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--- trimsaw2sop [2020/10/30 17:48] – created furst
+++ trimsaw2sop [2020/11/03 17:46] (current) – furst
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       * Coolant tank cleaning/refill
       * Blade Replacement
-  * The Form 2 is a 3D printer that uses SLA (stereolithography) to make a part. In SLA, a laser beam is directed into a tank of photoreactive resin, which hardens to form a layer of the part. The first layer adheres to the build platform, and each following layer adheres to the previous one. The finished part will be suspended upside-down above the resin tank. It has a build volume of 145 × 145 × 175 mm (5.7 × 5.7 × 6.9 in).
+  * The Trimsaw 2 uses 4, 5 or 6 inch diamond blades to make fine cuts in metals, glass, ceramics and PCBs. Specific blades for each material are available and should be changed before cutting new material. A variety of fixtures and guides are available with custom fixtures available for specific jobs (contact Dave Bothman or a Workshop Wizard for custom tooling). Spinning up to 3000 RPM the bottom of the blade is submerged in coolant to lubricate and cool the blade while in the cut. A blade splash guard and plexiglass cover reduce the amount of lubricant thrown by the blade.
 ====Safety====
 {{:tools:form2:labcoat.png?75|}}{{:tools:form2:rubergloves.png?75|}}{{:tools:form2:safetyglasses.png?75|}}
-  * Nitrile or neoprene gloves (not latex), safety glasses, and a lab coat must be worn when working with liquid resin printers. Safety glasses and a lab coat are required for working around IPA (isopropyl alcohol) when the Form Wash is open.
+  * Eye protection should be warn at all times while operating the saw
-  * Avoid eye contact with laser. Do not remove the front or back panels of the printer.
+  * All guards and shields should be in place before turning the saw on
-  * Care must be taken to prevent contaminating other areas with liquid resin - use containers to transport build platforms or parts that still have liquid resin on them.
+  * Hands should be kept free and out of the way of the blade at all times
-  * Dispose of resin contaminated gloves and other objects in the yellow hazardous waste bin in 2442.
+  * Nitral (NOT RUBBER OR CLOTH) gloves should be warn when cutting specific composites including carbon fiber and fiberglass
 ====Job Setup====
-**On The Computer:** \\
+**Switching Blades** \\
-  * On the desktop computer near the Form 2 printers, open the PreForm software from the start menu.
+  * Remove the table to expose the reservoir and the saw blade arbor
-{{:tools:form2:logo.png?75|}}
+  * Insert the two pins into the saw arbor and blade retaining nut normal to the surface of the arbor \\ {{:tools:diamondsaw:img_5739.jpg?400|}}
-  * To start a new print, click File > New
+  * Using the leverage on the pins, loosen the blade retaining nut to free the blade
-  * File > Open, select the .STL or .OBJ file you want to print.
+  * Carefully remove the blade from its arbor and replace with the blade matching the material you intend to cut (blades should be inspected for ware and cracks, damaged blades should be disposed of in the broken glass box)
-  * Set the scale, orientation, supports, and layout.
+  * Lightly LUBRICATE the threads on the end of the blade arbor with silicone grease to prevent thread galling. Silicone grease is on the bottom shelf of the chemical storage rack between the two fume hoods.
-    *Formlabs recommends orienting flat surfaces at an incline of at least 20°.
+  * Tighten the blade retaining nut HAND TIGHT (no need to go crazy on this)
-    *Avoid printing tall, thin features when using flexible resin as it tends to flex during printing, resulting in print failure
+  * Check to make sure that the blade is submerged in the coolant by about 0.25 inches. The required coolant level will depend on the blade diameter.
-    *While PreForm may indicate that a part is printable, it is not an indication the print will be successful. Care must be taken to ensure the part is supported properly and that the material choice is suitable.
+  * Replace the table
-  * If there is an 𝚇 next to printability, add manual supports, change support density and touchpoint size as needed until it becomes a ✓.
-  * Save the print job in your group folder.
-  * 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.|Print Log]]
-  * To start the upload, press the orange ‘Print’ button.
-  *  Make sure the selected material and version match the resin type loaded in the desired printer. Choose a layer thickness—thicker layers correspond to a faster print but reduce vertical resolution.\\
-{{:tools:form2:diagram.png?600|}}
-**On the Printer: ** \\
-  * Press the button on the Form 2 to confirm the print
-  * After the print is completed, slide out the build platform with the part attached and place it into a plastic bin with absorbent pad to catch any resin spill.
