Aadpl Cnc Manual 2010

7/30/2019 Aadpl Cnc Manual 2010

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AADPL CNC MANUAL 1

AA Digital Prototyping Lab

CNC Machining Manual


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AADPL CNC MANUAL 2

Contents

1. Important Health and Safety Warnings

2. Preparing Files

3. ARTCAM + Machining 3D Milling

4. ARTCAM + Machining 2D Cutting

5. Tips and Tricks

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AADPL CNC MANUAL 3

Important Health and Safety Warnings


2. Preparing Files



5. Tips and Tricks


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AADPL CNC MANUAL 4

Improper use of the CNC machine can causeserious health risks and risk of damage to themachine.

If you are using the CNC machine, you areresponsible for the safety of all people andequipment affected by using the machine.

Only persons with proper training and up-to-dateknowledge of the safe operation procedures

should use the CNC machine.

You can only use the materials that have beendesignated as safe to use, as posted in the DigitalPrototyping Lab.



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AADPL CNC MANUAL 5


If you are in doubt about the safe and properoperation of the laser cutting machine you MUSTask for assistance before operating the machine.

Failure to operate the CNC machine in a safe andresponsible way might result in seriousconsequences such as being held liable for

damages and being banned from using themachine in the future.


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AADPL CNC MANUAL 6


2. Preparing Files



5. Tips and Tricks

Preparing Files at Home


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AADPL CNC MANUAL 7

Procedure

How to submit files to the DPLThe CNC machines at the DPL are operated by the Digital Prototyping Lab staff. AA Studentscan submit 3D models for production in one of the machines at the lab between 10.00 am and1.00 pm, monday to friday.After delivering the file and material or paying for high-density foam which is supplied by the

DPL, your model is placed in the queue. At this time the lab staff can give you an estimation ofthe date and time your model will be finished, please be aware that there usually is a waitingtime between 1 and 8 working days (in busy periods).

Planning the size of your modelThe maximum cutting size of the big CNC machine is 1220x1220 mm.The maximum cutting size of the small CNC machines is 500x400 mm.The maximum thickness of materials in all machines is 50 mm.*

This has to do with the standard thickness of the high density foam sheets and also the lengthof the cutters.(*We have one cutter with a length of 75mm for use in the big CNC machine, with a diameterof 12 mm.)

When considering sizes for a model produced in the big CNC machine it is advisable to workwith the standard sheet sizes of high-density foam to avoid waste of material and highpurchase cost:The high-density foam comes in sheets of 1500x500x50 mm.

Other materials that can be used in the CNC machines are:MDFPlywoodBluefoamOther types of soft foamCast-acrylic

Modelling wax

All materials except high-density foam need to supplied by the individual student or can beordered through the DPL. In all cases when considering materials other than high-density foamit is strongly recommended to discuss your project with the DPL staff beforehand. In the DPLare also sample boxes of several different types and grades of medium and high-density foamsavailable.

Cost of MaterialsTwo grades of high-density foam are usually kept in stock at the Digital Prototyping Lab (M300and M450). Other grades and large amounts can be ordered for delivery on the next day.The prices fluctuate slightly due to exchange rates and other factors, the price for a block500x400x50 mm M300 grade (yellow) is currently 34.00 pounds (Jan2010).

You only pay for the material, if you bring your own material there is no charge.

File Preparation


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AADPL CNC MANUAL 8

File Preparation

General file preparationTo enable the translation and the preparation of your 3D model into ArtCam (the CNC toolpathpreparation software) you will need to ensure the following guidelines are met:

- the 3D model must be in millimetres, in 1:1 scale of the final physical model;

- the model must fit within the maximum cutting size of the machine;- the model must be submitted in the .3DS (3d studio) format;- separate blocks must be submitted as separate files;(for instance 'studentname_model5_01.3ds', 'studentname_model5_02.3ds', etc)- double sided models can be submitted as one 3d model;- models for the big CNC machine consisting of multiple sheets of high-density foam can besubmitted as one 3d model;- please supply 'clean' files: not other information, geometries, hidden objects/layers/ etc.

With regard to the minimum dimensions of detail please keep in mind that we can use differentcutters: 12, 6, 3 mm and the 1 mm Vbit.Holes, gaps or grooves within your model will not be milled if they are smaller than the size ofthe drill.

Please note that for the CNC milling software you do not need to submit a fully closed,watertight model (as opposed to modelling for 3D printing). A 3D model can containintersecting surfaces or solids, as the software will only consider the top surfaces.Be aware that the AA only has 3-axis milling machines, which means if your model featuresundercuts these will not be machined.

