SPRING User's Manual - Faculté Sciences et Technique de l'Ingénieur
Contents
1. Block Delete la Set Next Line M1 Optional Stop al Line 0 Flood Ctrl E 9 Run From Here Dwell y Mode Active bl GCodes M Codes 0 000 FIGURE 43 Reset button in Mach3 Once Mach3 is on you can move the CNC spindle in the cutting area using the keyboard Use the UP DOWN LEFT RIGHT keys to move in the X and Y plane To move up and down use the and keys Left of to the Enter key If you want to go faster simultaneously press the SHIFT and any key mentioned above Remove the lock nut holing the spindle tip onto the spindle and insert the chuck which has the right size four your tool diameter In our case we need a 1 8 chuck The chuck must be clipped into the lock nut it makes a very specific noise it can require some additional force turn it slightly if necessary Once the chuck in place insert the desired tool In our case we will be using the 2 5 mm 1 tooth countersink bit 36 SPRING User s Manual a Cutting tool chuck et lock nut b Chuck correctly inserted into the lock nut c Lock nut correctly screwed onto the spindle FIGURE 44 Usually it is best to use the shortest possible tool for any job The longer the tool the bigger the vibrations Also push the tool as far as the machining allows it into the chuck this will also reduce the intensity of the vibrations FIGURE 45 Tool correctly inserted into the chuck 10 CNC 31 Once everything is in place tighten the2. I T COLE POLYTECHNIQUE F D RALE DE LAUSANNE SPRING USER S MANUAL Nicolas Dubois Xavier Guidetti Timothy Marvel Nicol Sitzia SUPERVISOR Dr Matteo Galli This manual is written as an introduction and a guideline for mechanical engineering students on how to use the SPRING project room the tools which are available in it and as a starting point for DIY jobs We wish to thank Dr Matteo Galli who has supervised the reorganising and has always been helpful for solving problems we encountered D SPRING User s Manual Table des mati res 1 Introduction 4 2 General rules 4 3 Drilling 5 xl Drill Press 4 wow w aran me ak ao ie kot f de dee SEED e vite S4 e vin A SREB S UN S 7 3 2 Handheld drlll n n n n n un 8 4 Cutting 9 Ad Eto AW A A 9 5 6 4 2 Electric coping saw V e va a kn w w n kk w kk noun 10 L JOEN e eantas oo Be oe W DE ET TW EE 11 Polishing 13 PARE E 13 5 2 Bel sanderi sesos amp oa ba ee we HS AA as a we AL 15 Gluing 14 aora arras S S S PE W A n 14 NE 15 3 Hot air gun 16 8 Threading tapping and filing 17 8 1 Threading a rod s ssa woul mn fe eee bd spaga de we ew ee EDP weed eee Sw v 17 8 2 Threading inside a hole ee 18 5 9 COUMGELDONING s s sse emu five sad ERO Oe Em da pops RR Ee Os 18 9 Welding Soldering 19 9 1 Soldering l J ls e es ss mard BEDE ORG AAM OEE oe AA ES a fk Or ee de 04 19 10 CNC 20 10 1 The machine w m we w
3. FIGURE 61 The highest point of the dice must have a Z value of 0 Using the transformation matrix move the dice downwards by 14 half it s Z height Number ot Vertices El Transformation 3 Transform Identity mm gt gt in in gt gt mm Transformation Axis Amount o ao a Deg Rad FIGURE 62 Moving the dice downwards We now have to create the two holes with which we the mother piece will be held during the second phase of the machining On the XY plane create a 4mm wide circle centred at the zero point Create a copy and move the first one by 40 mm on the Y axis and the second one by 40mm on the Y axis 10 CNC 45 FIGURE 63 The two 4mm wide circles in the right position In the XY plane create a 45mm wide circle centred at the zero point It will be used for a machining limit for the surface machining This means that the CNC machine will neglect anything outside of that circle FIGURE 64 45mm wide circle centred at the zero point The drawing part is finished we can now move on and create the machining passes 10 3 3 Creating the machining passes with CamBam To machine the surfaces we will create tree profiles The first one will be a rough cut The second one a finishing cut along the X axis and the last one a finishing cut along the Y axis Select the surface and click on 3D profile 46 SPRING User s Manual raw Machining Script Plugins Tools
4. Fixing the Sheet Put the sheet to be cut into on the buffer sheet To achieve a good quality and to avoid any accidents we recommend using double faced Scotch tape between the buffer sheet and the PET sheet If possible aim for the parts being cut out and could move around once cut Another option is creating holding tabs in CamBam For 2D machining CamBam can do it automa tically To use that function click on the Profile to be machined and modify the Holding Tabs parameter In our case we will not be using this option because it has undesirable effects on the preci sion of the cutting We want our edges to be very accurate to make sure the parts will fit into one another FIGURE 41 Applying double faced Scotch tape 10 CNC 35 The sheet can now be fastened onto the buffer sheet with the metal clamps Use a sheet which has already been cut for the same piece to place the Scotch tape if available a Clamp fastend the right way b Clamping the sheet to the Buffer FIGURE 42 10 2 5 Machining with Mach3 Turn the CNC on and put on the safety goggles at your disposal The switches are below the drawer on the bottom left side of the table Press on the green button and then turn the three buttons into the I position Start Mach3 and click on OK in the small window which should pop up Click on Reset Edit G Code Rewind Ctrl W Recent File Single BLK Alt N lan Close G Code Reverse Run R Load G Code
5. It is important to remember that a jigsaw is a tool with a free blade it is important not to cut into either the power cable nor any part of one s body Choice of the blade The choice of the blade should be done according to the following table Blade Type Maximal depth fmm 140 10 20 D Feders mms ECN A E A For the blade speed it is necessary to remember that it depends inversely on the material hardness For a soft wood it can be set at the maximum speed while for aluminium it has to be very slow Changing the blade The blade needs to be changed when it is damaged or when cutting into a different material Loosen the mount and take the blade out Pay attention because it will get out alone as the spring behind it will push it outside Loosen again the mount and insert the new blade so that it is well placed at the bottom Verify if the blade is safely positioned Operating instructions To start off with draw a line along which the cut is supposed to go Use a pencil for wood or a permanent marker for metal This line is important since provided it has been properly followed it guarantees a good cut Place the piece in such a way that it can be clamped into position using g clamps Make sure the electric cable is long enough and that the proper blade is on the saw Start cutting by pushing the saw into the piece Don t push too hard this will affect the quality of the cut surface in a negative way When arriving to the
6. actual position of the tool Click on Regen Toolpath to update Move the tool to the centre of the sheet and place the pressure sensor for calibrating the Z axis right under the tip of the tool Be careful whilst placing the sensor if anything goes wrong you might end up breaking the tool FIGURE 49 Placing the sensor for the Z height calibration Once you ve made sure the tool is right above the sensor about 1 cm above click on Auto tool zero button FIGURE 50 Auto tool zero in Mach3 The CNC is now properly calibrated along the Z axis Remove the sensor and move the spindle next to the zero point Never start the machining with the spindle far away from the starting point a rapid displacement might cause damage if anything is in the path between the current position and the starting point most commonly a metal clamp If everything has been done properly you can now start the machining process by clicking on the Start button in Mach3 On the firts click nothing will happen Mach3 will ask you to confirm the instructions and the tool used Once that has been checked click and start again and the process will start 10 CNC 39 While the CNC is working keep a close eye on it and be ready to stop it if anything doesn t go according to plan If you ve clicked Stop and want to resume with the machining restart the G Code from the beginning using the Rewind G Code function Failing to do so will break th
7. create drawing directly in CamBam however we strongly advise you to always use a real drawing program since it will be easier to use and usually a better suited program CamBam is okay for minor modifications or last minute changes to the design The principle shapes available are Rectangle Circle Polyline Text and Points Their parameters appear in the box on the left hand side of the screen when they are created If interested we recommend the CamBam documentation 28 SPRING User s Manual e zz ng Script Plugins Tools Help Df asans 8a8utl FIGURE 31 Drawing tools For our box a small change regarding the original dxf file is necessary the size of the lid must be changed Create a rectangle starting at the zero point Click on the rectangle tool then on the zero point and then somewhere else on the screen Press the ESC button FIGURE 32 Creating a rectangle at the zero reference point In the box on the left hand side of the screen chose the size and position of the rectangle which has just been created Height of 70 Lower Left of 9 81 0 Width of 48 E Folyline 363 Polyline 364 Polyline 365 Polyiine 458 Polyline 459 1 Polyline 460 Polyiine 461 Polyline 462 Polyline 463 Polyine 464 a T Machining Basic E General 1D 466 E Polyline Direction CCW Number of Segments 4 E Rectangle Corner Radius 0 7 Lower Left
