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--- carbide_3d_nomad_883_training_sop [2020/09/08 17:47] – furst
+++ carbide_3d_nomad_883_training_sop [2020/09/13 21:47] (current) – furst
@@ Line 72: / Line 72: @@
 Carbide 3D makes a rudimentary design software called Carbide Create which can be used to create basic designs; however, Solidworks offers a much more robust features set do create complex and easily modifiable 3D models. This SOP assumes a base knowledge of Solidworks and assumes the user has taken ME-12S or has comparable machining knowledge.
-**Cam:** \\
+**CAM:** \\
-Once the design is complete the Carbide Motion can be used to create the toolpaths, however this SOP will use HSM Works due to its integration with Solidworks and more complex feature set. HSM Works is installed on any Innovations Workshop computer running Solidworks 2020 including the Ultimaker and Carbide 3D computers. To generate the toolpaths:
+Once the design is complete Carbide Create can be used to create the toolpaths, however this SOP will use HSM Works due to its integration with Solidworks and more complex feature set. HSM Works is installed on any Innovations Workshop computer running Solidworks 2020 including the Ultimaker and Carbide 3D computers. many toolpaths will likely be necessary to create the CAM nessesary to machine the part. To generate the toolpaths:
-  - 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) \\{{:tools:carbidecncrouter:cam_highlight_real.png?200|}}
   - The Command Window will now show HSM Works functions
-  - Select "New Job" to specify desired part to machine, define size of raw stock, and indicate the part zero and work holding coordinate system.
+  - Select "New Job" to specify desired part to machine, define size of raw stock, and indicate the part zero and work holding coordinate system. {{:tools:carbidecncrouter:job.png?300|}}
+    - Typically the back left corner is used for part zero as shown{{:tools:carbidecncrouter:annotation_2020-09-08_105857.png?400|}}
+  - Select the first desired machining operation from the 2D or 3D machining drop down {{:tools:carbidecncrouter:2d_and_3d_machining.png?200|}}
+    - The 2D machining drop down is used for many 2D operations including slotting, facing, pocketing, and chamfering \\ {{:tools:carbidecncrouter:2d.png?300|}}
+    - The 3D operations can do 2D machining operations such as adaptive pocket clearing, however it is typically used for adaptive clearing or machining requiring all 3 axis simultaneously {{:tools:carbidecncrouter:3d.png?200|}}
+  - 2D and 3D operations require many of the same input perimeters including
+    - Tool and cutting rate \\ {{:tools:carbidecncrouter:tool.png?200|}}
+      - Tools can be selected from the "all" category of the tool library based on desired tool and modified using the edit button if necessary to set number of flutes and sickout /geometry of tool and tool holder
+      - 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 {{:tools:carbidecncrouter:nomad_feeds_and_speeds.pdf|references}}
+    - 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.
+      - If this operation is finishing machining a feature based on the previous operation check "rest machining" and input the second tools diameter
+    - Cutting/retract heights
+      - Typically selecting machining geometry will set many of the heights automatically, however they can all be altered if necessary
+    - Machining passes  \\ {{:tools:carbidecncrouter:stock_jto_leave.png?200|}}
+      - 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 "multiple passes" should be used to reduce cutter load
+      - "Material to leave" can be adjusted to create roughing passes if desired. Many operations such as adaptive clearing will automatically leave stock as it is assumed to be roughing operations.
+    - 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.
+  - 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 "simulate" from the Solidworks command bar.
+    - 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 "stock" can be triggered on and off to see material removal in real time.
+  - 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 "Jog" select "Home Machine" and allow machine to home itself
+  - Select "measure tool" and the machine will use the automatic tool length measuring tool to zero out the tool
+  - Next while still under "Jog" position the machine can set part zero in three ways
+    - 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====
-  - **At the Computer:**:
-    -Load your STL file into the print software on the computer adjacent to the printer (Cura for Ultimaker, GrabCad Print for F270).
-    - Set Print Parameters:
-      - Position the part on the build tray in a way that is conducive to 3D printing (flat side down)
-      - Select appropriate layer or slice height (the more slices the higher the print resolution but the longer it takes to print)
-    - For Ultimaker:
-      - Select "generate support" if necessary
-      - 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://docs.google.com/forms/d/e/1FAIpQLScS3URUxoHOR62PdQeeSTAYg_suV061UsoFafrgoN0qn6DWYg/viewform.
-  - **At the printer:**
-    - 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.
-    - Start the job at the printer
-====Part Removal and Cleaning====
+**Starting Job:**
-**Ultimaker**
+  - Load the desired G-code using the "Load" page
-  * 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 it slip or the part break free unexpectedly.
+  - Zero out the machine to match part zero
-  * 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) \\
+  - Start Job
-**F270**
-  * 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
-----
+====Machine Limitations====
+  * Each tool change should be accompanied by a new job within HSM Works
+  * Tool shank diameter is limited to 7 mm
+  * Max stepdown is limited to .01" in metal and .04" in wood
+  * Work area is limited to 8" x 8" x 4" x,y,z
-====Rates====
+====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 {{:tools:carbidecncrouter:nomad_feeds_and_speeds.pdf|here}}
-F270:
+====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.
-|-
-! 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 \\
 Contact: Andrewfurst@ucsb.edu
 ====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 clearing or adjusting print.
+  * The acrylic shield must be in place and lowered before starting a job
- ====Safe Operating Procedures Review====
+  * The spindle must be completely stopped before adjusting or removing work piece
-  - 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, and support
+    - 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 using ether nozzle, typically nozzle one holds build material with nozzle two printing with dissolvable support material.
+    - Use 2D and 3D clearing and pocketing to remove the bulk of the material while using "stock to leave" to allow for a finishing pass
-  - Setting can be fined tuned using the "Custom" option from print settings
+    - Simulate the toolpaths to verify that the tool will not crash and is cutting in the desired location
-  - 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 "jog" heading using paper or a shim. DO NOT FORGET TO ADD OFFSET OF TOOL RADIUS AND SHIM THCINESS
-  - Connect thumb drive to printer -> select desired file -> select print\\
+  - Upload the G-Code into Carbide Motion under "load"
-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====
-  * If support was constructed from ABS carefully break away with pliers
+  * Use a file to debur the part
-  * If support was constructed from PVA soak part in warm water for several hours to dissolve support structure
 ====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 should be cleaned as needed
+  * The router should be vacuumed out after every operation and at the completion of each job
-  * Filament should be dried before use if printer has been idle for several weeks
+  * Once a month the router should be moved and chips cleared from underneath machine body
-  * Bed leveling should be completed every time print cores are swapped
+  * Twice a year the router should be partially disassembled, cleaned, and re-oiled
-  * Print cores should be swapped  or purged after clog or to change print line width. Used print heads should be kept for spare parts
 -----