller Look-up Guide]]<br />
<br />
===Setting the Z Origin Using the Z0 Sensor===<br />
''A tool that has an extremely narrow tip may break when it touches the tool sensor depending on which tool is to be used.''<br />
<br />
1. Secure the workpiece on the bed, and place the Z0 sensor at the place where you want to set the Z origin on the workpiece. Face the surface of the Z0 sensor without the magnet facing upward.<br />
<br />
[[image:Mill_z0.PNG]]<br />
<br />
2. Use the handset to move the tool to the position above the sensor.<br />
<br />
3. On the handset press OK + 8(Z-0). The tool slowly descend until it contacts the sensor. When the tool rises and stops, the setting operation is complete. <br />
<br />
Note: It is important the tool is electrically conductive from tip to shaft, and the sensor is clean. Failure to check will cause damage to the tool and sensor.<br />
<br />
4. Remove the sensor from the workpiece to a location where it will not interfere with future cutting operations.<br />
<br />
==Software==<br />
<br />
The standard software is Vectric's line of CAM software:<br />
<br />
===VCarvePro===<br />
<br />
[[image:Vcarvepro.png]]<br />
<br />
VCarve Pro provides a powerful but intuitive software solution for 2D design and calculation of 2D and 2.5D toolpaths for cutting parts on a CNC Router. <br />
<br />
The software can import 2D designs from other programs but also includes a full set of drawing and editing tools with advanced layout options such as True-Shape Nesting. The toolpath options cover all typical 2D routing operations such as Profiling, Pocketing, Auto-Inlays and Drilling as well as 2.5D strategies such as V-Carving, Prism carving, Fluting and even a decorative Texturing strategy. Each toolpath includes appropriate options to customize the settings and provide a high level of control for different types of operation. In addition all toolpaths can be previewed to show just how the part will look when it is actually cut, this allows instant feedback to allow toolpaths to be further optimized. <br />
<br />
'''Details''': http://www.vectric.com/products/vcarve-pro.htm<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/vcarve-pro<br />
<br />
===Cut3D===<br />
<br />
[[image:Vectric-cut3d.jpg|266px]]<br />
<br />
Cut3D is a dedicated toolpath engine for CNC machining 3D models that have been designed using a 3D CAD or Graphics design product such as AutoCAD, Rhino3D, 3D Studio etc. or scanned using a laser or touch probe device. Cut3D's exceptionally easy to use interface leads you step-by-step through the process of loading a model, setting the size, interactively placing tabs to hold the job in place, calculating single, double or four sided roughing and finishing toolpaths, previewing the results and finally saving the CNC code to run on your machine.<br />
<br />
3D Models that are too large / thick to machine because of gantry height, cutter length or limited material thickness can be 'Sliced' into separate pieces. Each slice can then be machined and the complete job assembled. <br />
<br />
'''Details''': http://www.vectric.com/products/cut3d.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/cut3d<br />
<br />
===PhotoVCarve===<br />
<br />
[[image:Vectric-photovcarve.gif|266px]]<br />
<br />
PhotoVCarve creates lines of grooves that vary in width and depth to represent the detail in a photograph or image. The quality of the finished result is very dependant upon a high level of contrast between the material surface and the machined grooves. This information is very important to remember when cutting designs using the PhotoVCarve software. <br />
<br />
PhotoVCarve machines dark areas in a photograph with wide groove and the lighter areas to have narrower ones. The software automatically calculates the toolpaths based on the cutter selected and maximum depth of groove required. <br />
<br />
'''Details''': http://www.vectric.com/products/photovcarve.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/photovcarve<br />
<br />
== Tooling ==<br />
<br />
=== End mills ==<br />
<br />
'''Up Cut and Down Cut'''<br />
Router end mills have two variants, up cut (left) and down cut (right)<br />
<br />
<gallery><br />
File:WP_20130813_015.jpg<br />
</gallery><br />
<br />
Most cutters are up cut, which have the cutting service on the top of the flutes and as they rotate lift the chips up and away from the material being cut.<br />
<br />
Down cut cutters have the cutting edge on the bottom of the flutes and push chips down towards the material being cut. This has the advantage of pressing the material being cut into the bed of the machine; this is especially useful for thin plastics. The other advantage is the top surface shows far less breakout and splintering, this is a big advantage for materials like laminates.<br />
<br />
On image on the left has been cut with an up-cut end mill and the image on the right a down-cut.<br />
<br />
<gallery><br />
File:WP_20130813_005.jpg<br />
File:WP_20130813_007.jpg<br />
</gallery><br />
<br />
NOTE: There is a very big disadvantage to down cut end mills, and that is that they do not clear there chips in blind holes. This means they need larger ramping moves to get to the correct cutting depth and if used in pockets without enough clearance, the friction can lead to burning or melting of the material being cut.<br />
<br />
Another down side to down-cut cutters, is that when cutting pockets, the bottom surface will not be as clean as that made with an up-cut cutter, which will do a far better job of clearing the waste chips that rub between the cutter and the material with a down-cut.<br />
<br />
== Stock Tooling ==<br />
<br />
In order to keep a small stock of cutters for general use, the CNC Router needs to have a means of generating money. Because there is no material provided for use with the CNC Router there is no way to bring in any funds for such things. Therefore, we ask that if you use one of the communal cutters please put 50p into the CNC Router Honesty Box. This will go towards funding for replenishing stock and also for the replacement of the sacrificial bed once it gets worn out.<br />
<br />
There will likely be 1 or two of each of the following cutters available for use, however please do not count on this being the case:<br />
<br />
* 2.5mm square cutter - single flute<br />
* 1/8" square cutter - single flute<br />
* 1/8" ball cutter - 2 flute<br />
<br />
* 6mm square cutter - 2 flute<br />
* 6mm ball cutter - 2 flute<br />
<br />
* engraver 0.2 30deg 1/8" 30mm length (8 of)<br />
* engraver 0.8 30deg 1/8" 30mm length (2 of)<br />
<br />
* 22mm 2 flute straight <br />
* 90deg x 32mm VBit<br />
<br />
<br />
Some Suppliers are listed below:<br />
<br />
== Feeds & Speeds ==<br />
<br />
What are feeds and speeds? Why are they important?<br />
<br />
[http://www.youtube.com/watch?v=ip2jm_6aUyk&feature=c4-overview&list=UUivA7_KLKWo43tFcCkFvydw Milling machine tutorial - cutter selection, speeds and feeds]<br />
<br />
[http://en.wikipedia.org/wiki/Speeds_and_feeds Wikipedia - Speeds and feeds]<br />
<br />
The phrase speeds and feeds (or feeds and speeds) refers to two separate velocities in machine tool practice, cutting speed and feed rate. They are often considered as a pair because of their combined effect on the cutting process. Each, however, can also be considered and analyzed in its own right.<br />
<br />
Cutting speed (also called surface speed or simply speed) is the speed difference (relative velocity) between the cutting tool and the surface of the workpiece it is operating on. It is expressed in units of distance along the workpiece surface per unit of time, typically surface feet per minute (sfm) or meters per minute (m/min). Feed rate (also often styled as a solid compound, feedrate, or called simply feed) is the relative velocity at which the cutter is advanced along the workpiece; its vector is perpendicular to the vector of cutting speed. Feed rate units depend on the motion of the tool and workpiece; when the workpiece rotates (e.g., in turning and boring), the units are almost always distance per spindle revolution (inches per revolution [in/rev or ipr] or millimeters per revolution [mm/rev]). When the workpiece does not rotate (e.g., in milling), the units are typically distance per time (inches per minute [in/min or ipm] or millimeters per minute [mm/min]), although distance per revolution or per cutter tooth are also sometimes used.<br />
<br />
===Spindle speed quick reference===<br />
<br />
{| class="wikitable"<br />
!|<br />
!|400Hz <br />
!|350Hz <br />
!|300Hz <br />
!|250Hz <br />
!|200Hz <br />
!|150Hz <br />
|-<br />
!|RPM<br />
|24000 <br />
|21000 <br />
|18000 <br />
|15000 <br />
|12000 <br />
|9000 <br />
|-<br />
|}<br />
<br />
===Feed rate quick reference===<br />
<br />
{| class="wikitable" <br />
!|100% <br />
!|75% <br />
!|66% <br />
!|50% <br />
!|33% <br />
!|25% <br />
|-<br />
!|6000<br />
|4500<br />
|3960<br />
|3000<br />
|1980<br />
|1500<br />
|-<br />
!|5000<br />
|3750<br />
|3300<br />
|2500<br />
|1650<br />
|1250<br />
|-<br />
!|4000<br />
|3000<br />
|2640<br />
|2000<br />
|1320<br />
|1000<br />
|-<br />
!|3000 <br />
|2250 <br />
|1980 <br />
|1500 <br />
|990 <br />
|750 <br />
|-<br />
!|2500 <br />
|1875 <br />
|1650 <br />
|1250 <br />
|825 <br />
|625 <br />
|-<br />
!|2000 <br />
|1500 <br />
|1320 <br />
|1000 <br />
|660 <br />
|500 <br />
|-<br />
!|1500 <br />
|1125 <br />
|990 <br />
|750 <br />
|495 <br />
|375 <br />
|-<br />
!|1000 <br />
|750 <br />
|660 <br />
|500 <br />
|330 <br />
|250 <br />
|-<br />
!|500 <br />
|375 <br />
|330 <br />
|250 <br />
|165 <br />
|125 <br />
|-<br />
|}<br />
<br />
=== Sample feed rates ===<br />
<br />
For working out feeds and speeds, recommend http://www.cnccookbook.com/CCGWizard.<br />
<br />
The feeds and speeds below have been tested on our machine. The 3mm cutters were single flute carbide. 2 flute HSS cutters may require different settings to avoid breakages.<br />
<br />
{| class="wikitable"<br />
!|MDF <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep <br />
|-<br />
!|3mm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|-<br />
!|6mm <br />
|3000/15Krpm <br />
|2000/13Krpm <br />
|1500/11Krpm <br />
|-<br />
!|22mm <br />
|3000/5000rpm <br />