8. diameter of the counter bore 9 WELDING SOLDERING 19 9 Welding Soldering 9 1 Soldering iron Safety rules On top of the general rules for the room specific rules apply for the soldering iron The user must make sure never to let the iron out of his eyesight when it is on We don t recommend the use of gloves when soldering small parts because the user will not be as precise thus we recommend being particularly careful when it is being used Goggles are mandatory We also recommend users to avoid inhaling the fumes from the soldering tin since it contains lead FIGURE 15 ERSA ANALOG 60 soldering iron Choice of the temperature When soldering pieces using soldering tin containing lead a 300 C operating temperature is enough to melt the soldering tin Higher temperature will increase the toxic fumes and cause the welding tin to become very liquid and maybe even to melt the surrounding pieces A too low temperature will not create a solid weld and it will be difficult to weld with it since it would require the user not to move during 30 seconds or more that can be difficult when every mm counts This is especially true with electronic circuit boards Operating instructions To begin with prepare all the necessary tools on the workbench You will need the following equipment the soldering iron soldering tin and the parts which are going to be welded The little sponge on the welding iron s main frame must be humidified bef
9. end of the piece make sure the piece cut out will not fall on the floor or cause any damage once it is loose from the original piece Once finished clean the surrounding area and the saw itself Tips If two people are present it can be a good idea that one of them vacuums the chips away as they are being produced rather than waiting to clean the up at the end For long or bulky pieces we highly recommend that two people do the job Whilst one makes sure the pieces don t move the other one can do the cutting without worrying Also make sure that the piece cut out will not break or cause damage due to it s own weight 5 POLISHING 13 5 Polishing 5 1 Sandpaper Safety rules Sand paper is a harmless tool Goggles are not compulsory but can be useful if the piece sanded is above the user s eyes Also the user pay attention not to hold onto the paper by the rugged side Operating instructions After having cut a piece it frequently happens that the cut is not completely clean This is when sandpaper should be used Start by fixing the piece in a vice and then start off sanding the piece with a low number rough piece of sandpaper Once all the large irregularities have gone use smaller and smaller grain bigger numbers and continue sanding until the surface has the desired finish Tips Use large grain small numbers typically 80 to start off with and then go down the size of grain Don t start off with a small grain larg
10. into We have prepared the following table for your convenience however keep in mind that the wider the drill bit gets the slower the operating speed must be The main danger is a too big operating speed Recommended operating speed in RPM according to the material of the piece being drilled into and tool diameter Soft wood Hard wood Plastic PVC PET Aluminium and Dibond 3mm 1 8 1800 1200 1500 1500 6mm 1 4 1800 1000 1500 1500 9mm 3 8 1800 1500 1000 12mm 1 2 1800 1000 i5mm 3 5 1800 The speed at which you descend into the material the feed rate should be around 2 3 mm s If you hear any suspicious noise odds are something went wrong try again using a lower feed rate or operating speed If you can not change the gear in which the drill press is set try using the hand held drill Once the speed has been determined in m min one needs to convert it into RPM s using the following formula n 1000v where v is the cutting speed and d the diameter of the drill tip If the calculated speed using the above formula is not achievable use the next inferior available speed On line information can also be useful especially for exotic materials FIGURE 4 Gearbox for the drill press Choosing the drill As long as using the drill press is possible it is recommended to use it It s more accurate and more powerful than the hand held drill The hand held drill is useful for operations on large objects whic
11. surfaces from a 3D file not used in this part The box will be made using the Profile and Pocket setting Completely cutting the pieces out of the sheet will be the last step All the machining that can be done before should be done wile the pieces are still part of the sheet 30 SPRING User s Manual To start of with you can create the three strips on the sliding lid Select the three corresponding rec tangles and click on pocket in the manufacturing menu File View Edit Draw Machining Script Plugins Tools Help D 5 E Units millimeters A A esa gagann D Drawing F System Layer Polyline 361 Polyline 362 Polyline 363 Polyine 367 Polyline 368 Polyine 375 Polyline 376 Polyine 458 Polyine 459 Polyline 460 Polyine 461 Polyine 462 Polyline 463 Polyine 464 E PolyRectangle 466 T Machining a Basic J General ID Layer Layer1 Primitive Type Polyline Tag 3 Polyline Closed Direction True CW m Number of Segments Points 3 Transformation Transform Collection Identity FIGURE 36 Polylines to select for the Pocket machining On the left of the screen in the Machining part of the menu a machining instruction has been created Select it and all the parameters to be adjusted for the proper manufacturing process will appear Visible in figure 34 This is a crucial step the link between the CNC and the drawing
12. thread a hole the hole must be drilled before The diameter of the hole depends of the thread of the screw for which the hole is being made The following table gives the size of the drill tips available in the workshop according to the screw size and the size of the thread MIO Diameter of the hole D thread 1 60 2 50 3 30 4 20 5 00 i i Operating instructions Start by choosing the tap which has the right diameter and insert it in the tap wrench easily identifiable by it s v shaped vise Place the tap vertically above the hole and start turning into the hole once it has been lubricated Make sure the the tap and the hole are co centric otherwise the thread will be cut sideways Just like for external threading for every full revolution of the tool make a half revolution going the other way to break of the chips Once finished clean out the hole and the surrounding area and don t forget to clean up the used area 8 3 Counterboring To drill a counterbore a right sized hole must be drilled into the desired piece using the drill pres For a cylindrical shaped head the dimensions of the hole are givin in the table bellow Diameter 20 320 Ce ds 3 30 6 00 8 00 10 00 11 00 15 00 18 00 20 00 a 1603 50 450 5 70 680 900 11 00 13 00 as o The following definitions are used in the table d2 diameter required for the frill d3 diameter of the screw head tl depth of the counter bore d5
13. to be done on the numbered band drilling in our case shown by a drill bit Two operating speeds are achievable 1 slow 2 fast choose the appropriate one It is essential to avoid accidents and to drill a straight hole to be in a stable position whilst drilling Apply a fair amount of pressure on the drill and start drilling If a lot of dust and chips are being created by the drilling have someone else hold a vacuum cleaner during the drilling Once the hole has been finished and as soon as the drill tip has cooled off clean the drill and tidy up the workspace The hand drill can also serve as an electric screwdriver with the proper tips The locking torque applied on the screw can be chosen between 1 smallest and 14 biggest Tips If drilling a large diameter hole first drill a small hole at the centre of the desired hole which will the serve as a centre reference for a large drill tip 4 CUTTING 9 4 Cutting 4 1 Hand saws Safety rules On top of the normal safety rules it is important to pay attention to the hand holding the piece in place so that any injuries may be avoided Never leave your fingers in the cutting area FIGURE 7 ULMIA 352 angle saw Choice of the saw The blade must be suited for the material being cut into Blades for both wood and metal are available The main difference between the two different blades is the size of the teeth Also in the case of the ulmia saws the blades have diff
14. to leave on the part after the roughing pass StepOver 0 7 the rate of new mater cut into between two passes percentage wise of the tool diameter A StepOver of 0 7 means that 70 of the surface being machined hasn t been machined during the previous pass meanwhile 30 already has StepOver Feedrate Cut Feedrate The StepOver is calculated using the horizontal displacement of the tool Tool Diameter 8 Tool Number 8 a number associated to the 8mm tool useful to identify it in Mach3 The parameters will result in a fast but rough cut The CNC will undergo the operation in 3 5mm deep machining passes 10 CNC 47 Create a copy of the machining instructions and modify the following settings Profile 3D Method Horizontal Boundary Margin 0 Depth Increment 16 Cut Feedrate 2000 Plunge Feedrate 2000 Spindle Speed 16000 Roughing Clearance 0 StepOver 0 3 Tool Diameter 3 175 Tool Number 3 This instruction will result in a series of sweeping passes of the dice along the X axis Since the roughe ning pass has already been done we chose a Depth Increment that is bigger than the target depth to save time we don t want the tool machining in empty space Only one pass will be made We can machine at a higher speed since there is not a lot of matter to remove Roughing Clearance is set to 0 and a reduced StepOver makes for a better surface after the machinig since we want this pass to be a finishing p