-  * Close the orange cover
-====Using the Form Wash:====
+====Blade Selection====
-  * Transport the part and build platform in the container to Fume Hood #4 in Elings 2442.
+  * CBN Bond blades are used for cutting ferrous metals. Metal bond blades <1,000 RPM, Resin bond blades >1000 RPM
-  * Wear a lab coat and safety goggles, as the Form Wash contains IPA.
+  * Diamond Metal Bond blades: high concentration blades for general use at high or low speeds, low concentration blades for ceramics, Silicon, glass. Cut at low speed ,1,000 RPM
-  *  Press ‘Open’
+  * Plated blades (diamonds nickel-plated to the rim) are good for cutting plastics, PCBs and composites. Cut at low or high speeds
-  * Slide the build platform into place
+  * UKAM Industrial Superhard Tools 15LCU diamond wafering blade, 23-4888ME - In stock
-  * Adjust the wash time to 10 minutes. For times for resins other than flexible and clear, consult the webpage “Form Wash Time Settings” through the Formlabs website.
+  * UKAM Industrial Superhard Tools CBN wafering blade, 23-4898ME - In stock
-  * Press ‘Start’
+  * [[http://consumables.alliedhightech.com/Sectioning-s/1818.htm|Allied blade catalog]]
-  * After the washing is over, press ‘Open’ and remove the build platform. Place it in the container.
+  * [[https://www.ukam.com/|UKAM Industrial Superhard Tools]]
-  * Press ‘Sleep’ to close the Form Wash
-  * Allow 30 minutes to pass for the remaining IPA on the part to evaporate
-**Using the Form Cure:**\\
-  * Release the part from the build platform:
+====Part Fixturing ====
-      * Place build platform on the removal jig. Tools are in the Fume Hood #4 in Elings 2442.
+Several fixtures are available:
-      * Slide a removal tool under the angled edge of the part’s base to separate it from the build platform.
+  * Miter Guide \\ {{:tools:diamondsaw:img_5735.jpg?400|}}
-  * Lift the cover of the Form Cure. Place the part in the center of the turntable.
+  * Multipurpose fixture \\ {{:tools:diamondsaw:img_5736.jpg?400|}}
-  * Select the curing time and temperature. Curing settings are dependent on which resin is used.
+  * Custom fixturing
-  * Refer to the webpage “Form Cure Time and Temperature Settings” through the Formlabs website for resin specific information. A longer cure time (up to an hour) will slightly increase the tensile strength of the part.
+  * Fence \\ {{:tools:diamondsaw:img_5738.jpg?400|}}
-  * Press ‘Start’
-  * Lift the cover and remove the part once the post-curing has completed.
-**Post Processing:**
+====Using the TrimSaw 2:====
-  * Use snips or tweezers to break support material off of the part. Be careful when finishing delicate parts to avoid breaking off small features.
+  * Check the blade installed, coolant levels and part material
-  * Use abrasives such as sandpaper and files to remove marks left by touchpoints until the surface is satisfactory.
+  * Select an appropriate fixturing jig to insure part remains securely held and square to the saw blade
+  * Adjust the blade splash guard so that it just clears the fixture and workpiece but catches as much coolant as possible
+  * Replace the plexiglass cover
+  * Turn on the TrimSaw using the power switch by the power cord, then using the arrow buttons select the appropriate speed
+  * Slowly and gently feed the workpiece into the blade, allow the blade to cut without force feeding
+  * When cut is complete withdraw the fixture and workpiece from the cut (do NOT attempt to clear workpiece while saw is in motion).
+  * Using paper towels wipe the Trimsaw down and clear any dust particulates from cutting
-**Replacing an empty resin cartridge with a full one of the same type:**\\
-More information on the resin system and changing a cartridge can be found on the webpage
-“Formlabs Resin Tank Information” through the Formlabs website.
-  - Remove the empty resin cartridge:
-    - Close the vent cap at the top right of the resin cartridge to prevent resin from spilling out once removed
-    - Hold the cartridge handle and lift to remove from the Form 2. Store the cartridge upright with the valve cover installed to protect storage surfaces from resin.
-  - Insert a new resin cartridge:
-    - Shake and rotate the new resin cartridge to ensure that the resin is mixed thoroughly.