|3000/5000rpm <br />
|1500/4Krpm<br />
|-<br />
|}<br />
<br />
{| class="wikitable"<br />
!|Plywood <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep<br />
|-<br />
!|3mm <br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|-<br />
!|6mm <br />
|3000/15Krpm <br />
|1500/15Krpm <br />
|1000/11Krpm <br />
|-<br />
!|22mm <br />
|3000/5Krpm <br />
|3000/5Krpm <br />
|1500/4Krpm <br />
|-<br />
|}<br />
<br />
== Tips & Tricks ==<br />
<br />
= Maintenance =<br />
<br />
The maintenance of the CNC Router is carried out by the Owners, with some basic maintenance being carried out by Users on every job.<br />
<br />
== Maintenance Schedule ==<br />
Every job<br />
* Vacuum cutting dust from bed and around machine<br />
* Sand down high points created on sacrificial bed by cutting/screwing<br />
<br />
As required, by users<br />
* Empty extraction bin <br />
<br />
Monthly<br />
* Inspect extraction hoses for splits/ wear<br />
* Clean and oil guide rails<br />
* Check level and condition of cooling water and replace as necessary<br />
* Inspect sacrificial bed, re-skim or replace as required<br />
<br />
== Maintenance Log ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
3/7/13: Lower spindle clamp bolts replaced with longer stainless ones, holes through tapped as original ones had stripped.<br />
<br />
== Maintenance Shopping List ==<br />
<br />
* Cutters<br />
* Sacrificial Bed (1.2m x 1.2m 12mm MDF)<br />
<br />
= Further Information =<br />
<br />
== Installation ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
<gallery><br />
File:Photo_1.JPG<br />
File:WP_20130509_005.jpg<br />
File:CNC_Router_controller_1.jpg<br />
File:CNC_Router_controller_2.jpg<br />
</gallery><br />
<br />
== Purchase ==<br />
Full Purchase, Delivery and Installation (£?????)<br />
<br />
== Notes ==<br />
<br />
http://www.shopbottools.com/mProducts/prSstandard.htm</div>Perfectphasehttp://wiki.makespace.org/Equipment/CNC_RouterEquipment/CNC Router2013-08-13T22:17:11Z<p>Perfectphase: /* Stock Tooling */</p>
<hr />
<div>{{RedTool}}<br />
<br />
[[Equipment|Equipment]] / CNC Router<br />
<br />
[[File:WP_20130509_005.jpg|thumb|460px|right|CNC Router]]<br />
<br />
<br />
== Summary ==<br />
<br />
A CNC router is a computer controlled shaping machine. These are related to the hand held router. Instead of hand held routing, the tool paths can be controlled via computer numerical control. It is a computer-controlled machine for cutting various hard materials, such as wood, composites, aluminum, steel, plastics, and foams. It is one of many kinds of tools that have CNC variants. A CNC router is very similar in concept to a CNC milling machine. The CNC router is controlled by a computer. Coordinates are uploaded into the machine controller from a separate CAD program<br />
<br />
* Capacity: 1200 x 1200 x 120mm<br />
* Rate (X,Y): 6000mm/min (Max) 5000mm/min (Working)<br />
* Rate (Z): 30mm/sec<br />
* Spindle Speed: 4500 to 24000rpm<br />
* Mechanical Precision: 0.01mm<br />
* Spindle Power: 1.5KW Variable Speed, Water-cooled<br />
* Blade Diameter: min 3.175mm, max 12.7mm <br />
* Order Format: HPGL, G code, u00, mmg, plt <br />
* Control System: DSP with USB connection <br />
<br />
Here are some examples we've made on the CNC router (please add a photo of yours any time you do a job!) <br />
<br />
<gallery><br />
File:WP_20130509_004.jpg<br />
File:WP_20130624_017.jpg<br />
File:WP_20130625_001.jpg<br />
</gallery><br />
<br />
= Using the CNC Router =<br />
== Owners ==<br />
<br />
The Owners are those who have volunteered to be in charge of the equipment, organising maintenance, training others to use it, and generally being a point of contact. The current Owners of the CNC Router are:<br />
<br />
* Stephen Woolhead<br />
* Chris Abri<br />
* Mark Mellors<br />
* Dave Ansell<br />
* David Bebb<br />
* Simon Stirley<br />
<br />
If you have any questions, problems or concerns around the CNC router, please use the mailing list thread:<br />
* [https://groups.google.com/d/topic/cammakespace/rkchD7VqM2c/discussion Log : CNC Router]<br />
<br />
== Training ==<br />
<br />
<div style="background:#FADADD; border:1px solid #FFC0CB; padding:5px"><br />
<b>YOU CAN ONLY USE THE CNC ROUTER IF YOU HAVE BEEN TRAINED</b><br><br />
and have been added to the [[Equipment/CNC_Router/Training#Trained_Users|Trained Users]] list by one of the Owners<br />
</div><br />
<br />
To get trained on the CNC router and be added to the qualified user list, you will need to arrange for a training session with one of the Owners. <br />
<br />
If you'd like to arrange training, please see:<br />
* [[Equipment/CNC_Router/Training|CNC Router Training]]<br />
<br />
== Health and Safety ==<br />
<br />
The CNC Router is a potentially dangerous piece of equipment which must only be operated by members who have received appropriate training and who take due care. The top things to always remember when using the CNC Router are:<br />
* '''ONLY USE THE CNC ROUTER IF YOU ARE ON THE LIST OF TRAINED USERS'''<br />
* '''NEVER LEAVE THE CNC ROUTER RUNNING UNATTENDED'''<br />
<br />
As a trained user, you should be very aware of the following risks and how to deal with them:<br />
<br />
'''FIRE''' - Cutting with the wrong settings could result in the material igniting.<br />
<br />
'''TRAPPING''' - Stand clear of the machine while in motion.<br />
<br />
'''DUST''' - Ensure extraction system is working.<br />
<br />
'''NOISE''' - Ensure that you wear the correct PPE when working with the machine for prolonged periods.<br />
<br />
== Instructions ==<br />
<br />
[http://wiki.makespace.org/File:MPC6610_CNC_Router_Manual_v1.0-En.pdf Router Manual]<br />
<br />
[[Equipment/CNC_Router/Hand_Controller|Hand Controller Look-up Guide]]<br />
<br />
===Setting the Z Origin Using the Z0 Sensor===<br />
''A tool that has an extremely narrow tip may break when it touches the tool sensor depending on which tool is to be used.''<br />
<br />
1. Secure the workpiece on the bed, and place the Z0 sensor at the place where you want to set the Z origin on the workpiece. Face the surface of the Z0 sensor without the magnet facing upward.<br />
<br />
[[image:Mill_z0.PNG]]<br />
<br />
2. Use the handset to move the tool to the position above the sensor.<br />
<br />
3. On the handset press OK + 8(Z-0). The tool slowly descend until it contacts the sensor. When the tool rises and stops, the setting operation is complete. <br />
<br />
Note: It is important the tool is electrically conductive from tip to shaft, and the sensor is clean. Failure to check will cause damage to the tool and sensor.<br />
<br />
4. Remove the sensor from the workpiece to a location where it will not interfere with future cutting operations.<br />
<br />
==Software==<br />
<br />
The standard software is Vectric's line of CAM software:<br />
<br />
===VCarvePro===<br />
<br />
[[image:Vcarvepro.png]]<br />
<br />
VCarve Pro provides a powerful but intuitive software solution for 2D design and calculation of 2D and 2.5D toolpaths for cutting parts on a CNC Router. <br />
<br />
The software can import 2D designs from other programs but also includes a full set of drawing and editing tools with advanced layout options such as True-Shape Nesting. The toolpath options cover all typical 2D routing operations such as Profiling, Pocketing, Auto-Inlays and Drilling as well as 2.5D strategies such as V-Carving, Prism carving, Fluting and even a decorative Texturing strategy. Each toolpath includes appropriate options to customize the settings and provide a high level of control for different types of operation. In addition all toolpaths can be previewed to show just how the part will look when it is actually cut, this allows instant feedback to allow toolpaths to be further optimized. <br />
<br />
'''Details''': http://www.vectric.com/products/vcarve-pro.htm<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/vcarve-pro<br />
<br />
===Cut3D===<br />
<br />
[[image:Vectric-cut3d.jpg|266px]]<br />
<br />
Cut3D is a dedicated toolpath engine for CNC machining 3D models that have been designed using a 3D CAD or Graphics design product such as AutoCAD, Rhino3D, 3D Studio etc. or scanned using a laser or touch probe device. Cut3D's exceptionally easy to use interface leads you step-by-step through the process of loading a model, setting the size, interactively placing tabs to hold the job in place, calculating single, double or four sided roughing and finishing toolpaths, previewing the results and finally saving the CNC code to run on your machine.<br />
<br />
3D Models that are too large / thick to machine because of gantry height, cutter length or limited material thickness can be 'Sliced' into separate pieces. Each slice can then be machined and the complete job assembled. <br />
<br />
'''Details''': http://www.vectric.com/products/cut3d.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/cut3d<br />
<br />
===PhotoVCarve===<br />
<br />
[[image:Vectric-photovcarve.gif|266px]]<br />
<br />
PhotoVCarve creates lines of grooves that vary in width and depth to represent the detail in a photograph or image. The quality of the finished result is very dependant upon a high level of contrast between the material surface and the machined grooves. This information is very important to remember when cutting designs using the PhotoVCarve software. <br />
<br />
PhotoVCarve machines dark areas in a photograph with wide groove and the lighter areas to have narrower ones. The software automatically calculates the toolpaths based on the cutter selected and maximum depth of groove required. <br />
<br />
'''Details''': http://www.vectric.com/products/photovcarve.html<br />
<br />
'''Training Resources''': http://support.vectric.com/training-material/photovcarve<br />
<br />
== Tooling ==<br />
<br />
===End mills==<br />
<br />
'''Up Cut and Down Cut'''<br />
Router end mills have two variants, up cut (left) and down cut (right)<br />
<br />
<gallery><br />
File:WP_20130813_015.jpg<br />
</gallery><br />
<br />
Most cutters are up cut, which have the cutting service on the top of the flutes and as they rotate lift the chips up and away from the material being cut.<br />
<br />