15. 14 Threading dies 8 1 Threading a rod Choice of the die The die must be chosen according to the rod that is to be threaded The number following Mx indicates the diameter in mm A 6mm wide rod must be threaded with a MG die Operating instructions To cut a thread on a rod start by fastening the rod in a vise If the rod doesn t have a chamfer use a metal file to create one After having measured the diameter of the rod with a calliper pick the right sized die Mount the die on the die wrench big metal piece with a circle in the centre and screw the screws on each side without applying too much pressure on them Oil or threading lube available in the Zinkol orange white container must be applied on the rod 18 SPRING User s Manual Place the die vertically at the top of the rod make sure it is placed exactly Even a slight angle might create a thread that isn t aligned with the rod Start by turning the die very slowly in the clockwise direction Keep in mind that the rod and the die must be co centric for this operation to succeed For every full 360 turn done cutting make a counter clockwise 180 rotation this allows chips to be evacuated Once the target depth has been reached gently remove the die by turning it in the anti clockwise direction all the way to the top The job is finished make sure the thread is co centric with the rod Don t forget the cleaning 8 2 Threading inside a hole Diameter of the hole To
16. 9 81 0 Width 48 E Transformation Transform Identity FIGURE 33 Size of the rectangle and display in the XY plane Delete the old smaller rectangle which this rectangle is going to replace 10 CNC 29 amBam 2080 File View Edit Draw Machining me Plugins Tools Help DU Units Millimeters YA A BEEBE RAS E Drawing P System Polyline 361 Polyline 362 Polyline 458 Polyine 459 Polyline 460 Polyine 461 Polyline 462 Polyine 463 Polyline 464 E PolyRectanale 466 T Machining SE sic Ge Layer Layer 1 Primitive Typ h Tag Polyline Closed True Direction CCW Number of Segments 4 Poi Collection E Transformati Transform Identity FIGURE 34 Deleting the smaller rectangle The drawings are now complete We will now take a look at the machining of the lines which have been drawn 10 2 3 Machining settings in CamBam CamBam has a set of different machining settings Profile Pocket Engrave 3D profile amongst others ls Help quae 3208000 FIGURE 35 Machining settings The different settings are explained bellow Profile Follows a closed line on the inside or the outside The tool path will be tangent to the line Pocket Empties everything which is inside a closed line Drill Drills a hole centred on a point or a circle Engrave Follows a line The tip of the tool will be exactly on the line 3D Profile used for 3D
17. Alt 6 Diagnostics Alt 7 E Mo ie ML 0 0000 r Mill gt G15 G1 G10 G17 G40 p Zera k Load Wizards Last Wizard NFS Wizards MU a CNC tool in the correct calibration position d Ctrl W b Calibration along the X and Y in Mach3 FIGURE 71 Click on Regen Toolpath then using the keyboard and the graphical interface on the top right hand side of the screen move the spindle all the way around the part to make sure that nothing will get in the way of the tool keep a close eye on the metal clamps It 7 Mill gt G15 G1 G10 G17 G40 G21 G90 G94 G54 G49 G99 G64 G izards Last Wizard Regen A Looi FIGURE 72 graphical interface and Regen Toolpath button Once the X and Y axes have been calibrated calibrate the tool along the Z axis Use the pressure sensor and place it on the mother piece not on the buffer 10 CNC ol FIGURE 73 Pressure sensor properly placed for calibration along the Z axis Everything is ready move the tool close to the starting point and click on Start Mach3 will ask you to confirm the operation after having checked that the proper tool 8mm has been mounted Click on Start a second time and the machining process will start Keep a close eye on the machine while it is cutting be ready to stop it if anything goes wrong tewind Ctri W single BLK Alt N m Reverse Run m Block Delete Y 11 Optional Stop la Flood Ctr
18. CAMIPRO system Only people with the explicit autho risation from the Mechanical Engineering department are allowed to work in it A large set of manual and power tools allowing the students to complete many tasks are available in the workshop In the first part of this presentation we will take a closer look at the general rules and safety requirements Later we will explain how to use the tools present At last we will offer detailed explications on the functioning of the CNC machine 2 General rules The following rules must be followed at all time in the workshop to prevent any form of accidents of happening Safety goggles are available in the blue drawer box next to the CNC machine Their purpose is to protect eyes against any form of injury for instance when drilling a hole in a block of aluminium with the drill press FIGURE 1 UVEX safety goggles Goggles must be worn when operating any machine with the blue safety glasses sticker We recommend keeping goggles on as long as power tools are being used A safe distance must be kept from any power tool Long hair must be tied up and any of the following must not be worn jewelry scarfs ties wristbands or indeed any piece of clothing which could get tangled up in the tool Also anyone operating am power tool is responsible of operating it and must stay in the room while it is operating The use of any tool under influence of drugs alcohol medicine or any other behavi
19. Help illimeters A x BEBHREAA 2 amp FIGURE 65 Creating a 3D Profile The parameters to be modified are the following Profile 3D Method Waterline Rough it s the method of creating the machining passes Waterline produces a series of passes going around the part on different levels Boundary Margin 3 the distance at which we define the Boundary Shape explained at the next point Boundary Method Selected Shapes defines the area which the CNC will cut into around the part We chose to control it by using the shape of the 45mm circle we ve created above Boundary Shape IDs 8 it needs to be the same as the id number of the 45mm circle Depth Increment 5 the increment of every machining pass Stock surface 0 The Z height under which the CNC will start machining Target Depth 15 the final target depth we want to achieve Cut Feedrate 1500 the la vitesse d avancement de l outil Milling Direction Mixed the direction along which the tool will make the cut Clockwise or anti clockwise around the part If you choose Mixed it will accept both direction this accelerates the machining Spindle Speed 12000 operating speed in RPM Max Crossover Distance 1 the maximal distance percentage wise the tool will move without returning to the 0 height Resolution 0 1 distance between two lines the program uses to scan the 3D part Roughing Clearance 0 5 thickness
20. LA 3000g Glue ARALDIT Standard 2x12ml Glue ARALDITE tube fliissig 3g 50678 00000 Measuring tools VOGEL sliding caliper Micrometre Ruler Roll meter STANLEY Powerlock legth 3m Depth caliper VOGEL mesuring capability 150mm mm inch Roughcast tape TESA tesakrepp 50mm 60100 00001 00 Pump with lever 0 10 bar Adaptor kit for pump Thermo shrinking sheath width 6 4mm x 1m CIMCO Universal grease MOTOREX 3000 0 85 kg G clamp 65x60mm Coping saw electric EXCALIBUR EX 16CEBS Blades for coping saw JET 130x0 92x0 3 teeth per cm 7 5 Blades for coping saw JET 130x1 08x0 34 teeth per cm 6 5 Blades for coping saw JET 130x1 25x0 38 teeth per cm 6 Blades for coping saw JET 130x3 0x0 5 teeth per cm 6 Blades for coping saw JET 130x2 0x0 25 teeth per cm 10 Blades for coping saw JET 130x3 0x0 5 teeth per cm 2 75 Quantity SPRING User s Manual Reference number 29 8205 0200 25 8374 0200 25 8376 0500 29 6502 0200 25 6524 0100 25 9980 0100 23 9960 0180 25 5450 0001 25 9915 0100 29 0915 0110 13 64 30 0100 13 6412 0100 31 1583 0024 31 1626 0100 13 1580 0100 13 3280 0030 13 1520 0100 81 7342 4550 23 4160 0100 23 4164 0100 17 2092 0200 25 3632 0850 12 7090 06506 24 7333 0110 24 7302 2257 24 7302 2258 24 7302 2259 24 7302 2261 24 7302 2262 24 7302 2263
21. a eee bi de di w g os 8 9 deeds ay SOO die ab RESO DHS S 20 10 2 Tutoriel d usinage 2 5D Ll aa n aa a w n knn n 20 LO Ze MON INN reo aa AAA AAN 20 10 2 2 Drawing in CamBadl enn nn 21 10 2 3 Machining settings in amBam 000000 eee eee 29 10 2 4 Fixing the Sheet w s w wou eae ke OPER ae we eR ww f n t n ee wo 34 10 2 5 Machining with Macho 0 xo naa eee Sew ee j s ieks ee on 35 IU Ob machining s errs reme a AAA AE AA 39 o Ll Drowns Ga varas 39 10 3 2 Drawing using Cam BAM e eos 446848248 8 Ba aaa ARE 39 10 3 3 Creating the machining passes with CamBam 45 10 3 4 Fixing the motherpiece ee 48 10 3 5 Machining with Mach3 v s 49 10 3 6 Fastening the mother piece for second part of the machining 53 SAA 54 10 3 8 Second machining pass with Machd3 a 54 10 4 Machining tables e s pe soss o aaa ada A A e det 96 TABLE DES MATIERES 11 1 Classical machining IL ONO sap a E 12 Inventory 57 ov of of 99 4 SPRING User s Manual 1 Introduction The name SPRING is a concatenation of the following french words Salle de PRojet pour ING nieur The SPRING workshop was created as part of a bachelor project during the 2015 spring semester The aim of the project was to refurbish the room in a economical and safe way so it could be used as a workshop by the students Access to the workshop is done through the
