carbide_3d_nomad_883_training_sop
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carbide_3d_nomad_883_training_sop [2020/09/08 18:24] – [Software] furst | carbide_3d_nomad_883_training_sop [2020/09/13 21:47] (current) – furst | ||
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**CAM:** \\ | **CAM:** \\ | ||
- | Once the design is complete | + | Once the design is complete Carbide |
- Select the CAM window from within the Solidworks Command Window (note that CAM is an HSM Works plug in and is different from Solidworks CAM and Solidworks CAM TBM and will not appear unless HSM Works is installed on the computer) \\{{: | - Select the CAM window from within the Solidworks Command Window (note that CAM is an HSM Works plug in and is different from Solidworks CAM and Solidworks CAM TBM and will not appear unless HSM Works is installed on the computer) \\{{: | ||
- The Command Window will now show HSM Works functions | - The Command Window will now show HSM Works functions | ||
Line 84: | Line 84: | ||
- Tool and cutting rate \\ {{: | - Tool and cutting rate \\ {{: | ||
- Tools can be selected from the " | - Tools can be selected from the " | ||
- | - Selecting a tool automatically generates generic feeds and speeds for a much more ridged machining center. Feeds and speeds should be set based on the provided chart under references | + | - Selecting a tool automatically generates generic feeds and speeds for a much more ridged machining center. Feeds and speeds should be set based on the provided chart under {{: |
- Desired machining geometry | - Desired machining geometry | ||
- Simply select the desired face or feature to machine in the current operation.Toggling off Z propagation and tangent propagation can be used to select smaller or partial features. | - Simply select the desired face or feature to machine in the current operation.Toggling off Z propagation and tangent propagation can be used to select smaller or partial features. | ||
Line 90: | Line 90: | ||
- Cutting/ | - Cutting/ | ||
- Typically selecting machining geometry will set many of the heights automatically, | - Typically selecting machining geometry will set many of the heights automatically, | ||
- | - Machining passes | + | - Machining passes |
- Part of feeds and speeds, HSM Works will auto fill many of the boxes, however due to the limited power and rigidity of the machine, stepdowns should be reduced based on the reference material and " | - Part of feeds and speeds, HSM Works will auto fill many of the boxes, however due to the limited power and rigidity of the machine, stepdowns should be reduced based on the reference material and " | ||
- " | - " | ||
- Linking | - Linking | ||
- Linking moves dictate how the cutter enters and exits the workpiece and can be altered to prevent the cutter from running into the stock while it attempts to start or finish a cut cleanly. | - Linking moves dictate how the cutter enters and exits the workpiece and can be altered to prevent the cutter from running into the stock while it attempts to start or finish a cut cleanly. | ||
+ | - Simulating | ||
+ | - Any toolpath generated can be previewed using the simulate function built into HSM Works. the Job or single operation can be selected before selecting " | ||
+ | - Simulating code is a great way to see unwanted movements the tool may make or seeing if the tool is undercutting into important areas of the stock or crashing into the workpiece. | ||
+ | - Within simulation " | ||
+ | - Posting | ||
+ | - Post the code by selecting Post Process and selecting Carbide 3D (grbl) as the post configuration. The program name or number should be numbers only, and is typically notated 00001 (not necessary for carbide but good practice for larger machines) make sure to select the desired output folder as by default Solidworks buries the G-code | ||
+ | ====Setting up the Carbide for a Job: | ||
+ | The Carbide router uses fun sized ER11 collets to hold tools from 1 mm to 7 mm but typically uses tools with a 1/8 inch shank. | ||
+ | **Changing tools:** | ||
+ | - Turn the router off and using an acid brush remove metal shavings and any dust from the tool head | ||
+ | - Using the 17 mm box wrench on the collet nut and the 12 mm open ended wrench on the spindle shaft flats loosen the collet and tool. | ||