-    - Align the cartridge with the opening at the back of the printer. Push down on the cartridge handle until the top of the cartridge is level with the printer.
-    - Press open the vent cap to ensure the resin tank can fill correctly
-====Switching a printer from one type of resin to another====
+**Post Processing:**
-More information on the resin system and changing a cartridge can be found on the webpage
+  * TrimSaw can leave small burs on metal or composite components, sanding lightly with a high grit sandpaper can remove sharp edges
-“Formlabs Resin Tank Information” through the Formlabs website. This includes videos and
-animations.
-  - Remove the build platform - this prevents resin from dripping onto the glass
-  - Remove resin cartridge:
-    - Close the vent cap at the top right of the resin cartridge to prevent resin from spilling out once removed.
-    - Hold the cartridge handle and lift to remove from the Form 2. Store the cartridge upright with the valve cover installed to protect storage surfaces from resin.
-  - Remove the resin tank
-    - Hold the front tabs of the resin tank
-    - Gently pull the front tabs of the resin tank to release the tank feet from the tank carrier. The Resin Tank LT wiper ejects during removal.
-  - Cover the resin tank and store on the left side of the fume hood
-  - Insert the resin tank for the resin that you plan to use
-    -  Lift the Form 2 orange cover. Use the tank grips to hold the Resin Tank LT, with the wiper resting inside the tank. If the tank contains resin, cover the tank with the plastic lid to align the wiper and minimize the risk of spills during insertion.
-    - Align and insert the four small feet of the resin tank into the corresponding slots in the tank carrier on the printer.
-    - Hold the front tabs and carefully push the tank until the tank feet lock into the slots on the tank carrier. Check the touchscreen display to confirm that the Form 2 detects the tank. The Form 2 will only detect the tank when the tank is fully inserted.
-  - Lock the wiper blade
-    - Align and insert the wiper foot into the wiper mount.
-    - Push the wiper toward the tank.
-    - Ensure the wiper foot is securely locked into the wiper mount.
-  - Insert resin cartridge:
-    - Shake and rotate the new resin cartridge to ensure that the resin is mixed thoroughly.
-    - Remove the protective valve cover from the underside of the cartridge. Use the cover to protect the bite valve during storage.
-    - Align the cartridge with the opening at the back of the printer. Push down on the cartridge handle until the top of the cartridge is level with the printer.
-    - Press open the vent cap to ensure the resin tank can fill correctly.
-  - Replace build platform
-  - Make sure that all of the resin tanks are correctly labeled.
 ====Maintenance====
-  * Cleaning resin tank interior
+  * Blade Cleaning
-    * Use the scraper from the finish kit to inspect the resin and the elastic layer. Starting from the top corner, gently scrape from top to bottom across the elastic layer.
+    * Cutting blade can become loaded with material despite coolant
-    * Check for the following issues that may lead to print failures or any excessive wear that requires replacing the tank:
+    * Using the Miter guide, load the silicon carbide dressing stick onto the saw and feed slowly into the spinning blade about two to three mm. \\ {{:tools:diamondsaw:img_5737.jpg?400|}}
-      * cured resin on the elastic layer
+  * Lubing threads
-      * debris or failed prints in the resin
+    * The aluminum blade retaining nut is prone to cold welding to the stainless steel blade arbor. This is known as "thread galling" and makes removing the nut difficult and can damage the arbor and the nut
-      * settled pigment on the elastic layer
+    * To prevent thread galling a small amount of silicone grease must be applied to the arbor prior to threading on the retaining nut.
-      * punctures, cuts, or gouges in the elastic layer
+  * Emptying coolant
-      * excessive “clouding” or wear in the elastic layer
+    * When not in use for long periods, the coolant within the TrimSaw has a tendency to evaporate leaving behind a incredibly discussing green goop
-  * Filtering Resin
+    * To prevent staff from having to clean this, if the TrimSaw is not in use for over a month it is advisable to drain the coolant tank
-    *  Use a filter to remove any debris or small bits of cured resin floating in the tank. Clean, debris-free resin helps avoid print failures, which may damage the tank.
+    * Draining coolant can be done with the ball valve on the rear of the saw and should be emptied into a container for safe waste disposal.
-  * Cleaning the tank window
+    * Rinse coolant tank twice with water after coolant has been emptied. Water can be disposed of directly into the sink
-    * Never use IPA on the acrylic tank window (it will cause cracks).