Down cut cutters have the cutting edge on the bottom of the flutes and push chips down towards the material being cut. This has the advantage of pressing the material being cut into the bed of the machine; this is especially useful for thin plastics. The other advantage is the top surface shows far less breakout and splintering, this is a big advantage for materials like laminates.<br />
<br />
On image on the left has been cut with an up-cut end mill and the image on the right a down-cut.<br />
<br />
<gallery><br />
File:WP_20130813_005.jpg<br />
File:WP_20130813_007.jpg<br />
</gallery><br />
<br />
NOTE: There is a very big disadvantage to down cut end mills, and that is that they do not clear there chips in blind holes. This means they need larger ramping moves to get to the correct cutting depth and if used in pockets without enough clearance, the friction can lead to burning or melting of the material being cut.<br />
<br />
Another down side to down-cut cutters, is that when cutting pockets, the bottom surface will not be as clean as that made with an up-cut cutter, which will do a far better job of clearing the waste chips that rub between the cutter and the material with a down-cut.<br />
<br />
== Stock Tooling ==<br />
<br />
In order to keep a small stock of cutters for general use, the CNC Router needs to have a means of generating money. Because there is no material provided for use with the CNC Router there is no way to bring in any funds for such things. Therefore, we ask that if you use one of the communal cutters please put 50p into the CNC Router Honesty Box. This will go towards funding for replenishing stock and also for the replacement of the sacrificial bed once it gets worn out.<br />
<br />
There will likely be 1 or two of each of the following cutters available for use, however please do not count on this being the case:<br />
<br />
* 2.5mm square cutter - single flute<br />
* 1/8" square cutter - single flute<br />
* 1/8" ball cutter - 2 flute<br />
<br />
* 6mm square cutter - 2 flute<br />
* 6mm ball cutter - 2 flute<br />
<br />
* engraver 0.2 30deg 1/8" 30mm length (8 of)<br />
* engraver 0.8 30deg 1/8" 30mm length (2 of)<br />
<br />
* 22mm 2 flute straight <br />
* 90deg x 32mm VBit<br />
<br />
<br />
Some Suppliers are listed below:<br />
<br />
== Feeds & Speeds ==<br />
<br />
What are feeds and speeds? Why are they important?<br />
<br />
[http://www.youtube.com/watch?v=ip2jm_6aUyk&feature=c4-overview&list=UUivA7_KLKWo43tFcCkFvydw Milling machine tutorial - cutter selection, speeds and feeds]<br />
<br />
[http://en.wikipedia.org/wiki/Speeds_and_feeds Wikipedia - Speeds and feeds]<br />
<br />
The phrase speeds and feeds (or feeds and speeds) refers to two separate velocities in machine tool practice, cutting speed and feed rate. They are often considered as a pair because of their combined effect on the cutting process. Each, however, can also be considered and analyzed in its own right.<br />
<br />
Cutting speed (also called surface speed or simply speed) is the speed difference (relative velocity) between the cutting tool and the surface of the workpiece it is operating on. It is expressed in units of distance along the workpiece surface per unit of time, typically surface feet per minute (sfm) or meters per minute (m/min). Feed rate (also often styled as a solid compound, feedrate, or called simply feed) is the relative velocity at which the cutter is advanced along the workpiece; its vector is perpendicular to the vector of cutting speed. Feed rate units depend on the motion of the tool and workpiece; when the workpiece rotates (e.g., in turning and boring), the units are almost always distance per spindle revolution (inches per revolution [in/rev or ipr] or millimeters per revolution [mm/rev]). When the workpiece does not rotate (e.g., in milling), the units are typically distance per time (inches per minute [in/min or ipm] or millimeters per minute [mm/min]), although distance per revolution or per cutter tooth are also sometimes used.<br />
<br />
===Spindle speed quick reference===<br />
<br />
{| class="wikitable"<br />
!|<br />
!|400Hz <br />
!|350Hz <br />
!|300Hz <br />
!|250Hz <br />
!|200Hz <br />
!|150Hz <br />
|-<br />
!|RPM<br />
|24000 <br />
|21000 <br />
|18000 <br />
|15000 <br />
|12000 <br />
|9000 <br />
|-<br />
|}<br />
<br />
===Feed rate quick reference===<br />
<br />
{| class="wikitable" <br />
!|100% <br />
!|75% <br />
!|66% <br />
!|50% <br />
!|33% <br />
!|25% <br />
|-<br />
!|6000<br />
|4500<br />
|3960<br />
|3000<br />
|1980<br />
|1500<br />
|-<br />
!|5000<br />
|3750<br />
|3300<br />
|2500<br />
|1650<br />
|1250<br />
|-<br />
!|4000<br />
|3000<br />
|2640<br />
|2000<br />
|1320<br />
|1000<br />
|-<br />
!|3000 <br />
|2250 <br />
|1980 <br />
|1500 <br />
|990 <br />
|750 <br />
|-<br />
!|2500 <br />
|1875 <br />
|1650 <br />
|1250 <br />
|825 <br />
|625 <br />
|-<br />
!|2000 <br />
|1500 <br />
|1320 <br />
|1000 <br />
|660 <br />
|500 <br />
|-<br />
!|1500 <br />
|1125 <br />
|990 <br />
|750 <br />
|495 <br />
|375 <br />
|-<br />
!|1000 <br />
|750 <br />
|660 <br />
|500 <br />
|330 <br />
|250 <br />
|-<br />
!|500 <br />
|375 <br />
|330 <br />
|250 <br />
|165 <br />
|125 <br />
|-<br />
|}<br />
<br />
=== Sample feed rates ===<br />
<br />
For working out feeds and speeds, recommend http://www.cnccookbook.com/CCGWizard.<br />
<br />
The feeds and speeds below have been tested on our machine. The 3mm cutters were single flute carbide. 2 flute HSS cutters may require different settings to avoid breakages.<br />
<br />
{| class="wikitable"<br />
!|MDF <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep <br />
|-<br />
!|3mm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|3000/24Krpm <br />
|-<br />
!|6mm <br />
|3000/15Krpm <br />
|2000/13Krpm <br />
|1500/11Krpm <br />
|-<br />
!|22mm <br />
|3000/5000rpm <br />
|3000/5000rpm <br />
|1500/4Krpm<br />
|-<br />
|}<br />
<br />
{| class="wikitable"<br />
!|Plywood <br />
!|3mm deep <br />
!|6mm deep <br />
!|12mm deep<br />
|-<br />
!|3mm <br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|2000/24Krpm <br />
|-<br />
!|6mm <br />
|3000/15Krpm <br />
|1500/15Krpm <br />
|1000/11Krpm <br />
|-<br />
!|22mm <br />
|3000/5Krpm <br />
|3000/5Krpm <br />
|1500/4Krpm <br />
|-<br />
|}<br />
<br />
== Tips & Tricks ==<br />
<br />
= Maintenance =<br />
<br />
The maintenance of the CNC Router is carried out by the Owners, with some basic maintenance being carried out by Users on every job.<br />
<br />
== Maintenance Schedule ==<br />
Every job<br />
* Vacuum cutting dust from bed and around machine<br />
* Sand down high points created on sacrificial bed by cutting/screwing<br />
<br />
As required, by users<br />
* Empty extraction bin <br />
<br />
Monthly<br />
* Inspect extraction hoses for splits/ wear<br />
* Clean and oil guide rails<br />
* Check level and condition of cooling water and replace as necessary<br />
* Inspect sacrificial bed, re-skim or replace as required<br />
<br />
== Maintenance Log ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
3/7/13: Lower spindle clamp bolts replaced with longer stainless ones, holes through tapped as original ones had stripped.<br />
<br />
== Maintenance Shopping List ==<br />
<br />
* Cutters<br />
* Sacrificial Bed (1.2m x 1.2m 12mm MDF)<br />
<br />
= Further Information =<br />
<br />
== Installation ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
<gallery><br />
File:Photo_1.JPG<br />
File:WP_20130509_005.jpg<br />
File:CNC_Router_controller_1.jpg<br />
File:CNC_Router_controller_2.jpg<br />
</gallery><br />
<br />
== Purchase ==<br />
Full Purchase, Delivery and Installation (£?????)<br />
<br />
== Notes ==<br />
<br />
http://www.shopbottools.com/mProducts/prSstandard.htm</div>Perfectphasehttp://wiki.makespace.org/File:WP_20130813_007.jpgFile:WP 20130813 007.jpg2013-08-13T22:06:44Z<p>Perfectphase: </p>
<hr />
<div></div>Perfectphasehttp://wiki.makespace.org/File:WP_20130813_005.jpgFile:WP 20130813 005.jpg2013-08-13T22:05:37Z<p>Perfectphase: </p>
<hr />
<div></div>Perfectphasehttp://wiki.makespace.org/File:WP_20130813_015.jpgFile:WP 20130813 015.jpg2013-08-13T21:56:50Z<p>Perfectphase: </p>
<hr />
<div></div>Perfectphasehttp://wiki.makespace.org/Equipment/VacuumFormer/RiskAssessmentEquipment/VacuumFormer/RiskAssessment2013-07-26T20:27:57Z<p>Perfectphase: /* Final assessment of risk */</p>
<hr />
<div>= Risk assessment form for Vacuum Former = <br />
<br />
[[Equipment|Equipment]] / [[Equipment/VacuumFormer|Vacuum Former]]<br />
<br />
===Activity=== <br />
Vacuum forming plastic material<br />
<br />
===Hazard identification===<br />
''Consider the hazards involved in conducting this activity and list each hazard''<br />
<br />
1. Fire<br />
<br />
2. Burns<br />
<br />
3. Electric Shock<br />
<br />
===Persons at risk===<br />
''Consider who might be put at risk by the hazards listed above''<br />
* The user is subject to 1, 2 and 3. <br />
* The space and all occupants are subject to 1.<br />
<br />
===Initial assessment of risk===<br />
{| class="wikitable"<br />
|-<br />
!|Hazard identified <br />
!|Severity <br />
!|Probability <br />
!|Risk Factor (Severity x probability)<br />
|-<br />
|Fire<br />
|5<br />
|2<br />
|10<br />
|-<br />
|Burns<br />
|3<br />
|3<br />
|9<br />
|-<br />
|Electric Shock<br />
|3<br />
|2<br />
|6<br />
|}<br />
<br />
Categorising the risk level as 1-4(Low), 5-9(Moderate), 10-15(High) or 16-25 (Unacceptable) shows that the potential level of risk in this activity is '''High'''. <br />
Further measures are '''needed/not needed''' to reduce the risk to an acceptable level.<br />
<br />
===Control measures===<br />
* Necessary control measures arising from the hazard identified of '''Fire''' are:<br />
** Don't leave the machine running unattended.<br />
** Do not overheat the plastic material.<br />
* Necessary control measures arising from the hazard identified of '''Burns''' are:<br />
** Always use handles, do not touch the hood.<br />
** Always wait a couple of minutes before touching the plastic.<br />
** Never put your hand between the plastic and the heater elements.<br />
* Necessary control measures arising from the hazard identified of '''Electric Shock''' are:<br />
** Carry out a visual check and check the test date before use.<br />
<br />
===Final assessment of risk===<br />