+ | - Unscrewing the nut all the way allows the collet and tool to be removed from the spindle and changed out with a different tool of the same shank or with a different sized collet. | ||
+ | - Separating the collet from the collet nut can be done by pushing on the back end of the collet so that it becomes angled within the retaining collet nut and then can be pulled out. | ||
+ | - Before reinstalling the new collet and tool, wipe down the tool shank as well as the collet and spindle tapper. | ||
+ | **Homing and Zeroing the machine: | ||
+ | - With the tool installed, make sure the bed is empty and the cover is closed before turning on the machine | ||
+ | - Launch Carbide Motion on the Carbide computer | ||
+ | - Under " | ||
+ | - Select " | ||
+ | - Next while still under " | ||
+ | - The less accurate way is to position the tool at part zero established in HSM Works by jogging the machine to the part zero location and pressing zero | ||
+ | - An edge finder can be used at the minimum RPM to find the part X and Y zero. The cutting tool can then be replaced in the spindle and re-zeroed using the automatic tool length touch off. Z zero can be established by sliding a paper of known thickness or a thin metal shim along the top of the part and slowly jogging the spindle down until slight resistance is felt on the shim from the tool tip. X and Y axles must then be adjusted by the radius of the edge finder, and Z Zero must be offset by the shim thickness | ||
+ | - The fastest way to establish part zero is by using the paper or shim on all three axis and offsetting X and Y by the radius of the tool plus shim thickness, and the Z axis by shim thickness. | ||
- | ====Job Setup==== | + | **Starting Job:** |
- | - **At the Computer:**: | + | - Load the desired G-code using the "Load" |
- | -Load your STL file into the print software on the computer adjacent to the printer (Cura for Ultimaker, GrabCad Print for F270). | + | - Zero out the machine |
- | | + | - Start Job |
- | - Position | + | |
- | - Select appropriate layer or slice height (the more slices the higher the print resolution but the longer it takes to print) | + | |
- | - For Ultimaker: | + | |
- | - Select | + | |
- | - Check appropriate filament and bed temperatures (should be set if using standard filament load out) | + | |
- | - Send job to Ultimaker using USB drive | + | |
- | - For F270: | + | |
- | - The F270 the printer will print a raft before printing the model. Make sure first layer is set to support material or removal will be incredibly difficult. | + | |
- | - Send job to F270 over Ethernet | + | |
- | - Record the material used and print time in the online log along with the other job information requested. The print log should be on the desktop or https:// | + | |
- | | + | |
- | - Ultimaker: | + | |
- | - Make sure print bed is clean | + | |
- | - F270: | + | |
- | - Make sure that there is enough room on an CLEAN build tray for your part, and that the build tray is secured in the printer with the locking arm horizontal. Build trays may be used until the entire build area has been printed on, but printed areas should ideally not be reused. | + | |
- | | + | |
- | ====Part Removal and Cleaning==== | + | ====Machine Limitations==== |
- | **Ultimaker** | + | * Each tool change |
- | * Remove part from print bed using a spatula or razor being careful not to cut yourself or scratch the build plate. Make sure no body part is in line with the tool should | + | * Tool shank diameter is limited |
- | * If support was used, submerge print in warm water for several hours to dissolve PVA filament. (prints can warp if submerged in water for over 24 hours) \\ | + | * Max stepdown is limited to .01" |
- | **F270** | + | * Work area is limited to 8" x 8" x 4" x,y,z |
- | * Don gloves, face shield, and lab coat | + | |
- | * Carefully, slowly and without splashing cleaning solution open the support removal tank lid, remove and open the tank | + | |
- | * Place large parts directly in the tank, small parts may be put in the SS box and placed into the main basket. | + | |
- | * Carefully, slowly and without splashing lower the basket back into the tank and close the lid. | + | |
- | * Set timer for 6 hours setting the temperature to 80 degrees C. | + | |
- | * After cleaning time has elapsed follow the instructions above for opening and removing parts. | + | |