A properly prepared file in Rhino

File Preparation


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AADPL CNC MANUAL 9

Double-Sided MillingModels which feature complex geometries or openings can sometimes be produced bymachining from a block of material from both sides. The digital files need to produced in aparticular way so that the material can be rotated in the machine while keeping the modelfirmly in place. This is usually done by including a frame, which also serves as a base to

calibrate the machine on, in order to make sure both halves of the model match accurately.After the machining of the parts has finished, they are usually cut out of the frame using a knifeor a dremel, and the attachment points are then sanded to make the geometry lookcontinuous.While preparing files for double-sided milling its important to keep to the following guidelines:

Submit a single .3DS file containing a clean model considering minimum thicknesses;-As guideline for the thicknesses of double-sided milling projects keep a minimum of 5mm in alldirections-Include a frame around the parts to be milled, with a minimum thickness of 20 mm and aheight of 50 mm;-Keep a spacing of minimum 20mm in between separate parts;-Include 'bridges' in between the frame and the parts, with a minimum width of 5 mm, heightof 50 mm;-Place these bridges at regular intervals around all edges of the model, so that there is nowhereany cantilevering larger than 40 mm or spans larger than 80 mm.-Place the bridges close to or exactly touching the sides of the model -there is no need tointersect the geometries. (Leave a distance slightly smaller than the size of the intended drill bitin between the bridges and the part to allow easy cutting and finishing after the pieces havebeen milled.)

A file prepared for double-sided milling

File Preparation


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AADPL CNC MANUAL 10

2D CuttingThe CNC machine can be used for various other operations such as 2D cutting, drilling, areaclearing (like engraving) and text or pattern engraving. These operations can be performed onflat sheet materials such as plywood, MDF or acrylics, or in combination with 3D milling. Forinstance when holes or specifically shapes slots are needed in a 3D machined model, it is more

efficient to use a separate 2D cutting operation as this is faster and giving much more accurateresults.

To prepare files for these procedures a 2D drawing is needed with a rectangle marking theoutline of the piece:- Submit a 2D drawing file in .3DM (Rhino) format;-Combine multiple sheets in one drawing, clearly labeled;- Drawing must be in mm in 1:1 physical model scale;- Apply a sheet size 1200x1200 mm or 500x400 mm for the Roland MDX-540;- Text, drilling holes, areas and outline cut shapes need to be in separate layers;- Layers must be named after the machine operation: such as drilling 6mm diameter or areaengrave 7 mm down;- Each shape that will be cut or areas that will be engraved to a certain depth needs to bemarked with a single, closed polyline (this needs to be CHECKED use the selectOpenCurvescommand in Rhino to detect shapes that are not closed);- Check if there are no duplicate lines on top of eachother;- Holes that will be drilled need to be marked with a circle;- Separate shapes need to be at a minimum distance of 20 mm from eachother and from theedges of the sheet;

A file prepared for 2D cutting

File Preparation


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AADPL CNC MANUAL 11


2. Preparing Files



5. Tips and Tricks



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AADPL CNC MANUAL 12

CNC Milling: General Setup

Understanding toolpath setupSetting up the toolpaths in a correct way is important to ensure there is no risk of damagingthe machine or the material, and that time it takes to produce the part is optimised.Determining the right method is about finding the right combination of cutting tool, cuttingspeed, stepdown and stepover settings, depending on the type of material being used, the

characteristics of the geometry and the finish quality that is appropriate.

border all arounddifferent methods of fixing a piece of material on the machine bed

screws in the sides blocks to hold the piece

Cutting toolsThere is a wide range of different cutting tools to choose from, with tools made in differentdiameters, shape design, cutting flute geometry and material properties.The most common types used in architectural prototpying are End Mills for roughing and 2Dcutting and V-Bit and Ball Nose cutters for finishing operations.

The overall length of the cutting tool determines how deep the tool can cut into any material intotal (given that a certain length needs to be used to fix the cutter into the spindle of themachine).The length of the cutting area within the tool determines how deep the material can be cut inone operation this is called the maximum stepdown. This stepdown value will only be used to

its maximum when the material that is being cut is soft; for harder materials a smaller value isoften required, setting the toolpaths to mill away layers of materials in separate passes.

The diameter of the cutting tool determines to how much the distance between each line can beset when using a rastering toolpath operation this is called the stepover. When rastering, thetool will move through the material in a zig-zag movement from left to right and back, steppingback a small distance each time the tool starts a new line. The maximum stepover distancecannot be greater than the diameter of the tool, and usually a percentage of the diameter isrecommended to release the pressure on the drill.

General Setup


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AADPL CNC MANUAL 13

Setting up a multi-pass toolpathIn any CNC-milling project where the total cutting depth is more than the maximum stepdownvalue of the tool, a multi-pass setup is necessary.Usually the parts in the AADPL are being milled first with a 6 mm End Mill, which can mill at adepth of 25 mm at one time.