22. ak FIGURE 60 Rotation of the new part 44 SPRING User s Manual Now we have to modify the size of the dice so that it will fit into the wooden piece were going to use This must be accurately measured to make sure the cut from the second side will be precise and clean Select the surface and click on Edit Transform Resize and enter 28 the thickness of our mother piece in Z new size check that Preserve aspect ratio has been selected OK File View Edit Draw Machining Script Plugins Tools Help Dae bd Explode ISHEREe Daeg C Drawing P Join Ctri J Offset Open Offset Union Ctrl U Subtract Intersection Size New Size Percent 81 2990 ig 899424 213 90096 my 87352539 on Gon gt Trim Fillet Intersection Points Break at Intersections Ctrl B Mz 13 09017 213 900967 Convert To gt 100 Preserve aspect ratio IV Polyline Resize Ctri E _ mmtoinches Surface Rotate Ctrl R inches to mm Apply Close Select All Ctri A Align kb oo Select All On Layer Mirror am Basil Array Copy Cut Ctrl X E General Polar Array Copy ID Copy Ctrl C Center Extents Layer Paste Ctrl V i 13882867379E 08 100 Primitive Typd Center Of Points Tag Undo Ctrl Z Apply Transformations E Mesh Redo Ctrl Y Number of Faces b Setting the Z new size Number of Vertices E Transformation a Resize command
23. already be fastened to the CNC bed if it s not the case fasten it a Metal clamp properly setup b Buffer fastened on the CNC FIGURE 68 Use two other clamps to fasten the motherpiece at it s tips 10 CNC 49 FIGURE 69 Fastening the mother piece to the buffer 10 3 5 Machining with Mach3 Turn the CNC on under the drawer on the left hand side of the table press on the green button and turn the three switches and start Mach3 click OK on the small pop up window Put your safety goggles on and using Mach3 move the spindle of the CNC so that the lock nut is easily reachable Unscrew the lock nut insert the chuck into which the 8mm tool will fit and loosely screw the lock nut back int place Insert the 8mm wide roughening tool and tighten the lock nut FIGURE 70 8mm tool correctly set up In Mach3 click on the Reset button big and red To load your g code click on load G Code and open the file you ve created with CamBam The CNC will need to be calibrated along the 3 axes Proceed the same way as in the 2 5D machining process The zero point for this design is at the centre of the dice Try to set the O point as close as possible to centre of the mother piece use a ruler and a pencil to mark the centre Once you ve reached the centre of the motherpiece with the tip of the tool click on Zero X and Zero X 50 SPRING User s Manual Plugin Control Help Offsets Alt 5 Settinge4
24. and modify the G coe the drilling operation of the two holes must me taken out Select the drilling operation right click and chose Enable Disable MOP in the menu E 2DSurface1 AA 3DSurface2 Gl 3DSurface3 Generate toolpaths Produce gcode Select drawing objects Set start point Tool s to geometi EE 24 Basic ee Speed and feeds calculator E General Enabled Enable Disable MOP C Ctrl X Primitive IDs ras me Style Copy Ctrl C Tag Paste Ctrl V Paste format Shift Ctrl V Delete DEL Stock Surface Rename Target Depth Reset to defaults E Drilling Custom Script Drill Lead Out False Drilling Method Spiral Mil CW 0 FIGURE 80 Cancelling the drilling operation in CamBam Select Part1 right click and choose generate G code Save the new G Code 10 3 8 Second machining pass with Mach3 Open the code with Mach3 using the Load G Code command The new code will be the same as the old one but without the drilling operation This is an important difference since we don t want the tool drilling into the screws Install the 8mm tool and recalibrate the machine along the Z axis autotool zero 10 CNC JI FIGURE 81 Calibrating along the Z axis Bring hte tool tip close to the zero point and click on Start click a second time to start once you ve checked that the right tool is inserted Once the rough pass has finished start by cleaning the area with a
25. aner and finally release the drilled piece out of the vise Finally clean and put away all the used equipment 8 SPRING User s Manual In case of an emergency or malfunction the drill can be stopped using the round red emergency button Also it is possible that the jaw chuck loosens itself from the drill press this is because the jaw chuck has been mounted in such a way to prevent it from jamming if the cutting toque is to big In case of such a disturbance put the jaw chuck back into place once the drill bit has been removed using a rubber mallet Tips When drilling an end to end hole into wood we advise that you use an extra wooden piece as a buffer this will make for a better surface If the piece is very fragile use two buffers one on top one underneath 3 2 Handheld drill Safety rules On top of the standard safety rules specific rules apply to the hand held drill The pieces to be drilled into must be fixed to an immobile piece of furniture using either a vise or crew clamp Only turn the drill on once it is pointing in the direction of the piece and always store it in such a way that it can not be hit accidentally Also note that inhaling of chips and dust when drilling into hard materials should be avoided FIGURE 6 BOSCH GSR 14 4 2 LI hand held drill Operating instructions After having checked that the battery is loaded and in place lock the jaw chuck manually Choose the desired type of work
26. as 3 degrees of freedom Two different types of machining are possible 2 5D and 3D The difference will be explained in detail using examples 10 2 Tutoriel d usinage 2 5D The aim of this tutorial is to show the user how to completely achieve a 2 5D manufacturing process in the workshop You will create a 2D document which will be translated using CamBam into G code Mach3 will then interpret the G code and transmit the information to the CNC machine The piece used for this example is a box designed for a pack of playing cards but you are free to create any piece of your own provided it is within the dimensions of the machine The sheet used will be a 3mm thick PET sheet The surface is needed is roughly 30 cm by 30 cm 10 2 1 Drawing To begin with a new project always starts with a new drawing In the case of 2 5D machining the drawing must be a 2D drawing saved as a 2D file The 3D drawing of the part is of no direct use If a 3D drawing is the only one available make a 2D projection of the desired side The 2D file must be saved as a dxf file format which can be read by any of the following programs Catia SolidWorks Adobe Illustrator Inkscape If the drawing program allows for it work in millimetres since it s the unit used by the CNC This will also allow you to know the size of the part and will save time since no resizing process will need to be done Keep in mind that the zero point will be set drawing the piece close to t
27. ass Create a copy of the first finishing machining instruction and modify the following settings Profile 3D Method Vertical All the settings are the same the only thing we want to change is that the machining passes will be done along to the Y axis Select the two 4mm wide circles and select the Drill instruction button File View Edit Draw Machining Script Plugins Tools Help llimeters 7 NA nea 3984900 FIGURE 66 Creating a Drill type of machining instruction Modify the following settings Depth Increment 1 Target Depth 34 Spindle Speed 16000 Tool Diameter 3 175 Tool Number 3 Simply put we want to drill a 4mm wide and 34 mm deep hole Every thing is ready To make sure the tool path is correct right click on Part1 and chose the generate toolpath option If everything has been done correctly you should be able to see the path the tool will take 48 SPRING User s Manual FIGURE 67 Toolpaths for the machining In the same menu you can now chose produce g code Save the file it is now time to start with the machining process 10 3 4 Fixing the motherpiece As for any machining the bottom of the part being cut must be protected by a buffer It s purpose is to protect the CNC cutting bed the cutting tools and in our case it will be used as a base to be drilled into to fasten the motehrpiece during the second part of the process The buffer sheet should
28. e copy command Go back to layer 0 and click on Select All on Layer in the edit menu and after that click on Break at intersections in the same menu Now return to the following lines and click on the join command in the Edit menu Intersection Points Break at Intersections Ctrl B Convert To Transform Polyline Surface Select All Select All On Layer Cut Copy Paste Undo Redo ine d tion r of Sex Collection sformation sform Identity FIGURE 28 Polylines to select for the Join command 10 CNC 27 Select the 7 polylines you have just joined copy them Edit and Copy and paste them into layerl Edit and Paste View Edit Draw Machining Script Plugins Tools Help a Ri Units Millimeters A A as 80008 39098906 rawing System Polyline 377 a EMF Layerl Polyiine 375 Polyline 376 Basic neral vitive Type Polyline ed True ction ber of Segments its Collection isformation isform Identity FIGURE 29 Polylines to select for the Copy command Come back to layer 0 and delete it right click and Delete 17 eye Ef Layers New layer Set as active layer Hide Hide all but this Show Show all Clear Select all on layer Shift Ctrl A Cut Ctrl X Copy Ctrl C Paste Ctrl V Delete DEL Rename 1 Basic FIGURE 30 Deleting layer 0 It is possible to