The assessed risk taking into account the implementation of the control measures listed, and adherence to the SSOW (Safe System of Work) if applicable is as follows: <br />
<br />
{| class="wikitable"<br />
|-<br />
!|Hazard identified <br />
!|Severity <br />
!|Probability <br />
!|Risk Factor<br />
|-<br />
|Fire<br />
|1<br />
|1<br />
|1 (Low)<br />
|-<br />
|Burns<br />
|1<br />
|1<br />
|1 (Low)<br />
|-<br />
|Electric Shock<br />
|3<br />
|1<br />
|4 (Low)<br />
|}<br />
<br />
''When completing Risk Assessment please consider the if First Aid assistance might be appropriate if the calculated Risk level (Severity x Probability) is greater than 5''<br />
<br />
The risk now falls into the category '''LOW''' and is considered to be acceptable.<br />
<br />
Authorised by <br />
<br />
Sign: <br />
<br />
Print: <br />
<br />
Date:</div>Perfectphasehttp://wiki.makespace.org/Equipment/VacuumFormer/RiskAssessmentEquipment/VacuumFormer/RiskAssessment2013-07-26T20:27:45Z<p>Perfectphase: /* Initial assessment of risk */</p>
<hr />
<div>= Risk assessment form for Vacuum Former = <br />
<br />
[[Equipment|Equipment]] / [[Equipment/VacuumFormer|Vacuum Former]]<br />
<br />
===Activity=== <br />
Vacuum forming plastic material<br />
<br />
===Hazard identification===<br />
''Consider the hazards involved in conducting this activity and list each hazard''<br />
<br />
1. Fire<br />
<br />
2. Burns<br />
<br />
3. Electric Shock<br />
<br />
===Persons at risk===<br />
''Consider who might be put at risk by the hazards listed above''<br />
* The user is subject to 1, 2 and 3. <br />
* The space and all occupants are subject to 1.<br />
<br />
===Initial assessment of risk===<br />
{| class="wikitable"<br />
|-<br />
!|Hazard identified <br />
!|Severity <br />
!|Probability <br />
!|Risk Factor (Severity x probability)<br />
|-<br />
|Fire<br />
|5<br />
|2<br />
|10<br />
|-<br />
|Burns<br />
|3<br />
|3<br />
|9<br />
|-<br />
|Electric Shock<br />
|3<br />
|2<br />
|6<br />
|}<br />
<br />
Categorising the risk level as 1-4(Low), 5-9(Moderate), 10-15(High) or 16-25 (Unacceptable) shows that the potential level of risk in this activity is '''High'''. <br />
Further measures are '''needed/not needed''' to reduce the risk to an acceptable level.<br />
<br />
===Control measures===<br />
* Necessary control measures arising from the hazard identified of '''Fire''' are:<br />
** Don't leave the machine running unattended.<br />
** Do not overheat the plastic material.<br />
* Necessary control measures arising from the hazard identified of '''Burns''' are:<br />
** Always use handles, do not touch the hood.<br />
** Always wait a couple of minutes before touching the plastic.<br />
** Never put your hand between the plastic and the heater elements.<br />
* Necessary control measures arising from the hazard identified of '''Electric Shock''' are:<br />
** Carry out a visual check and check the test date before use.<br />
<br />
===Final assessment of risk===<br />
The assessed risk taking into account the implementation of the control measures listed, and adherence to the SSOW (Safe System of Work) if applicable is as follows: <br />
<br />
{| class="wikitable"<br />
|-<br />
!|Hazard identified <br />
!|Severity <br />
!|Probability <br />
!|Risk Factor<br />
|-<br />
|Fire<br />
|1<br />
|1<br />
|1 (Low)<br />
|-<br />
|Burns<br />
|1<br />
|1<br />
|1 (Low)<br />
|-<br />
|Electric Shock<br />
|4<br />
|1<br />
|4 (Low)<br />
|}<br />
<br />
''When completing Risk Assessment please consider the if First Aid assistance might be appropriate if the calculated Risk level (Severity x Probability) is greater than 5''<br />
<br />
The risk now falls into the category '''LOW''' and is considered to be acceptable.<br />
<br />
Authorised by <br />
<br />
Sign: <br />
<br />
Print: <br />
<br />
Date:</div>Perfectphasehttp://wiki.makespace.org/Equipment/VacuumFormerEquipment/VacuumFormer2013-07-26T19:50:08Z<p>Perfectphase: /* Further Information */</p>
<hr />
<div>{{OrangeTool}}<br />
<br />
[[Equipment|Equipment]] / Vacuum Former<br />
<br />
[[File:300xq.PNG|thumb|460px|right|Vacuum Former]]<br />
<br />
=WORK IN PROGRESS=<br />
<br />
This page is a work in progress, the Vacuum Former should be installed in the space on 26/7/2013<br />
<br />
== Summary ==<br />
<br />
Vacuum forming is a technique that is used to shape a variety of plastics. It is used to form/shape thin plastic, usually plastics such as; polythene and perspex. Vacuum forming is used when an unusual shape like a ‘dish’ or a box-like shape is needed. <br />
<br />
[http://wiki.makespace.org/File:Formech_300XQ.pdf Vacuum Former Manual]<br />
<br />
http://www.youtube.com/watch?v=scqkjU10198<br />
<br />
Formech 300XQ<br />
<br />
Technical Specifications<br />
<br />
* Material size 450x300mm / 18x12"<br />
* Forming area 430x280mm / 17x11" <br />
* Max. depth of draw 160mm / 6.3" <br />
* Max. material thickness 6mm / .25" <br />
* Overall width 650mm / 25" <br />
* Overall height 530mm / 20" <br />
* Overall depth 970mm / 38" <br />
* Weight 75kg / 165lbs <br />
<br />
Here are some examples we've made on the Vacuum Former(please add a photo of yours any time you do a job!) <br />
<br />
<gallery><br />
File:300XQ.gif<br />
</gallery><br />
<br />
= Using the Vacuum Former =<br />
== Owners ==<br />
<br />
The Owners are those who have volunteered to be in charge of the equipment, organising maintenance, training others to use it, and generally being a point of contact. The current Owners of the Vacuum Former are:<br />
<br />
* Stephen Woolhead<br />
* New owners welcomed, get in touch!<br />
<br />
If you have any questions, problems or concerns around the Vacuum Former, please use the mailing list thread:<br />
* [https://groups.google.com/d/msg/cammakespace/LMH8YH7WjMk/6KwuQIKhBnMJ Discussion Log : Vacuum Former]<br />
<br />
== Training ==<br />
<br />
No formal training is required to operate the Vacuum Former. If you intend to make something using the vacuum former please read the Health & Safety and Safety Notes sections below before doing so. The manual is also available online in case you require additional information. <br />
<br />
Informal training sessions will be listed in the Meetup diary <br />
<br />
Requests for more sessions, or discussion about them should be directed to the discussion thread: Training:Vinyl Cutter<br />
<br />
== Health and Safety ==<br />
<br />
Risk assessment: [[Equipment/VacuumFormer/RiskAssessment]]<br />
<br />
The Vacuum Former is a potentially dangerous piece of equipment which must only be operated by members who have received appropriate training and who take due care. The top things to always remember when using the Vacuum Former are:<br />
* '''ONLY USE THE VACUUM FORMER IF YOU ARE ON THE LIST OF TRAINED USERS'''<br />
* '''NEVER LEAVE THE VACUUM FORMER RUNNING UNATTENDED'''<br />
<br />
As a trained user, you should be very aware of the following risks and how to deal with them:<br />
<br />
'''FIRE''' - Heating the material for too long or with the wrong settings could result in the material igniting.<br />
<br />
'''ELECTRIC SHOCKS''' - Regular maintenance & electric survey should mean machine is safe to use. Do not use if there are any signs of damage<br />
<br />
'''BURNS''' - Caution should be taken when using machine, ensure formed part is cool before removing. Never operate with missing or damaged safety features.<br />
<br />
== Instructions ==<br />
<br />
[http://wiki.makespace.org/File:Formech_300XQ.pdf Vacuum Former Manual]<br />
<br />
1. First, a former is made from a material such as a soft wood. The edges or sides are shaped at an angle so that when the plastic is formed over it, the former can be removed easily.<br />
<br />
2. The former is placed in a vacuum former at the lowest position.<br />
<br />
3. A sheet of plastic (for example, compressed polystyrene) is clamped in position above the mould.<br />
<br />
4. The heater is then turned on and the plastic slowly becomes soft and pliable as it heats up. The plastic can be seen to 'warp' and 'distort' as the surface expands.<br />
<br />
5. After a few minutes the plastic is ready for ‘forming’ as it becomes very flexible.<br />
<br />
6. The heater is turned off and the mould is moved upwards by lifting the lever until it locks in position.<br />
<br />
7. The 'vacuum' is turned on and this pumps out all the air beneath the plastic sheet. Atmospheric pressure above the plastic sheet pushes it down on the mould. At this stage the shape of the mould can be clearly seen through the plastic sheet. When the plastic has cooled sufficiently the vacuum pump is switched off.<br />
<br />
8. The plastic sheet is removed from the vacuum former. The sheet has the shape of the former pressed into its surface.<br />
<br />
9. The excess plastic is trimmed so that only the plastic required remains - the completed item.<br />
<br />
===Reducing Windows===<br />
Reducing windows allow the use of smaller sheet material for smaller mouldings. Reducing windows allow for better sheet utilisation.<br />
<br />
To fit the reducing window.<br />
* Lift the clamp frame.<br />
* Place the lower reducing window plate on to the top frame aperture so that the corner locating screws are aligned.<br />
* Place the top reducing window plate on the underside of the clamp frame. There are folded sections on the front and rear. The rear edge has the larger return and wraps completely around the clamp frame bar. The front fold is smaller and returns against the front clamp frame bar. The fixing bolt is fitted through the clamp frame bar and reducing plate and secured using the fixing nut.. See diagram below of side view of the top plate fitting.<br />
<br />
[[image:Reducing_windows.PNG|600px]]<br />
<br />
* Close the clamp frame. Check alignment oftop and bottom plate. Fit the required plastic material on the sealed lower reducing plate. The material toggle clamps will need adjusting so that the clamp frame can be locked to achieve the necessary clamping pressure.<br />
<br />
== Heating times ==<br />
<br />
Different materials and thickness require different heating times, here is a list that has been found to produce good results<br />
<br />
?????<br />
<br />
== Tips & Tricks ==<br />
<br />
'''If the platform does not raise, ensure the heater is fully back.'''<br />