+    * Leave Trimsaw open to allow complete evaporation of any remaining water
-    * If dust, fingerprints, and/or contamination are present, clean the clear acrylic tank window with NOVUS No. 1 and a clean microfiber cloth. The clear acrylic tank window is located on the underside of the resin tank. Apply 1-2 full sprays of NOVUS No. 1, and wipe using long, sweeping strokes top to bottom and across the tank window. Fold the microfiber cloth after each swipe to prevent dust and debris from scratching the acrylic.
+  * Filling coolant
+    * Fill the TrimSaw coolant tank with DI water to the max fill line (about a gallon)
+    * Add 120 mL of Coolmist coolant concentrate to DI water and mix
 -----
-====Form 2 Quick Review====
+====TrimSaw 2 Quick Review====
 Tool Lead:    \\
 Contact: andrewfurst@ucsb.edu      \\
 ====Safety Concern====
-  * Lab coat and gloves must me used when handling resin
+  * Eye protection should be warn at all times while operating the saw
-  * Anything with uncured resin must be transported within a container to avoid spilling
+  * All guards and shields should be in place before turning the saw on
+  * Hands should be kept free and out of the way of the blade at all times
+  * Nitral (NOT RUBBER OR CLOTH) gloves should be warn when cutting specific composites
 ====Safe Operation Procedures Review====
-  - Check resin cartridge and tank, make sure build material matches and is desired material.
+  * Check the blade installed, coolant levels and part material
-  - If resin is not desired material, disconnect wiper at build tank, remove build plate by sliding towards front of fume hood. Remove cartridge, cap valve on bottom and close valve on top of cartridge. Replace build tank, wiper, and cartridge with desired material.
+  * Select an appropriate fixturing jig to insure part remains securely held and square to the saw blade
-  - Launch Preform on Ultimaker computer
+  * Adjust the blade splash guard so that it just clears the fixture and workpiece but catches as much coolant as possible
-  - Import desired STL
+  * Replace the plexiglass cover
-  - Select "one click print" in the top left corner menu, change position, orientation, resolution and support as desired (note: that Preform will report on print ability of model, changing part rotation can affect print ability.
+  * Turn on the TrimSaw using the power switch by the power cord, then using the arrow buttons select the appropriate speed
-  - Select print (orange button) from top left menu
+  * Slowly and gently feed the workpiece into the blade, allow the blade to cut without force feeding
-  - Select desired printer
+  * When cut is complete withdraw the fixture and workpiece from the cut (do NOT attempt to clear workpiece while saw is in motion).
-  - Press button on Formlabs printer to start print
 ====Post Processing====
-  - Excess resin should be removed from the build tray and part with IPA over a waste container.
+  * Using paper towels wipe the Trimsaw down and clear any dust particulates from cutting
-  - Place build tray and part in the Form Wash for 20 to 30 minuets (part can be placed individually within basket if necessary
+  * TrimSaw can leave small burs on metal or composite components, sanding lightly with a high grit sandpaper can remove sharp edges
-  - Allow 30 minuets for IPA to evaporate before placing part in Form Cure
-  - Set Form Cure time and temperature based on resin type, place part within form cure, wait for time to elapse
-====Maintenance====
-  * Switching resin types
-    * Close breather valve on resin cartridge
-    * Remove the resin cartridge by pulling straight up on the handle behind the form labs printers
-    * Cap the cartridge valve using the included orange tap and cap
-    * Remove the wiper by pulling straight out towards the front of the fume hood.
-    * Pull the resin tray out of the printer by pulling firmly straight out toward you
-    * Lift the wiper and resin tray out simultaneously, and carefully place on resin shelf within fume hood.
-    * Cover resin tray with black plastic cover and label
-    * Replace resin tray with clean or desired resin tank. Push tank and wiper firmly back toward the Form 2 until it clicks into place
-    * Replace resin cartridge and open valve
+====Switching Blades====
+  * Insert the two pins into the saw arbor and blade retaining nut normal to the surface of the arbor
+  * Using the leverage on the pins, loosen the blade retaining nut to free the blade
+  * Carefully remove the blade from its arbor and replace with the blade matching the material you intend to cut
+  * Lightly LUBRICATE the threads on the end of the blade arbor with a grease to prevent thread galling.
+  * Tighten the blade retaining nut HAND TIGHT (no need to go crazy on this)
+  * Insure the coolant level is in contact with the bottom of the blade and filled to the fill line