29. e drill allowing the back camshaft to move towards the front haft to ease the tension in the belt Move the belt in the desired position using the specific j shaped tool available in the gearbox Once in place use the crowbar to force the back shaft back into position and lock the screw Once the speed is set the drill bit must be placed into the jaw chuck To access the jaw chuck the protection Plexiglas must be turned sideways It is important that the drill bit is centred in the jaw chuck Take the piece to be drilled into and place it into the vise The height of the support piece on which the vise is sitting must be adjusted so that the piece only sits slightly lower than the drill bit at it s rest point When everything is in place the drill can be turned on using the green button Please note that the Plexiglas window needs to be in the closed position for the drill to start To start drilling slowly lower the drill bit using the big shaft on the right hand side of the drill The speed of descent should be proportional to the material removal rate of the drill bit The depth of the hole can be measured using the depth indicator on the drill press Once the desired depth has been reached gently let the drill bit rise to it s rest location Use the red button next to the green start button to turn the drill off Once the drill has stopped completely rotate the Plexiglas window into the open position clean the the chips with a brush or a vacuum cle
30. e is possible using the select AN command found in the Edit menu 10 CNC 23 Tools Help Explode esoo 2084005 Join Offset Open Offset Union Subtract Intersection Trim Fillet Intersection Points Break at Intersections Convert To Transform Polyline Surface Select All Select All On Layer x re read from FT utorial 2D 2DBOX d unhandled entity VIEWPORT FIGURE 20 Selecting all the lines Choose Join with a Joint Tolerance of 0 1 in the Edit menu You will see that the lines have been grouped into different polylines FIGURE 21 Creating a polyline using individual lines After having clicked on the right button of the mouse choose the Layer sub menu and click on New Layer CA CamBam 2050 0 File View Edit Draw Machining Script Plugins Tools H D E Units Millimeters A A SH mi FIGURE 22 Creating a new layer 24 SPRING User s Manual Click on it and with the help of the CTRL button select the following polylines and click on the Copy command in the Edit menu ur iew Edit Draw Machining Script Plugins Tools Help Wm Bplode 109020008 sagann Joi g Ctri J Offset Open Offset Union Ctri U Subtract Intersection Trim Fillet Intersection Points Break at Intersections Ctrl B Convert To Transform Polyline Surface Select All Ctrl A F Select All On Layer Cut Ctrl X C
31. e number it is a waste of time and sandpaper 5 2 Belt sander Safety rules On top of the above mentioned safety rules other tool specific rules must be followed During the operation a large amount of dust will be generated we recommend to avoid inhaling it Also it is important that fingers are kept out of the belt area to prevent injuries Glasses are compulsory Use the Operating instructions Start off by fixing the piece in a vice or by clamping it onto a table We recommend wearing an apron to prevent the dust of going onto your clothing Plug the bystander in and start work Once the job is finished unplug the belt sander and thoroughly clean the piece using the vacuum cleaner Tips lt A second person vacuuming the dust away as it is being produced is a good idea it creates much less of a mess in the workshop 14 SPRING User s Manual 6 Gluing 6 1 Glue Gun Hot glue is a very efficient and wide spread way of gluing all sorts of different materials It is an alternative to welding and screwing worth considering for medium size parts which are not designed to undergo large amounts of stress Safety rules Hot glue implies hot temperature The temperature of the glue gun can vary between 110 C and 190 C Touching it can burn your skin and have long lasting effects on it Newly deposited glue will also be hot so avoid touching it In case of contact between hot glue and skin we recommend not to puncture any resulting bliste
32. e operating speed decreases to keep the same tangential speed The following tables contains data for a 2mm wide miller Wood MDF Plastic PVC Spindle Speed rev min 10 12 000 8 000 8 000 6 000 8 000 Depth Increment mm 1 1 1 03 1 3 1 Cut Feedrate mm s 1 000 1 000 1 00 Max Crossover E 08 08 08 os 05 11 ONLINE RESOURCES 11 Online resources 11 1 Classical machining 11 2 CNC WWW cnczone com 113 CamBam Documentation www cambam info of 08 SPRING User s Manual 12 INVENTORY 12 Inventory ULMIA saw 17 190 352 blade length 550mm ULMIA saw blades legth 550mm metal Set of wood drill bits HSS G FAMAG 1596 Hand held drill a accu 14 4V Li lon 1 5 Ah BOSCH GSR 14 4 2 LI Soldering station 60W ERSA ANALOG 60 Soldering tips ERSA DUR 832 SDLF SB pointy long Soldering tin BEROGEN width 1mm 0 5kg Sn Pb Yo 40 60 staples MARKWELL 14 3mm Quantity 1 1 1 3 3 2 10 0 1 1 1 1 3 3 1 2 4 2 30 10 30 1 10 1 1 1 1 1 99 21 1725 0500 21 2110 0010 Pieces Vacuum cleaner 1600 W K RCHER WD 5 200M Vacuum cleaner bags 5pieces KARCHER 6 904 257 0 Fine ash filter KARCHER 2 863 161 0 O Brush ERZINGER 1565 Blue dustpan 260mm Oval metal brush 100g Spunge Frina 180x125x65 mm Oakum 1kg DELTA Deltafil A DZ4108 200 Cotton tissues DELTA Deltanet paqu A 5kg Knitt Deltanet Digital scale PESOLA 3000g Digital scale PESO
33. e tool since the computational ins truction to start turning the tool is given at the start For short pauses use the Free hold function which stops the displacement without slowing the rota tional speed of the tool This allows you to resume by pressing Start Never use your hands in the cutting area Any piece which could move once cut should be fixed using scotch tape beforehand and never held by hand Once the code has finished running and the machining is finished move the tool into free space using the keyboard remove all scrap parts and un mount the tool if you don t need it anymore Don t forget to clean the whole area using the vacuum cleaner turn the CNC off and turn the computer off Remove the protection film on the pieces and glues the pieces together 10 3 3D machining The aim of this tutorial is to teach you how to manufacture a 3d piece with the CNC machine in the workshop The piece used as an example is a 12 faced dice Use a 20 mm long and 28 mm thick piece of wood 10 3 1 Drawing This type of machining starts with a 3D file containing the desired object The required file format is stl so CamBam can open it Typically you will design the part using Catia save it as stl Don t forget to work in millimetres and to place the part close the zero point in Catia The stl file used for the example can be found at Copy your files on a USB stick to be used on the computer connected to the CNC 10 3 2 Drawin
34. ely solid gluing Operating instructions Prepare paper towels a piece of cardboard toothpicks a glue syringe and of course the pieces to be glued together Break the white cap on the glue syringe off and squeeze out the desired amount of both liquids on the cardboard piece Clean the tip of the syringe with a paper towel Once the resin and the hardening compound have been well mixed using the toothpick apply a thin layer of glue on the pieces to be joined Wait 10 hours for the glue to dry and reach it s full material capabilities FIGURE 12 Epoxy glue left and normal glue right 16 SPRING User s Manual 7 Hot air gun Safety rules On top of the already mentioned safety rules for the room specific safety rules apply to the hot air gun The maximal temperature the air gun can reach is 600 C thus it is very important that it is never pointed at someone We strongly advise the use of gloves to hold the part worked on in place unless for the use of heat shrinking tubes for obvious problems concerning precision Never lay the hot air gun on it s side Always make sure the hot tip is pointing upwards Watch out for inflammable material FIGURE 13 Hot air gun Operating instructions To start off with prepare all the necessary material the gun the part cables heat shrinking tubes Choose the tip best suited for your needs heating a small point around a cable and mount it on the gun Plug the gun into a power
35. erent colors and the type is indicated on the saw metal and bois for wood le a FIGURE 8 Metal blade a Wooden blade b Operating instructions To make sure the piece is not moving whilst it s being cut it is best to clamp it on the saw using a G clamp They are available in the blue draw chest next to the drill press The angle at wich the cut is made has to be set The available angles are 45 36 30 22 57 Once set the user can start to cut into the matter The cutting process involves two different steps The active step during which pressure is applied in a forward motion and a passive phase where the blade is brought back to it s initial position It is best to use the whole length of the blade The recommended cycle rate is 1 Hz Fingers must be kept out of the cutting zone at all times 10 SPRING User s Manual FIGURE 9 G clamp and simple clamp Once the cut has been finished clean the blade and the surrounding area with a vacuum cleaner When cutting metal don t forget that the edges might be sharp if this is the case use a metal file to round the edges to avoid cuts When cutting wood watch out for splinters Tips If a very precise cut is needed in wood or polymer plastic it is possible to use the metal blade since it s finner yet still capable to cut through softer than metal matter In any other situation we recommend the use of the wooden blade since it requires less effo