<br />
'''DO NOT use to cook pizza'''<br />
<br />
'''How long does it take to heat the plastic sheet?'''<br />
* This depends on which material and thickness is specified.<br />
<br />
'''How do I know when the plastic is ready to form?'''<br />
* Generally speaking it is necessary with any new material to establish the correct heating cycle. Plastic is ready to form when it becomes soft and pliable especially nearer to the clamping frame. This is known as glass transition temperature (Tg). Once you have established the time you can set the heater timer for accurate and repeated heating cycles.<br />
<br />
'''Why is the plastic webbing on the mould?'''<br />
* Material is too hot.<br />
* Insufficient vacuum.<br />
* Excess of material. Use reducing windows.<br />
* Poor mould design.<br />
<br />
'''Why can't I achieve good definition on the finished part?'''<br />
* Material too cold<br />
* Mould too cold.<br />
* Insufficient vacuum.<br />
* Insufficient vacuum holes in the mould<br />
<br />
'''Why Is the plastic thinning over the mould when formed?'''<br />
* Sheet cooled whilst forming.<br />
* Mould design with insufficient draft angles.<br />
* Too thin plastic gauge.<br />
* Pre-stretch required.<br />
* Plug assist required.<br />
<br />
'''Why does the plastic bubble and pit when heated?'''<br />
* Material is Hygroscopic which needs to be pre-dried prior to forming.<br />
* Overheating.<br />
* Mould or plastic sheet too dusty<br />
<br />
'''Why does the plastic stick to the mould when I try to release?'''<br />
* Mould not fixed on baseboard.<br />
* Insufficient draft.<br />
* Mould undercuts.<br />
<br />
== Material Stock ==<br />
If you have any requests for material stock, please add them the [https://groups.google.com/d/msg/cammakespace/LMH8YH7WjMk/6KwuQIKhBnMJ Log].<br />
<br />
Stock material will be provided and an honesty box will be provided.<br />
<br />
<br />
= Maintenance =<br />
<br />
The maintenance of the Vacuum Former is carried out by the Owners, with some basic maintenance being carried out by Users on every job.<br />
<br />
== Maintenance Schedule ==<br />
<br />
'''Every job:''' None required<br />
<br />
'''As required, by users:''' Ensure the inside of the machine and the heater tray is cleared of dust, dirt and debris. Do not allow dirt and loose particles to build up, particularly on the heater tray.<br />
<br />
'''Monthly:''' Check strength of vacuum and condition of seals. Check state of electrical system.<br />
<br />
== Maintenance Log ==<br />
<br />
Installed on 26th July 2013. (with any luck)<br />
<br />
<br />
== Maintenance Shopping List ==<br />
<br />
* Service Kit (~£50)<br />
<br />
<br />
= Further Information =<br />
<br />
http://www.formech.com/<br />
<br />
== Installation ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
<gallery><br />
File:WP_20130726_001.jpg<br />
File:WP_20130726_002.jpg<br />
</gallery><br />
<br />
== Purchase ==<br />
Full Purchase, Delivery and Installation (£2500)<br />
<br />
== Notes ==</div>Perfectphasehttp://wiki.makespace.org/Equipment/VacuumFormerEquipment/VacuumFormer2013-07-26T19:46:18Z<p>Perfectphase: /* Tips & Tricks */</p>
<hr />
<div>{{OrangeTool}}<br />
<br />
[[Equipment|Equipment]] / Vacuum Former<br />
<br />
[[File:300xq.PNG|thumb|460px|right|Vacuum Former]]<br />
<br />
=WORK IN PROGRESS=<br />
<br />
This page is a work in progress, the Vacuum Former should be installed in the space on 26/7/2013<br />
<br />
== Summary ==<br />
<br />
Vacuum forming is a technique that is used to shape a variety of plastics. It is used to form/shape thin plastic, usually plastics such as; polythene and perspex. Vacuum forming is used when an unusual shape like a ‘dish’ or a box-like shape is needed. <br />
<br />
[http://wiki.makespace.org/File:Formech_300XQ.pdf Vacuum Former Manual]<br />
<br />
http://www.youtube.com/watch?v=scqkjU10198<br />
<br />
Formech 300XQ<br />
<br />
Technical Specifications<br />
<br />
* Material size 450x300mm / 18x12"<br />
* Forming area 430x280mm / 17x11" <br />
* Max. depth of draw 160mm / 6.3" <br />
* Max. material thickness 6mm / .25" <br />
* Overall width 650mm / 25" <br />
* Overall height 530mm / 20" <br />
* Overall depth 970mm / 38" <br />
* Weight 75kg / 165lbs <br />
<br />
Here are some examples we've made on the Vacuum Former(please add a photo of yours any time you do a job!) <br />
<br />
<gallery><br />
File:300XQ.gif<br />
</gallery><br />
<br />
= Using the Vacuum Former =<br />
== Owners ==<br />
<br />
The Owners are those who have volunteered to be in charge of the equipment, organising maintenance, training others to use it, and generally being a point of contact. The current Owners of the Vacuum Former are:<br />
<br />
* Stephen Woolhead<br />
* New owners welcomed, get in touch!<br />
<br />
If you have any questions, problems or concerns around the Vacuum Former, please use the mailing list thread:<br />
* [https://groups.google.com/d/msg/cammakespace/LMH8YH7WjMk/6KwuQIKhBnMJ Discussion Log : Vacuum Former]<br />
<br />
== Training ==<br />
<br />
No formal training is required to operate the Vacuum Former. If you intend to make something using the vacuum former please read the Health & Safety and Safety Notes sections below before doing so. The manual is also available online in case you require additional information. <br />
<br />
Informal training sessions will be listed in the Meetup diary <br />
<br />
Requests for more sessions, or discussion about them should be directed to the discussion thread: Training:Vinyl Cutter<br />
<br />
== Health and Safety ==<br />
<br />
Risk assessment: [[Equipment/VacuumFormer/RiskAssessment]]<br />
<br />
The Vacuum Former is a potentially dangerous piece of equipment which must only be operated by members who have received appropriate training and who take due care. The top things to always remember when using the Vacuum Former are:<br />
* '''ONLY USE THE VACUUM FORMER IF YOU ARE ON THE LIST OF TRAINED USERS'''<br />
* '''NEVER LEAVE THE VACUUM FORMER RUNNING UNATTENDED'''<br />
<br />
As a trained user, you should be very aware of the following risks and how to deal with them:<br />
<br />
'''FIRE''' - Heating the material for too long or with the wrong settings could result in the material igniting.<br />
<br />
'''ELECTRIC SHOCKS''' - Regular maintenance & electric survey should mean machine is safe to use. Do not use if there are any signs of damage<br />
<br />
'''BURNS''' - Caution should be taken when using machine, ensure formed part is cool before removing. Never operate with missing or damaged safety features.<br />
<br />
== Instructions ==<br />
<br />
[http://wiki.makespace.org/File:Formech_300XQ.pdf Vacuum Former Manual]<br />
<br />
1. First, a former is made from a material such as a soft wood. The edges or sides are shaped at an angle so that when the plastic is formed over it, the former can be removed easily.<br />
<br />
2. The former is placed in a vacuum former at the lowest position.<br />
<br />
3. A sheet of plastic (for example, compressed polystyrene) is clamped in position above the mould.<br />
<br />
4. The heater is then turned on and the plastic slowly becomes soft and pliable as it heats up. The plastic can be seen to 'warp' and 'distort' as the surface expands.<br />
<br />
5. After a few minutes the plastic is ready for ‘forming’ as it becomes very flexible.<br />
<br />
6. The heater is turned off and the mould is moved upwards by lifting the lever until it locks in position.<br />
<br />
7. The 'vacuum' is turned on and this pumps out all the air beneath the plastic sheet. Atmospheric pressure above the plastic sheet pushes it down on the mould. At this stage the shape of the mould can be clearly seen through the plastic sheet. When the plastic has cooled sufficiently the vacuum pump is switched off.<br />
<br />
8. The plastic sheet is removed from the vacuum former. The sheet has the shape of the former pressed into its surface.<br />
<br />
9. The excess plastic is trimmed so that only the plastic required remains - the completed item.<br />
<br />
===Reducing Windows===<br />
Reducing windows allow the use of smaller sheet material for smaller mouldings. Reducing windows allow for better sheet utilisation.<br />
<br />
To fit the reducing window.<br />
* Lift the clamp frame.<br />
* Place the lower reducing window plate on to the top frame aperture so that the corner locating screws are aligned.<br />
* Place the top reducing window plate on the underside of the clamp frame. There are folded sections on the front and rear. The rear edge has the larger return and wraps completely around the clamp frame bar. The front fold is smaller and returns against the front clamp frame bar. The fixing bolt is fitted through the clamp frame bar and reducing plate and secured using the fixing nut.. See diagram below of side view of the top plate fitting.<br />
<br />
[[image:Reducing_windows.PNG|600px]]<br />
<br />
* Close the clamp frame. Check alignment oftop and bottom plate. Fit the required plastic material on the sealed lower reducing plate. The material toggle clamps will need adjusting so that the clamp frame can be locked to achieve the necessary clamping pressure.<br />
<br />
== Heating times ==<br />
<br />
Different materials and thickness require different heating times, here is a list that has been found to produce good results<br />
<br />
?????<br />
<br />
== Tips & Tricks ==<br />
<br />
'''If the platform does not raise, ensure the heater is fully back.'''<br />
<br />
'''DO NOT use to cook pizza'''<br />
<br />
'''How long does it take to heat the plastic sheet?'''<br />
* This depends on which material and thickness is specified.<br />
<br />
'''How do I know when the plastic is ready to form?'''<br />
* Generally speaking it is necessary with any new material to establish the correct heating cycle. Plastic is ready to form when it becomes soft and pliable especially nearer to the clamping frame. This is known as glass transition temperature (Tg). Once you have established the time you can set the heater timer for accurate and repeated heating cycles.<br />
<br />
'''Why is the plastic webbing on the mould?'''<br />
* Material is too hot.<br />
* Insufficient vacuum.<br />