- | * Rinse part in warm water | + | |
- | ---- | + | ====Choosing tools==== |
+ | Many tools are optimized for different materials, and although a 2 flute endmill can do most operations, it is not always ideal. Single and duel high helix endmills are available for plastics, woods, and composits, with carbide endmills and burs available for abrasive materials such as glass fiber reinforced materials such as circuit boards. | ||
+ | Feeds and speeds can be found {{: | ||
- | ====Rates==== | + | ====File Types==== |
+ | G-Code files will be posted with the file extension .nc whereas Carbide Create will post files with the file extension .egc. G-code files can be opened directly into a text editor if necessary to preview or edit the desired code. .egc is a propriety package for G-Code used by Carbide for some god forsaken reason, in order to preview the G-code directly it is first necessary to upload the file to Carbide motion before copying and pasting the code into a preferred text editor. | ||
- | F270: | ||
- | {| | ||
- | |- | ||
- | ! Material || $/Spool || cu in/Spool || $/cu in || $/cc | ||
- | |- | ||
- | PLA || 79 || 60 || 1.31 ||.08 | ||
- | |- | ||
- | ABS || 164 || 60 || 2.73 || .17 | ||
- | |- | ||
- | Sup || 228 || 60 || 3.79 || .23 | ||
- | |} | ||
- | |||
- | F270 hourly charge: $1/hr to pay for head replacement | ||
- | |||
- | Ultimaker: | ||
- | ABS: .12/gram | ||
----- | ----- | ||
- | =====Ultimaker 3 Quick Review===== | + | =====Carbide 3D Quick Review===== |
Tool Lead: Andrew Furst \\ | Tool Lead: Andrew Furst \\ | ||
Contact: Andrewfurst@ucsb.edu | Contact: Andrewfurst@ucsb.edu | ||
====Safety Concerns==== | ====Safety Concerns==== | ||
- | * Both print heads and bed are heated during operation. Do not attempt to clean, remove, or adjust without allowing for adequate cool down time. | + | * Safety Glasses must be worn when machine is running |
- | * Keep hands clear of printer during operation. Pause print before | + | * The acrylic shield must be in place and lowered before starting a job |
- | | + | * The spindle must be completely stopped |
- | - Launch Cura version 4 (blue icon) | + | * After milling is completed, the work piece will have developed sharp burrs which must be removed with a hand file or sandpaper |
- | - From connected printers, select IW-Ultimaker3 | + | ====Safe Operating Procedures Review==== |
- | - Select File -> Open Files -> Open desired project (.STL file type) | + | - Design part using Solidworks or other CAD platform |
- | - Using task bar on the left hand side, position model as desired | + | - Using HSM Works or Carbide Create generate tool paths |
- | - From print settings, select slice height, infill percentage, | + | - Each different tool needs to be a separate job as only one tool can be loaded into the Carbide at a time |
- | - Support can be generated | + | |
- | - Setting can be fined tuned using the "Custom" | + | - Simulate the toolpaths to verify that the tool will not crash and is cutting in the desired |
- | - Within custom settings, nozzle and build plate temps can be adjusted (build plate temps should be based off of build material) | + | - Using the 17 and 11 mm wrenches loosen the collet nut to change out the tool or collet itself if switching shank diameter |
- | - Save the file from Cura on a thumb drive | + | - Home the machine and zero the tool using Carbide Motion under the " |
- | - Connect thumb drive to printer -> select desired file -> select print\\ | + | - Upload |
- | Note: Adjusting settings may lead to more (OR LESS) successful prints. Contact Workshop Wizard responsible for Ultimaker if print fails or knowledge of advanced settings is desired. | + | - Start program |
====Post Processing==== | ====Post Processing==== | ||
- | * If support was constructed from ABS carefully break away with pliers | + | * Use a file to debur the part |
- | | + | |
====Maintenance==== | ====Maintenance==== | ||
- | * Bed should be cleaned with IPA between prints | + | * Tools should be wiped clear of chips or coolant using an acid brush |
- | * Print heads and silicone head protector | + | * The router |
- | * Filament | + | * Once a month the router |
- | * Bed leveling | + | * Twice a year the router |
- | * Print cores should be swapped | + | |
----- | ----- | ||
carbide_3d_nomad_883_training_sop.txt · Last modified: 2020/09/13 21:47 by furst