36. g Script Plugins Tools Help Explode BS88088 sasaunn Join Ctri J Offset Open Offset Union Ctrl U Subtract Intersection Trim Fillet Intersection Points Break at Intersections Ctrl B Convert To gt Transform gt Polyline Surface gt Select All Ctrl A A Select All On Layer El k Basi Cut Ctrl X General 1D Copy Ctrl C Layer Paste Ctrl V Primitive Type Tag Undo Ctrl Z Polyline Redo Ctrl Y Closed alse Directio k Number of Segments Points Collection Transformation Transform Identity X 6 sections read from FT utorial 2D 2DBOX cht unhandled entity VIEWPORT FIGURE 26 Polylines to select for the Join command Select the two polylines you have just joined copy them Edit Copy and paste them into Layerl Edit and paste 26 SPRING User s Manual Draw Machining Script Plugins Tools Help Explode LILIE sasaun Join Ctri J Open Offset Union Ctrl U Subtract Intersection Trim Fillet Intersection Points Break at Intersections Ctrl B Convert To Transform gt Polyline Surface gt iF Select All Ctri A Select All On Layer Basi Cut Ctri X eral Copy Ctrl C Paste Ctrl V itive Type Undo Ctrl Z ine Redo Ctrl Y ed Tue stion CW ber of Segments 24 s Collection sformation sform Identity X 6 sections read from F Tutorial 2DVDBOX d FIGURE 27 Polylines to select for th
37. g using CamBam Open CamBam and open the imported stl file To turn and move the part use the CTRL and ALT keys simultaneously with the mouse buttons The left mouse button turn the part The right button allows you to move the part To zoom in or out use the mouse scroll wheel To get to a view perpendicular to a plane use the View XY YZ ZX plane buttons 40 SPRING User s Manual 4 CamBam orig File View Edit Draw Machining Script Plugins Tools Help Da Reset neamumna D Dr Zoom to fit Zoom actual size T Show toolpaths Show cut widths Show stock Show nests E Show grid g Snap to grid Ctrl G Snap to objects Window opacity gt XZ Plane YZ Plane Toolpath view filter Ctrl F FIGURE 51 Normal views in CamBam 3D machining with a 3 axes machine requires two different machining processes in between which the part will have to be turned around so that both sides can be machined To do so you will have to create through holes as benchmarks and fixing points once the piece has been turned around On top of that it is necessary to insert holding tabs to hold the part in place so that it will not loosen itself towards the end of the machining this would be dangerous and bad for the quality of the final part since the something will be broken off instead of machined FIGURE 52 Holding tabs used to fasten the finished part to it s mother piece We start b
38. h can not be moved easily It can also be used as an electric screwdriver with special shaped bits Safety rules for drilling Glasses are mandatory for any drilling operation The risk of a piece of matter being projected into the user s eyes is real In order to prevent anyone from being spun around by the drill long hair must be tied and any of the following must not be worn jewelry scarfs ties wristbands large long sleeves Hands must be kept out of the drilling area Once finished the removal 3 DRILLING 7 of any chips should be done with a brush to avoid getting fingers burned The chips and drill bit can reach high temperatures and must cool first Cleaning the used parts is compulsory 3 1 Drill Press Safety rules Besides the general safety rules special safety rules apply to anyone using the drill press The piece of matter being drilled into must always be safely held by the vise Under no circumstances should small pieces be held by the operators hands the risk of injury is very high The ALDURO vise is available next to the drill press FIGURE 5 ALDURO BM 11 Drill press Operating instructions To modify the operating speed on the drill press one has to access the gear box on top of the drill press In the gearbox the position of the belt can be changed the higher the faster Please note that the belt should always operate horizontally To change the position unscrew the screw on the left hand side of th
39. he other side on the part to be thrown away will have the traces of the tool since it s diameter is not equal to zero This is important since it allows for the tight fitting of the pieces Cut Width allows to grow the size of the pass to a larger size than the tool diameter In our case the tool will pass through twice resulting in the same as if a 3 5mm wide tool had been used Finally select the following lines and create another Profile 10 CNC 33 Plugins Tools Help 12 BOBEu8e sasoun FIGURE 39 Polylines to be selected for the second Profile machining The parameters are the following Depth Increment 1 5 Final Depth Increment 2 Target Depth 3 5 Cut Feedrate 1000 Corner Overcut true Spindle speed 12000 Tool Diameter 2 5 Tool Number 2 Make a right click on on of the manufacturing settings and click on generate toolpath This function in CamBam allows you to visualise the path the tool will make To have a complete view select part 1 right click and choose generate toolpath again but this time for the whole Part1 34 SPRING User s Manual FIGURE 40 The toolpath utility The work in CamBam is done Right click on Part 1 and choose Produce G code Save the G code and prepare yourself to start working on the CNC In our case the CNC will start by the stripes on the lid the cut the three pockets and at last cut out the pieces 10 2 4
40. he zero point will save time during the placement of the sheet dxf files can be created with CAT Drawings of a Catia piece Create a drawing in the XY plane on the desired part and then save it as a dxf file 10 CNC 21 Ds D marrer Fichier Edition Affichage Insertion Outils Fen tre Aide A fun S Pefaut A E sli I i Calguel E Enregistrer sous Save in ji Box 3mm vl cy Ey Name a Date modified Type i dak z e E 2D80X 27 04 2015 18 17 DXF File BOXDXF 21 04 2015 16 50 DXF File Desktop Libraries File name BOXDXF Cancel Save as type dd vw FIGURE 17 Saving dxf file in Catia The dfx files used for this tutorial are in to be filled The CatPart files are also available if anyone is interested by modifying the design for himself Once the file is ready put it on a usb stick and transfer it to the computer controlling the CNC Please note that this computer is NOT connected to the Internet 10 2 2 Drawing in CamBam Open CamBam and load your dxf file If it has been saved properly the piece should appear on the screen in the XY plane File View Edit Draw Machining Script Plugins Tools Help DE Units Milimetes A aseanaosa 2a89ua C Drawing System e 1 0000 151 0000 FIGURE 18 dxf drawing imported into CamBam This is the point where the G Code for the CNC will be p
41. l F la Auto Tool Zero well cv Mode Remember Return Elapsed 00 40 On pe gt Zimmibit sog oworr crans des 0 Units Re art after Tool Change pike FIGURE 74 Tool window in Mach3 tool n 8 selected Once the rough pass has been finished the CNC will stop and ask you to change the tool Install the 3 175mm tool these stops are automatic when a different tool number has been selected in CamBam Unscrew the lock nut insert the 1 8 chuck gently screw the lock nut back onto the spindle and insert the 3 175mm 2 teeth tool at least 35mm of the tool must be outside of the chck in order to drill the 2 fixation holes Don t forget to tighten the lock nut 52 SPRING User s Manual fa 4 f e 4 sr kS a Mill and chuck to be used b 3 175mm tool correctly installed FIGURE 75 During this operation you will most likely have to move the CNC manually Provided you don t hit the mechanical stops the calibration will remain the same Once the tool has been changed you have to redo the calibration along the Z axis using the autotool zero function Cleaning the piece using the vacuum cleaner is also a good idea FIGURE 76 Pressure sensor for the calibration along the Z axis placed on the part Before resuming the machining place the tip as close as possible to the start point this will prevent breaking the tool against a metal clamp Click on Start and watch the CNC poli
42. lock nut using the 21 and 30 size wrenches No need to tighten it too much you could damage the chuck or the tool FIGURE 46 Tightening the lock nut Chose Load G Code in Mach3 and select the file you ve created with CamBam Edit G Code Rewind Ctri W Recent File Single BLK AItN_ i 7 G lt Reverse Run _ Block Delete m Set Next Line M1 Optional Stop Line o Run From Here nee _On Off Z Inhibit G Codes M Codes 0 000 FIGURE 47 Load G Code button in Mach3 The CNC will start working using the coordinates from CamBam Thus you need to set the zero point in Mach3 Move the tip of the tool the desired zero position in the XY plane Keep in mind that the once cut the sheet can still be used for smaller pieces so try to leave as much space as possible uncut this prevents wasting plastic Once you ve reached the desired zero point click on the Zero X and Zero Y Tsets Alt 5 Settings Alt 6 Diagnostics Alt 7 Mill gt G15 G1 G10 G17 G40 atntete Fo co me Frsore Load Wizards Last Wizard n meo sa Tr al a Zero X and Zero Y button b Tool manually moved to the bottom left corner of the sheet FIGURE 48 38 SPRING User s Manual Manually move the spindle to each corner of the piece to make sure the tool will cut into the sheet but not into any of the metal clamps On the top right side you can see a map of the toolpath and the
43. lt in the CNC machine doing three 5mm machining passes The final depth will be of 3x5mm 15mm StepOver In the pocket setting you can choose by how much the tool will step over on the next pass For instance a 30 StepOver will result in 70 of the surface of a pass will already have been machined in the previous pass SpindleSpeed operating speed of the tool in rpm ToolDiameter diameter of the tool used for the machining operation The two most important parameters are CutFeedrate and SpindleSpeed Their choice depends upon the material being machined and the tool used Further information is given in the chapter dedicated to the matter For more exotic parameters please read the documentation The parameters to be modified for the firs machining pass are the following Target Depth 0 3 Cut Feedrate 1000 Spindle speed 12000 Tool Diameter 2 5 Tool Number 2 Once the parameters have been set select the following lines and click on Profile 32 SPRING User s Manual ript Plugins Tools Help 000 gsasoun FIGURE 38 Polylines to select for the Profile machining Modify the following parameters Depth Increment 1 Target Depth 2 Cut Feedrate 1000 Corner Overcut true Spindle speed 12000 Cut Width 3 5 Tool Diameter 2 5 Tool Number 2 The overcut moves the tool around the square edge in such a way that the final edge will be square and not round on one side t