* Excess of material. Use reducing windows.<br />
* Poor mould design.<br />
<br />
'''Why can't I achieve good definition on the finished part?'''<br />
* Material too cold<br />
* Mould too cold.<br />
* Insufficient vacuum.<br />
* Insufficient vacuum holes in the mould<br />
<br />
'''Why Is the plastic thinning over the mould when formed?'''<br />
* Sheet cooled whilst forming.<br />
* Mould design with insufficient draft angles.<br />
* Too thin plastic gauge.<br />
* Pre-stretch required.<br />
* Plug assist required.<br />
<br />
'''Why does the plastic bubble and pit when heated?'''<br />
* Material is Hygroscopic which needs to be pre-dried prior to forming.<br />
* Overheating.<br />
* Mould or plastic sheet too dusty<br />
<br />
'''Why does the plastic stick to the mould when I try to release?'''<br />
* Mould not fixed on baseboard.<br />
* Insufficient draft.<br />
* Mould undercuts.<br />
<br />
== Material Stock ==<br />
If you have any requests for material stock, please add them the [https://groups.google.com/d/msg/cammakespace/LMH8YH7WjMk/6KwuQIKhBnMJ Log].<br />
<br />
Stock material will be provided and an honesty box will be provided.<br />
<br />
<br />
= Maintenance =<br />
<br />
The maintenance of the Vacuum Former is carried out by the Owners, with some basic maintenance being carried out by Users on every job.<br />
<br />
== Maintenance Schedule ==<br />
<br />
'''Every job:''' None required<br />
<br />
'''As required, by users:''' Ensure the inside of the machine and the heater tray is cleared of dust, dirt and debris. Do not allow dirt and loose particles to build up, particularly on the heater tray.<br />
<br />
'''Monthly:''' Check strength of vacuum and condition of seals. Check state of electrical system.<br />
<br />
== Maintenance Log ==<br />
<br />
Installed on 26th July 2013. (with any luck)<br />
<br />
<br />
== Maintenance Shopping List ==<br />
<br />
* Service Kit (~£50)<br />
<br />
<br />
= Further Information =<br />
<br />
== Installation ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
<gallery><br />
File:WP_20130726_001.jpg<br />
File:WP_20130726_002.jpg<br />
</gallery><br />
<br />
== Purchase ==<br />
Full Purchase, Delivery and Installation (£2500)<br />
<br />
== Notes ==</div>Perfectphasehttp://wiki.makespace.org/Equipment/VacuumFormerEquipment/VacuumFormer2013-07-26T19:43:57Z<p>Perfectphase: /* Reducing Windows */</p>
<hr />
<div>{{OrangeTool}}<br />
<br />
[[Equipment|Equipment]] / Vacuum Former<br />
<br />
[[File:300xq.PNG|thumb|460px|right|Vacuum Former]]<br />
<br />
=WORK IN PROGRESS=<br />
<br />
This page is a work in progress, the Vacuum Former should be installed in the space on 26/7/2013<br />
<br />
== Summary ==<br />
<br />
Vacuum forming is a technique that is used to shape a variety of plastics. It is used to form/shape thin plastic, usually plastics such as; polythene and perspex. Vacuum forming is used when an unusual shape like a ‘dish’ or a box-like shape is needed. <br />
<br />
[http://wiki.makespace.org/File:Formech_300XQ.pdf Vacuum Former Manual]<br />
<br />
http://www.youtube.com/watch?v=scqkjU10198<br />
<br />
Formech 300XQ<br />
<br />
Technical Specifications<br />
<br />
* Material size 450x300mm / 18x12"<br />
* Forming area 430x280mm / 17x11" <br />
* Max. depth of draw 160mm / 6.3" <br />
* Max. material thickness 6mm / .25" <br />
* Overall width 650mm / 25" <br />
* Overall height 530mm / 20" <br />
* Overall depth 970mm / 38" <br />
* Weight 75kg / 165lbs <br />
<br />
Here are some examples we've made on the Vacuum Former(please add a photo of yours any time you do a job!) <br />
<br />
<gallery><br />
File:300XQ.gif<br />
</gallery><br />
<br />
= Using the Vacuum Former =<br />
== Owners ==<br />
<br />
The Owners are those who have volunteered to be in charge of the equipment, organising maintenance, training others to use it, and generally being a point of contact. The current Owners of the Vacuum Former are:<br />
<br />
* Stephen Woolhead<br />
* New owners welcomed, get in touch!<br />
<br />
If you have any questions, problems or concerns around the Vacuum Former, please use the mailing list thread:<br />
* [https://groups.google.com/d/msg/cammakespace/LMH8YH7WjMk/6KwuQIKhBnMJ Discussion Log : Vacuum Former]<br />
<br />
== Training ==<br />
<br />
No formal training is required to operate the Vacuum Former. If you intend to make something using the vacuum former please read the Health & Safety and Safety Notes sections below before doing so. The manual is also available online in case you require additional information. <br />
<br />
Informal training sessions will be listed in the Meetup diary <br />
<br />
Requests for more sessions, or discussion about them should be directed to the discussion thread: Training:Vinyl Cutter<br />
<br />
== Health and Safety ==<br />
<br />
Risk assessment: [[Equipment/VacuumFormer/RiskAssessment]]<br />
<br />
The Vacuum Former is a potentially dangerous piece of equipment which must only be operated by members who have received appropriate training and who take due care. The top things to always remember when using the Vacuum Former are:<br />
* '''ONLY USE THE VACUUM FORMER IF YOU ARE ON THE LIST OF TRAINED USERS'''<br />
* '''NEVER LEAVE THE VACUUM FORMER RUNNING UNATTENDED'''<br />
<br />
As a trained user, you should be very aware of the following risks and how to deal with them:<br />
<br />
'''FIRE''' - Heating the material for too long or with the wrong settings could result in the material igniting.<br />
<br />
'''ELECTRIC SHOCKS''' - Regular maintenance & electric survey should mean machine is safe to use. Do not use if there are any signs of damage<br />
<br />
'''BURNS''' - Caution should be taken when using machine, ensure formed part is cool before removing. Never operate with missing or damaged safety features.<br />
<br />
== Instructions ==<br />
<br />
[http://wiki.makespace.org/File:Formech_300XQ.pdf Vacuum Former Manual]<br />
<br />
1. First, a former is made from a material such as a soft wood. The edges or sides are shaped at an angle so that when the plastic is formed over it, the former can be removed easily.<br />
<br />
2. The former is placed in a vacuum former at the lowest position.<br />
<br />
3. A sheet of plastic (for example, compressed polystyrene) is clamped in position above the mould.<br />
<br />
4. The heater is then turned on and the plastic slowly becomes soft and pliable as it heats up. The plastic can be seen to 'warp' and 'distort' as the surface expands.<br />
<br />
5. After a few minutes the plastic is ready for ‘forming’ as it becomes very flexible.<br />
<br />
6. The heater is turned off and the mould is moved upwards by lifting the lever until it locks in position.<br />
<br />
7. The 'vacuum' is turned on and this pumps out all the air beneath the plastic sheet. Atmospheric pressure above the plastic sheet pushes it down on the mould. At this stage the shape of the mould can be clearly seen through the plastic sheet. When the plastic has cooled sufficiently the vacuum pump is switched off.<br />
<br />
8. The plastic sheet is removed from the vacuum former. The sheet has the shape of the former pressed into its surface.<br />
<br />
9. The excess plastic is trimmed so that only the plastic required remains - the completed item.<br />
<br />
===Reducing Windows===<br />
Reducing windows allow the use of smaller sheet material for smaller mouldings. Reducing windows allow for better sheet utilisation.<br />
<br />
To fit the reducing window.<br />
* Lift the clamp frame.<br />
* Place the lower reducing window plate on to the top frame aperture so that the corner locating screws are aligned.<br />
* Place the top reducing window plate on the underside of the clamp frame. There are folded sections on the front and rear. The rear edge has the larger return and wraps completely around the clamp frame bar. The front fold is smaller and returns against the front clamp frame bar. The fixing bolt is fitted through the clamp frame bar and reducing plate and secured using the fixing nut.. See diagram below of side view of the top plate fitting.<br />
<br />
[[image:Reducing_windows.PNG|600px]]<br />
<br />
* Close the clamp frame. Check alignment oftop and bottom plate. Fit the required plastic material on the sealed lower reducing plate. The material toggle clamps will need adjusting so that the clamp frame can be locked to achieve the necessary clamping pressure.<br />
<br />
== Heating times ==<br />
<br />
Different materials and thickness require different heating times, here is a list that has been found to produce good results<br />
<br />
?????<br />
<br />
== Tips & Tricks ==<br />
<br />
'''If the platform does not raise, ensure the heater is fully back.'''<br />
<br />
'''DO NOT use to cook pizza'''<br />
<br />
'''How long does it take to heat the plastic sheet?'''<br />
* This depends on which material and thickness is specified.<br />
<br />
'''How do I know when the plastic is ready to form?'''<br />
* Generally speaking it is necessary with any new material to establish the correct heating cycle. Plastic is ready to form when it becomes soft and pliable especially nearer to the clamping frame. This is known as glass transition temperature (Tg). Once you have established the time you can set the heater<br />
timer for accurate and repeated heating cycles.<br />
<br />
'''Why is the plastic webbing on the mould?'''<br />
* Material is too hot.<br />
* Insufficient vacuum.<br />
* Excess of material. Use reducing windows.<br />
* Poor mould design.<br />
<br />
'''Why can't I achieve good definition on the finished part?'''<br />
* Material too cold<br />
* Mould too cold.<br />
* Insufficient vacuum.<br />
* Insufficient vacuum holes in the mould<br />
<br />
'''Why Is the plastic thinning over the mould when formed?'''<br />
* Sheet cooled whilst forming.<br />
* Mould design with insufficient draft angles.<br />
* Too thin plastic gauge.<br />
* Pre-stretch required.<br />
* Plug assist required.<br />
<br />
'''Why does the plastic bubble and pit when heated?'''<br />
* Material is Hygroscopic which needs to be pre-dried prior to forming.<br />
* Overheating.<br />
* Mould or plastic sheet too dusty<br />
<br />
'''Why does the plastic stick to the mould when I try to release?'''<br />
* Mould not fixed on baseboard.<br />
* Insufficient draft.<br />
* Mould undercuts.<br />
<br />
== Material Stock ==<br />
If you have any requests for material stock, please add them the [https://groups.google.com/d/msg/cammakespace/LMH8YH7WjMk/6KwuQIKhBnMJ Log].<br />
<br />
Stock material will be provided and an honesty box will be provided.<br />
<br />
<br />
= Maintenance =<br />
<br />
The maintenance of the Vacuum Former is carried out by the Owners, with some basic maintenance being carried out by Users on every job.<br />
<br />
== Maintenance Schedule ==<br />
<br />
'''Every job:''' None required<br />
<br />
'''As required, by users:''' Ensure the inside of the machine and the heater tray is cleared of dust, dirt and debris. Do not allow dirt and loose particles to build up, particularly on the heater tray.<br />
<br />
'''Monthly:''' Check strength of vacuum and condition of seals. Check state of electrical system.<br />
<br />
== Maintenance Log ==<br />
<br />
Installed on 26th July 2013. (with any luck)<br />
<br />
<br />
== Maintenance Shopping List ==<br />
<br />
* Service Kit (~£50)<br />
<br />
<br />
= Further Information =<br />
<br />
== Installation ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
<gallery><br />
File:WP_20130726_001.jpg<br />
File:WP_20130726_002.jpg<br />
</gallery><br />
<br />
== Purchase ==<br />
Full Purchase, Delivery and Installation (£2500)<br />
<br />
== Notes ==</div>Perfectphasehttp://wiki.makespace.org/Equipment/VacuumFormerEquipment/VacuumFormer2013-07-26T19:43:46Z<p>Perfectphase: /* Reducing Windows */</p>
<hr />
<div>{{OrangeTool}}<br />
<br />
[[Equipment|Equipment]] / Vacuum Former<br />
<br />
[[File:300xq.PNG|thumb|460px|right|Vacuum Former]]<br />
<br />
=WORK IN PROGRESS=<br />
<br />
This page is a work in progress, the Vacuum Former should be installed in the space on 26/7/2013<br />
<br />
== Summary ==<br />
<br />
Vacuum forming is a technique that is used to shape a variety of plastics. It is used to form/shape thin plastic, usually plastics such as; polythene and perspex. Vacuum forming is used when an unusual shape like a ‘dish’ or a box-like shape is needed. <br />
<br />
[http://wiki.makespace.org/File:Formech_300XQ.pdf Vacuum Former Manual]<br />
<br />
http://www.youtube.com/watch?v=scqkjU10198<br />
<br />
Formech 300XQ<br />
<br />
Technical Specifications<br />
<br />
* Material size 450x300mm / 18x12"<br />
* Forming area 430x280mm / 17x11" <br />
* Max. depth of draw 160mm / 6.3" <br />
* Max. material thickness 6mm / .25" <br />
* Overall width 650mm / 25" <br />
* Overall height 530mm / 20" <br />
* Overall depth 970mm / 38" <br />
* Weight 75kg / 165lbs <br />
<br />
Here are some examples we've made on the Vacuum Former(please add a photo of yours any time you do a job!) <br />
<br />
<gallery><br />
File:300XQ.gif<br />
</gallery><br />
<br />
= Using the Vacuum Former =<br />
== Owners ==<br />
<br />
The Owners are those who have volunteered to be in charge of the equipment, organising maintenance, training others to use it, and generally being a point of contact. The current Owners of the Vacuum Former are:<br />
<br />
* Stephen Woolhead<br />
* New owners welcomed, get in touch!<br />
<br />
If you have any questions, problems or concerns around the Vacuum Former, please use the mailing list thread:<br />
* [https://groups.google.com/d/msg/cammakespace/LMH8YH7WjMk/6KwuQIKhBnMJ Discussion Log : Vacuum Former]<br />
<br />
== Training ==<br />
<br />
No formal training is required to operate the Vacuum Former. If you intend to make something using the vacuum former please read the Health & Safety and Safety Notes sections below before doing so. The manual is also available online in case you require additional information. <br />
<br />
Informal training sessions will be listed in the Meetup diary <br />
<br />
Requests for more sessions, or discussion about them should be directed to the discussion thread: Training:Vinyl Cutter<br />
<br />
== Health and Safety ==<br />
<br />
Risk assessment: [[Equipment/VacuumFormer/RiskAssessment]]<br />
<br />
The Vacuum Former is a potentially dangerous piece of equipment which must only be operated by members who have received appropriate training and who take due care. The top things to always remember when using the Vacuum Former are:<br />
* '''ONLY USE THE VACUUM FORMER IF YOU ARE ON THE LIST OF TRAINED USERS'''<br />
* '''NEVER LEAVE THE VACUUM FORMER RUNNING UNATTENDED'''<br />
<br />
As a trained user, you should be very aware of the following risks and how to deal with them:<br />
<br />
'''FIRE''' - Heating the material for too long or with the wrong settings could result in the material igniting.<br />
<br />
'''ELECTRIC SHOCKS''' - Regular maintenance & electric survey should mean machine is safe to use. Do not use if there are any signs of damage<br />
<br />
'''BURNS''' - Caution should be taken when using machine, ensure formed part is cool before removing. Never operate with missing or damaged safety features.<br />
<br />
== Instructions ==<br />
<br />
[http://wiki.makespace.org/File:Formech_300XQ.pdf Vacuum Former Manual]<br />
<br />
1. First, a former is made from a material such as a soft wood. The edges or sides are shaped at an angle so that when the plastic is formed over it, the former can be removed easily.<br />
<br />
2. The former is placed in a vacuum former at the lowest position.<br />
<br />
3. A sheet of plastic (for example, compressed polystyrene) is clamped in position above the mould.<br />
<br />
4. The heater is then turned on and the plastic slowly becomes soft and pliable as it heats up. The plastic can be seen to 'warp' and 'distort' as the surface expands.<br />
<br />
5. After a few minutes the plastic is ready for ‘forming’ as it becomes very flexible.<br />
<br />
6. The heater is turned off and the mould is moved upwards by lifting the lever until it locks in position.<br />
<br />
7. The 'vacuum' is turned on and this pumps out all the air beneath the plastic sheet. Atmospheric pressure above the plastic sheet pushes it down on the mould. At this stage the shape of the mould can be clearly seen through the plastic sheet. When the plastic has cooled sufficiently the vacuum pump is switched off.<br />
<br />
8. The plastic sheet is removed from the vacuum former. The sheet has the shape of the former pressed into its surface.<br />
<br />
9. The excess plastic is trimmed so that only the plastic required remains - the completed item.<br />
<br />
===Reducing Windows===<br />
Reducing windows allow the use of smaller sheet material for smaller mouldings. Reducing windows allow for better sheet utilisation.<br />
<br />
To fit the reducing window.<br />
* Lift the clamp frame.<br />
* Place the lower reducing window plate on to the top frame aperture so that the corner locating screws are aligned.<br />
* Place the top reducing window plate on the underside of the clamp frame. There are folded sections on the front and rear. The rear edge has the larger return and wraps completely around the clamp frame bar. The front fold is smaller and returns against the front clamp frame bar. The fixing bolt is fitted through the clamp frame bar and reducing plate and secured using the fixing nut.. See diagram below of side view of the top plate fitting.<br />
<br />
[[image:Reducing_windows.PNG|300px]]<br />
<br />
* Close the clamp frame. Check alignment oftop and bottom plate. Fit the required plastic material on the sealed lower reducing plate. The material toggle clamps will need adjusting so that the clamp frame can be locked to achieve the necessary clamping pressure.<br />
<br />
== Heating times ==<br />
<br />
Different materials and thickness require different heating times, here is a list that has been found to produce good results<br />
<br />
?????<br />
<br />
== Tips & Tricks ==<br />
<br />
'''If the platform does not raise, ensure the heater is fully back.'''<br />
<br />
'''DO NOT use to cook pizza'''<br />
<br />
'''How long does it take to heat the plastic sheet?'''<br />
* This depends on which material and thickness is specified.<br />
<br />
'''How do I know when the plastic is ready to form?'''<br />
* Generally speaking it is necessary with any new material to establish the correct heating cycle. Plastic is ready to form when it becomes soft and pliable especially nearer to the clamping frame. This is known as glass transition temperature (Tg). Once you have established the time you can set the heater<br />
timer for accurate and repeated heating cycles.<br />
<br />
'''Why is the plastic webbing on the mould?'''<br />
* Material is too hot.<br />
* Insufficient vacuum.<br />
* Excess of material. Use reducing windows.<br />
* Poor mould design.<br />
<br />
'''Why can't I achieve good definition on the finished part?'''<br />
* Material too cold<br />
* Mould too cold.<br />
* Insufficient vacuum.<br />
* Insufficient vacuum holes in the mould<br />
<br />
'''Why Is the plastic thinning over the mould when formed?'''<br />
* Sheet cooled whilst forming.<br />
* Mould design with insufficient draft angles.<br />
* Too thin plastic gauge.<br />
* Pre-stretch required.<br />
* Plug assist required.<br />
<br />
'''Why does the plastic bubble and pit when heated?'''<br />
* Material is Hygroscopic which needs to be pre-dried prior to forming.<br />
* Overheating.<br />
* Mould or plastic sheet too dusty<br />
<br />
'''Why does the plastic stick to the mould when I try to release?'''<br />
* Mould not fixed on baseboard.<br />
* Insufficient draft.<br />
* Mould undercuts.<br />
<br />
== Material Stock ==<br />
If you have any requests for material stock, please add them the [https://groups.google.com/d/msg/cammakespace/LMH8YH7WjMk/6KwuQIKhBnMJ Log].<br />
<br />
Stock material will be provided and an honesty box will be provided.<br />
<br />
<br />
= Maintenance =<br />
<br />
The maintenance of the Vacuum Former is carried out by the Owners, with some basic maintenance being carried out by Users on every job.<br />
<br />
== Maintenance Schedule ==<br />
<br />
'''Every job:''' None required<br />
<br />
'''As required, by users:''' Ensure the inside of the machine and the heater tray is cleared of dust, dirt and debris. Do not allow dirt and loose particles to build up, particularly on the heater tray.<br />