44. oint List b From Mesh File Fill Region From Bitmap From Text File b Circle extruded properly a Command Extrude FIGURE 55 Select the cylinder which you have just created it s name is Surface 3 and translate it using the translation matrix to open it click on Transform on the left hand side of the screen and click on the three dots which appear on the right Chose translate Z axis and an amount of 20 click on apply which will enter the translation in the matrix and then on OK mm gt gt in in gt gt mm Transformation Axis Amount Transiation y z 20 6 Deg C Rad FIGURE 56 Opening and setting the parameters of the transformation matrix We now want a copy of the cylinder select it right click and click on copy After that select the Default layer right click and click on past DU Units Millimeters A A oa a O Drawing Pa System New layer Set as active layer Hide Hide all but this Show Show all Clear Select all on layer Shift Ctrl A Cut Ctrl X Copy Ctrl C Delete DEL Rename Basic E General FIGURE 57 Creating a copy of the cylinder 10 CNC Select on of the two cylinders and open it s transformation matrix to turn it Chose Rotation Y axis 30 Apply and OK Repeat the same modification with the second c
45. opy Ctrl C Paste Ctrl V yp Undo Ctrl Z Redo Ctrl Y rue Collection Identity FIGURE 23 Polylines to be selected Select the Layer that you have just created Layerl right click and the click on paste File View Edit Draw Machining Script Plugins Tools Help D EH Units Millimeters A A Sauna C Drawing System L 2DBOX EP Layers SEN J Machining New layer y Set as active layer Hide Hide all but this Show Show all Clear Select all on layer Shift Ctrl A Cut Ctrl X Copy Ctrl C Paste Ctrl V Delete DEL Rename Alpha FIGURE 24 Pasting in the new layer Go back to Layer 0 select the following polyines and click on Break at intersection in the edit menu and choose an intersection tolerance of 0 1 10 CNC 25 View Edit Draw Machining Script Plugins Tools Help e pese 2098900650 Join Ctri J Offset Open Offset Union Ctrl U Subtract Intersection Trim Fillet Intersection Points Break at Intersections Ctrl B Convert To gt Transform Polyline gt Surface Select All Ctri A Select All On Layer Cut Ctrl X Copy Ctrl C Paste Ctrl V Undo Ctri Z Redo Ctrl Y i alse n Unknown rofS t Collection nation orm Identity FIGURE 25 Polylines to select for the Break at Intersection command Choose only the following polylines and click on join in the Edit menu File View Edit Draw Machinin
46. ore use This allows the user to clean the tip of the soldering iron Before plugging in the power socket make sure all the switches are in the off position and that the soldering tip is in it s casing Once the iron is plugged in and the temperature has been selected wait for the iron to reach it s operating temperature without leaving it by it self another person seeing it might not guess that the iron is at 200 C The indicator light will start blinking when the temperature has been reached the iron is fully operational Hold the soldering iron on the junction between the two parts to bee welded until little drops of soldering tin start falling into the position The amount of tin to be used depends on the size of the connection to be made The deposited tin can be reheated and worked into position until the desired weld has been achieved Once the welding is finished clean the tip of the welding iron on the little damp sponge when it is still hot Turn the iron off and unplug it Before putting it away in it s box the iron must have cooled off to room temperature this can take 20 min Never cool the iron of by using cold water Congratulations you ve finished welding 20 SPRING User s Manual 10 CNC FIGURE 16 CNC 10 1 The machine The CNC machine is a very useful and powerful tool It s accurate and efficient The main parts of the machine are the main frame the cutting area and the spindle The machine h
47. our altering substance is strictly prohibited Smoking and eating are not allowed in the room The rules are available on the door in case of any doubt please read them carefully 3 DRILLING 5 FIGURE 2 Safety goggles sticker 3 Drilling Choice of the drill bit A specific tool exists for each type of material this general rule is especially true for drilling In the workshop metal and wood bits are available The wooden tips are identifiable by their central sharp point and two side going blades The metal tips simply have two sharpened sides In order to drill other materials than wood or metal one needs a specific drill bit Hard mineral material concrete and bricks for instance require a specific concrete drill bit and percussion drill not available in the workshop c FIGURE 3 wood bit a metal bit b concrete c Drilling into plastic material can be done with the metal drill tips This operation however requires cleaning if the tips since the plastic will melt onto the tip The diameter of a drill tip is usually indicated on the box in case of doubt use a calliper to determine the tips dimensions Choosing the rotational speed A proper operating speed avoiding any structural damage to the piece is a fundamental parameter to set for any drilling operation 6 SPRING User s Manual There are many tables indicating the operating speed mm min according to the size of the tool and the material to be drilled
48. relies on getting this step right Polyline 461 7 Polyline 462 Polyline 463 Polyline 464 E PolyRectangle 466 Machining 3 4 Pati 4 Basic E General Enabled Name Primitive IDs Style Tag E Cutting Depth Clearance Plane Depth Increment Final Depth Increment Stock Surface Target Depth E Experimental Transform E Feedrates Cut Feedrate Plunge Feedrate E G Code Options Custom MOP Footer Custom MOP Header Start Point Velocity Mode Work Plane E Lead In Out Lead In Move Lead Out Move E Options Collision Detection Cut Ordering Milling Direction Optimisation Mode Region Fill Style Roughing Finishing E Spindle Control Spindle Direction True Pocket1 363 362 361 m FIGURE 37 Machining with it s settings 10 CNC 31 For every manufacturing process CamBam has default parameters Most of them are the right ones but some will need some tuning The most important parameters for 2 5D manufacturing are InsideOutise CutFeedRate DepthIncre ment TargetDepth StepOver SpindleSpeed ToolDiameter InsideOutside allows the user to choose to follow the inside or the outside of a line Profile setting CutFeedrate It is the tool s speed at which it advances mm min DepthIncrement the increment for every machining pass TargetDepth The final depth the tool will reach For instance a TargetDepth of 15 with a DepthIncrement of 5 will resu
49. repared We will show how it is done using the example of the box To move around in the drawing keep the mouse s wheel pressed down To zoom in and out use the mouse s wheel the normal way 22 SPRING User s Manual The first important step is to make sure that all the individual lines determining the shape are united into one big poly line If this is not already the case they have to be joined manually To do so select all the individual lines whilst CTRL is pressed Once all the lines are selected use the Join command found in the Edit menu Any Joint Tolerance will do if the lines have been created as complete lines in the 3D program Catia SolidWorks etc File View Draw Machining Script Plugins Tools Help D a WH Emplode BOBEEEBH YE A Offset a Open Offset fa Union Ctrl U E Subtract Intersection 7 Fillet Intersection Points Break at Intersections Ctrl B Convert To Transform Polyline Surface r MF SR P Select All Ctrl A SelectAll On Layer A Basil El General n ID Copy Ctrl C Layer Paste Ctrl V Primitive Type Tag Undo Ctrl Z El Misc Redo Ctrl Y Points Collection FIGURE 19 Join Command in CamBam If you want to cut a line at an intersection with another one to create a different polyline select both lines and use the Break at intersection command found in the Edit menu To join them together again proceed as instructed above Selecting every lin
50. rs We strongly advise against inhaling the fumes FIGURE 11 RAPID EG 330 Glue gun Operating instructions Prepare the surfaces to be glued together on a table and clean them Take the glue gun and insert a glue stick in the rear end of the glue gun if none is already present Install the small metal support piece allowing the glue gun to sit upright on it s own when not in the user s hand Plug the glue gun in the power socket and wait or it to warm up During the time it takes to warm up leave a small container under the tip of the glue gun to avoid any excess glue of soiling the table A pickle glass jar screw cap is available for this purpose Once the glue is at melting temperature point the tip at the surface to be glued and start by slightly pressing on the trigger to release the liquid glue Be careful with the quantities too much glue might be visible after the operation and might be unstable on the long run Once enough glue is on one piece a large amount of pressure has to be applied on the two pieces whilst the glue dries After all the gluing has been done wait for the glue gun to cool off before cleaning it off 6 GLUING 15 and putting it back into it s box Tips Use g clamps to press pieces together No need to put a lot of glue on the desired surface it might end up overrunning 6 2 Epoxy glue Epoxy glue is a mix of resin and hardening compound Once mixed it becomes very resistant and allows for extrem