<br />
'''Monthly:''' Check strength of vacuum and condition of seals. Check state of electrical system.<br />
<br />
== Maintenance Log ==<br />
<br />
Installed on 26th July 2013. (with any luck)<br />
<br />
<br />
== Maintenance Shopping List ==<br />
<br />
* Service Kit (~£50)<br />
<br />
<br />
= Further Information =<br />
<br />
== Installation ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
<gallery><br />
File:WP_20130726_001.jpg<br />
File:WP_20130726_002.jpg<br />
</gallery><br />
<br />
== Purchase ==<br />
Full Purchase, Delivery and Installation (£2500)<br />
<br />
== Notes ==</div>Perfectphasehttp://wiki.makespace.org/Equipment/VacuumFormerEquipment/VacuumFormer2013-07-26T19:42:49Z<p>Perfectphase: /* Reducing Windows */</p>
<hr />
<div>{{OrangeTool}}<br />
<br />
[[Equipment|Equipment]] / Vacuum Former<br />
<br />
[[File:300xq.PNG|thumb|460px|right|Vacuum Former]]<br />
<br />
=WORK IN PROGRESS=<br />
<br />
This page is a work in progress, the Vacuum Former should be installed in the space on 26/7/2013<br />
<br />
== Summary ==<br />
<br />
Vacuum forming is a technique that is used to shape a variety of plastics. It is used to form/shape thin plastic, usually plastics such as; polythene and perspex. Vacuum forming is used when an unusual shape like a ‘dish’ or a box-like shape is needed. <br />
<br />
[http://wiki.makespace.org/File:Formech_300XQ.pdf Vacuum Former Manual]<br />
<br />
http://www.youtube.com/watch?v=scqkjU10198<br />
<br />
Formech 300XQ<br />
<br />
Technical Specifications<br />
<br />
* Material size 450x300mm / 18x12"<br />
* Forming area 430x280mm / 17x11" <br />
* Max. depth of draw 160mm / 6.3" <br />
* Max. material thickness 6mm / .25" <br />
* Overall width 650mm / 25" <br />
* Overall height 530mm / 20" <br />
* Overall depth 970mm / 38" <br />
* Weight 75kg / 165lbs <br />
<br />
Here are some examples we've made on the Vacuum Former(please add a photo of yours any time you do a job!) <br />
<br />
<gallery><br />
File:300XQ.gif<br />
</gallery><br />
<br />
= Using the Vacuum Former =<br />
== Owners ==<br />
<br />
The Owners are those who have volunteered to be in charge of the equipment, organising maintenance, training others to use it, and generally being a point of contact. The current Owners of the Vacuum Former are:<br />
<br />
* Stephen Woolhead<br />
* New owners welcomed, get in touch!<br />
<br />
If you have any questions, problems or concerns around the Vacuum Former, please use the mailing list thread:<br />
* [https://groups.google.com/d/msg/cammakespace/LMH8YH7WjMk/6KwuQIKhBnMJ Discussion Log : Vacuum Former]<br />
<br />
== Training ==<br />
<br />
No formal training is required to operate the Vacuum Former. If you intend to make something using the vacuum former please read the Health & Safety and Safety Notes sections below before doing so. The manual is also available online in case you require additional information. <br />
<br />
Informal training sessions will be listed in the Meetup diary <br />
<br />
Requests for more sessions, or discussion about them should be directed to the discussion thread: Training:Vinyl Cutter<br />
<br />
== Health and Safety ==<br />
<br />
Risk assessment: [[Equipment/VacuumFormer/RiskAssessment]]<br />
<br />
The Vacuum Former is a potentially dangerous piece of equipment which must only be operated by members who have received appropriate training and who take due care. The top things to always remember when using the Vacuum Former are:<br />
* '''ONLY USE THE VACUUM FORMER IF YOU ARE ON THE LIST OF TRAINED USERS'''<br />
* '''NEVER LEAVE THE VACUUM FORMER RUNNING UNATTENDED'''<br />
<br />
As a trained user, you should be very aware of the following risks and how to deal with them:<br />
<br />
'''FIRE''' - Heating the material for too long or with the wrong settings could result in the material igniting.<br />
<br />
'''ELECTRIC SHOCKS''' - Regular maintenance & electric survey should mean machine is safe to use. Do not use if there are any signs of damage<br />
<br />
'''BURNS''' - Caution should be taken when using machine, ensure formed part is cool before removing. Never operate with missing or damaged safety features.<br />
<br />
== Instructions ==<br />
<br />
[http://wiki.makespace.org/File:Formech_300XQ.pdf Vacuum Former Manual]<br />
<br />
1. First, a former is made from a material such as a soft wood. The edges or sides are shaped at an angle so that when the plastic is formed over it, the former can be removed easily.<br />
<br />
2. The former is placed in a vacuum former at the lowest position.<br />
<br />
3. A sheet of plastic (for example, compressed polystyrene) is clamped in position above the mould.<br />
<br />
4. The heater is then turned on and the plastic slowly becomes soft and pliable as it heats up. The plastic can be seen to 'warp' and 'distort' as the surface expands.<br />
<br />
5. After a few minutes the plastic is ready for ‘forming’ as it becomes very flexible.<br />
<br />
6. The heater is turned off and the mould is moved upwards by lifting the lever until it locks in position.<br />
<br />
7. The 'vacuum' is turned on and this pumps out all the air beneath the plastic sheet. Atmospheric pressure above the plastic sheet pushes it down on the mould. At this stage the shape of the mould can be clearly seen through the plastic sheet. When the plastic has cooled sufficiently the vacuum pump is switched off.<br />
<br />
8. The plastic sheet is removed from the vacuum former. The sheet has the shape of the former pressed into its surface.<br />
<br />
9. The excess plastic is trimmed so that only the plastic required remains - the completed item.<br />
<br />
===Reducing Windows===<br />
Reducing windows allow the use of smaller sheet material for smaller mouldings. Reducing windows allow for better sheet utilisation.<br />
<br />
To fit the reducing window.<br />
* Lift the clamp frame.<br />
* Place the lower reducing window plate on to the top frame aperture so that the corner locating screws are aligned.<br />
* Place the top reducing window plate on the underside of the clamp frame. There are folded sections on the front and rear. The rear edge has the larger return and wraps completely around the clamp frame bar. The front fold is smaller and returns against the front clamp frame bar. The fixing bolt is fitted through the clamp frame bar and reducing plate and secured using the fixing nut.. See diagram below of side view of the top plate fitting.<br />
<br />
[[image:Reducing_windows.PNG]]<br />
<br />
* Close the clamp frame. Check alignment oftop and bottom plate. Fit the required plastic material on the sealed lower reducing plate. The material toggle clamps will need adjusting so that the clamp frame can be locked to achieve the necessary clamping pressure.<br />
<br />
== Heating times ==<br />
<br />
Different materials and thickness require different heating times, here is a list that has been found to produce good results<br />
<br />
?????<br />
<br />
== Tips & Tricks ==<br />
<br />
'''If the platform does not raise, ensure the heater is fully back.'''<br />
<br />
'''DO NOT use to cook pizza'''<br />
<br />
'''How long does it take to heat the plastic sheet?'''<br />
* This depends on which material and thickness is specified.<br />
<br />
'''How do I know when the plastic is ready to form?'''<br />
* Generally speaking it is necessary with any new material to establish the correct heating cycle. Plastic is ready to form when it becomes soft and pliable especially nearer to the clamping frame. This is known as glass transition temperature (Tg). Once you have established the time you can set the heater<br />
timer for accurate and repeated heating cycles.<br />
<br />
'''Why is the plastic webbing on the mould?'''<br />
* Material is too hot.<br />
* Insufficient vacuum.<br />
* Excess of material. Use reducing windows.<br />
* Poor mould design.<br />
<br />
'''Why can't I achieve good definition on the finished part?'''<br />
* Material too cold<br />
* Mould too cold.<br />
* Insufficient vacuum.<br />
* Insufficient vacuum holes in the mould<br />
<br />
'''Why Is the plastic thinning over the mould when formed?'''<br />
* Sheet cooled whilst forming.<br />
* Mould design with insufficient draft angles.<br />
* Too thin plastic gauge.<br />
* Pre-stretch required.<br />
* Plug assist required.<br />
<br />
'''Why does the plastic bubble and pit when heated?'''<br />
* Material is Hygroscopic which needs to be pre-dried prior to forming.<br />
* Overheating.<br />
* Mould or plastic sheet too dusty<br />
<br />
'''Why does the plastic stick to the mould when I try to release?'''<br />
* Mould not fixed on baseboard.<br />
* Insufficient draft.<br />
* Mould undercuts.<br />
<br />
== Material Stock ==<br />
If you have any requests for material stock, please add them the [https://groups.google.com/d/msg/cammakespace/LMH8YH7WjMk/6KwuQIKhBnMJ Log].<br />
<br />
Stock material will be provided and an honesty box will be provided.<br />
<br />
<br />
= Maintenance =<br />
<br />
The maintenance of the Vacuum Former is carried out by the Owners, with some basic maintenance being carried out by Users on every job.<br />
<br />
== Maintenance Schedule ==<br />
<br />
'''Every job:''' None required<br />
<br />
'''As required, by users:''' Ensure the inside of the machine and the heater tray is cleared of dust, dirt and debris. Do not allow dirt and loose particles to build up, particularly on the heater tray.<br />
<br />
'''Monthly:''' Check strength of vacuum and condition of seals. Check state of electrical system.<br />
<br />
== Maintenance Log ==<br />
<br />
Installed on 26th July 2013. (with any luck)<br />
<br />
<br />
== Maintenance Shopping List ==<br />
<br />
* Service Kit (~£50)<br />
<br />
<br />
= Further Information =<br />
<br />
== Installation ==<br />
<br />
Installed on 9th May 2013.<br />
<br />
<gallery><br />
File:WP_20130726_001.jpg<br />
File:WP_20130726_002.jpg<br />
</gallery><br />
<br />
== Purchase ==<br />
Full Purchase, Delivery and Installation (£2500)<br />
<br />
== Notes ==</div>Perfectphasehttp://wiki.makespace.org/File:Reducing_windows.PNGFile:Reducing windows.PNG2013-07-26T19:41:31Z<p>Perfectphase: </p>
<hr />
<div></div>Perfectphase