51. rt and time NEVER use the wood blade for any metal object 4 2 Electric coping saw Safety rules On top of the general safety rules mentioned above other specific rules apply to this power tool We highly recommend the use of gloves especially if the pieces cut are small Never let the saw out of sight without making sure it has been properly turned off Changing the blade To change a blade proceed the according to the following instructions Loosen the stress in the blade using the white leaver Unscrew the top and bottom attachment Gently take the blade out of position and insert the new blade into position Tighten the top and bottom attachments using the adjustment wheel to make sure the stress in the blade is sufficient once the white leaver is back into position Operating speed and choice of the blade Wood MDF Plastic PVC Operating speed Type of blade The speed is expressed as a percentage of the maximal operating speed Please make sure that the right type of blade is mounted A wood blade won t last long cutting aluminium 4 CUTTING 11 FIGURE 10 EXCALIBUR EX 16 CEBS electric coping saw Operating instructions To start off with the blade must be chosen according to the material of the piece Blades for aluminium and wood are available Once the proper blade has been chosen make sure nothing can get into the way of the piece being cut Keep in mind that a large piece being turned into different direction
52. s might take up more space than expected Plug the operating tip of the vacuum cleaner into the chip exiting route on the lower right hand side of the saw It is highly recommended to work with the vacuum cleaner it can avoid the user a long and hairy cleaning of the saw Set the height of the safety system to be slightly higher than the piece beingg cut this prevents the piece of hanging on to the blade Glasses must be worn during the operation of this power tool Before turning on the saw make sure the vacuum cleaner is in place and working and check to be sure that the speed is set to the minimum This greatly reduces the risk of injury in case the blade has not been mounted properly Set the operating speed to the speed best suited for the material and start cutting Never make any sudden moves this might break the blade and the cut will be of a mediocre quality Advance slowly and firmly along the cutting lines When the blade exits the piece slow down to avoid any sudden gestures When the cutting is done turn the speed back to the minimal setting before turning the machine off Don t forget to clean the area 4 3 Jigsaw Safety rules On top of the overall rules applying to the workshop special rules apply to the jigsaw Make sure the piece being cut into is well anchored to the table to prevent int from moving during the cutting operation We strongly recommend the use of gloves and ear protection 12 SPRING User s Manual
53. sh the dice 10 CNC 93 FIGURE 77 Dice after the first part of the machining process When the G Code is finished move the CNC away from the part without loosing the X and Y calibration which you must keep for the second part and remove the motherpiece without removing the buffer sheet 10 3 6 Fastening the mother piece for second part of the machining If you want to you can enlarge the the two fixation holes using the drill press however make sure that you drill in the centre of the holes or else the machine will be slightly off base This will allow you to fasten the mother piece to the buffer using wood screws FIGURE 78 Enlarged 6mm wide holes using the drill press Come back to the CNC and fasten the motherpiece on the buffer sheet with the already machined face pointing downwards To do so use two 5x35 wood screws 4 of them are available in the drawer underneath the CNC and insert them into the holes you ve created in the buffer sheet These screws make sure that the motherpiece is exactly in the same place as before but with the other face up so it can now be machined Fastening the motherpiece using the metal clamps is not necessary since the screws are already holding the piece 54 SPRING User s Manual a Screws to be used to fasten the motherpiece on the bii fer sheet b Motherpiece correctly fastened to the buffer sheet FIGURE 79 10 3 7 Modifying the G Code in CamBam Return to CamBam
54. socket and turn it on The gun will need approximately 10 seconds to warm up Once the operating temperature is reached start working Once the job is done unplug and rest the gun with the tip pointing upwards to make sure the work surface is not damaged It will take roughly 20 minutes for it to cool off As long as touching it with your hands is not possible walt Use the extra time to tidy up all the remaining tools used Tips For heat shrinking tubes we suggest the use of power setting n 7 and air flow setting n 2 Be careful not to damage any wooden pieces The hot air gun can be used to melt glue from the glue gun and PET to use as a basic welding material 8 THREADING TAPPING AND FILING 17 8 Threading tapping and filing Threading a rod is the mechanical operation of creating a screw thread Industrial threading is done in many different ways Tapping a hole is the opposite operation cutting an inner thread so that a screw can hold in place In the workshop a series of taps dies and drill bits are available in the following dimensions M3 M4 M5 M6 M8 M10 and M12 The tables come from Le B A BA l atlier de Jean Marc Colomb collaborateur technique de l atelier de l Institut des mat riaux de PEPFL Safety rules Manually thread cutting involves no major safety risk as long as fingers are kept out of the immediate cutting area it is however a delicate process requiring a lot of manual skills FIGURE
55. vacuum cleaner change the tool 3 175mm recalibrate along the Z axis and move the tip close to the zero point Click on start and enjoy the polishing of the dice FIGURE 82 Calibration along the Z axis for the 3 175mm tool Once the code has finished running you can turn the CNC and the computer off Please clean all the remaining chips using a vacuum cleaner and put every tool back in place where it belongs Unscrew the motherpiece from the buffer sheet Using a pair of pliers seperate the the motherpiece and the dice by cutting the holding tabs Use sandpaper to clean the faces of your dice Your dice is now finished 56 SPRING User s Manual FIGURE 83 Finished dice 10 4 Machining tables The following table contains the settings for different types of material Once you ve acquired some ex perience you should be able to tune the settings to your particular wishes Please keep in mind that the operating speed revolutions per minute mutliplied by the radius of the tool will give you the tangential speed This speed is very important Lets take a 3mm wide miller operating at 12 000 rpm Viangenvietic Lo 200 300 mm s If you use a 4mm mill to do the same job you can compute the rotational speed using Utangentielle ci 300 2 Urotation rayon outil 2 150 tr sec We can clearly see that the operating speed now reaches 9 000 rpm We can deduce that the when the size of the tool increases th
56. y creating the holding tabs Select the layer Default and hide it using the hide command right click menu to see the origin of the axes 10 CNC File View Edit Draw Machining Script Plugins O D 5 E Units Millimeters 31 Basic E General FIGURE 53 Hiding the Default Layer using the hide command Chose the view orthogonal to the XY plane using View gt XY plane and create a new circle with a 1 5mm diameter centered at the origin you can t see the circle it s normal Hit ENTER to finish FIGURE 54 Creating a 1 5mm wide circle centred at the origin AA New layer Set as active layer Hide all but this Show Show all Clear Select all on layer Shift Ctrl A Cut Copy Paste Delete Rename Ctri X Ctrl C Ctrl V DEL Show to Default layer using the show command Extruding a 40mm circle you ve just created To do so select it and click on Draw Surface gt Extrude Chose an Extrusion Height of 100 and a Arc Expand Tolerance of 0 1 it s the triangulation parameter of the extruded circle 42 SPRING User s Manual eq CamBam igi File View Edit Draw Machining Script Plugins Tools Help D 6 El Units Bl Polyline P BEBE EA YE 6 Circle C BA Points D a Rectangle B Text T Arc A More b P
57. ylinder but with an agle of 30 Whilst the CTRL key is pressed select the three volume pieces the dice and the two cylinders you ve Ver ve q ran ation Transformation 0 86602539649 0 0 50000001261 0 jo 1 jo o fo 50000001261 0 0 86602539649 0 10 0000002523 o 17 320507929 1 mm gt gt in in gt gt mm Identity Transformation Axis Amount Deg C Rad OK Cancel FIGURE 58 Rotation du premier cylindre just created in the menu on the top left of the screen Click on Edit Join to unite the three pieces into one Join Tolerance of 0 01 Select the new piece you ve just assembled and with the help of the rotational matrix turn it by a CRELLE EEEN FE CamBam origi File View Edit Draw Machining Script Plugins Tools Help Dea Explodi O Drawing Join Ctri J IE sal Offset a pP Layi Open Offset EN Union Ctrl U Subtract Intersectio pu Trim Fillet Intersection Point Break at Intersections Ctrl B Convert Ti Transform Polyline Surface Select All Ctri A Select All On Layer sr 2 B Cut Ctrl X El General Copy Ctrl C Paste Ctrl V Undo Ctrl Z Redo Ctrl Y FIGURE 59 Joining the two cylinders and the dice 90 angle with regards to the X axis El Transformation CIN PS fo fo fo o 4 3711390001 0 99999999999 0 0 0 99999999996 4 3711390001 0 fo
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