First pass of the 6 mm End Mill taking awaythe top 25 mm of material around the partthat is being machined

Second pass of the 6 mm End Mill takingaway any material between 25 and 50 mm(or less) of material, measuring from the topsurface

Finished part after it the boundary ofmaterial that had been left to secure theblock in place while machining, has been cutoff

Roughing and finishing toolpathsSome cutting tools are better at take material away quickly, while others are better to give thefinal part a highly detailed finish. Taking the first layers of material away, which is calledroughing, can be done with a high stepover and stepdown value, which saves time. The

finishing pass can be set with a small stepover value using the same tool or using a separatetool, depending on the shape characteristics of the part and depending on the detail size.

Traditional setup of roughingtoolpath, using a 6 mm EndMill and two passes of -25mmand -50 mm, and a 4 mmstepover

Finishing toolpath setup usinga V-Bit set to -50 mmmaximum Z-depth and a 1 mmstepover

Time-saving setup using aroughing pass with the 6 mmEnd Mill for only the top 25mm down; and a finishing pass

to mill the last 15 mm awaywhile doing the finishing(Geometry checked in relationto the maximum stepdown ofthe V-Bit)

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General Setup


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AADPL CNC MANUAL 14

Double-sided milling setupFor projects which need milling from both sides the toolpath setup is similar to single-sidedmilling, but repeated for both top and bottom side.Depending on the desired level of detail and surface finish smoothness, either one or bothsurface can be machined using a V-Bit finishing pass.

Roughing pass with a 6 mm End Mill

Finishing pass using a V-Bit

Rotation of the block, using the framearound the part as reference

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Roughing pass with a 6 mm End Mill

Finishing pass using a V-Bit

Cutting out of the frame using a knife

Finished and sanded part

General Setup


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AADPL CNC MANUAL 15

CNC Milling: ARTCAM Setup

Open ArtCam and start anew Project.From the File menu, chooseNew, Model

Input the size of the block ofmaterial that will be placedin the machine, in mm andoriented the same way aswhen standing in front ofthe machine

When setting up a project for CNC Milling it is of crucial importance to relate thesettings in the digital file to the physical setup of the CNC machine.Aspects such as the dimensions of the material, the position of screws and theproperties of the cutting tool need to correspond to the settings in ArtCam.

Any discrepancies between these settings will result in errors which can causedamage to the workpiece and to the machine!

It is important to prepare the setup of a CNC project using the following instructionsin a CONCENTRATED and PRECISE manner. Double-check all the settings if necessarybefore starting the actual machining process.

3D Milling: ARTCAM Setup


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AADPL CNC MANUAL 16

An empty workspace willappear switch between 2Dand 3D using the icon abovethe viewport

Use Reliefand Import 3dModel from the menu toload a digital model

Use the Centerbutton toplace the model on theworkspace, use preciseplacement from one of thecorners of the model ifnecessary

Use the scale input fields ifnecessary to match thedimensions of the digitalmodel to the size of thematerial

If necessary, unlinkthe Z-size to stretch the model tothe maximum height of 50mm.

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AADPL CNC MANUAL 17

Use the Paste button toapply the digital model intothe workspace

If necessary, this can be

done several times to createmultiple copies of the samefile in one workspace

If the Paste function is usedmistakenly, close thiswindow and use Relief,Resetfrom the menu

Switch to 2D and use theGreyscale from CompositeReliefbutton to create asnapshot of the model intopview

Use the Create Rectangletool under Vector Tools tomark the area which will bemachined

Make sure this rectangledoes not overlap with thearea that will be used toplace screws in thematerial for fixing it ontothe bed of the machine

Instead of a rectangle,circular or freeform shapescan be used

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AADPL CNC MANUAL 18

Select the Toolpaths tab andchoose the Machine Reliefbutton under 3D Toolpathsto start the setup of thetoolpath

Choose Selected Vector asthe area to machine

Under Machine Safe Ztype25 mm at the fields for SafeZand Z Home Position

(This is the safe heightwhich at with the cuttingtool can travel around abovethe material)

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AADPL CNC MANUAL 19

At the Tool section, use theSelect button to access theArtCam library with cuttingtools

For the initial millingprocedure choose the EndMill 6 mm type cutter

Make sure the settings forthe tool are exactly asshown here:

Tool Units: mmRate Units: m/min

Stepdown: 25Stepover: 4Spindle Speed: 15000

Feed Rate: 5.5Plunge Rate: 2.5

Click Setup under Materialto define the materialthickness



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AADPL CNC MANUAL 20

Make sure the followingoptions are defined:

Material Thickness: 50(-or less, corresponding to

the actual material)

Top Offset: 0(recommended to savemilling time change toBottom Offset if necessary)

Material Z Zero: Top

Use the move cursor tohover over the differentcolored areas of the modelin 2D view to check thecutting depths at the bottomof the window

(Check whether the darkestcolor areas dont exceed theexpected cutting depth)

Set the multi-pass settingsfor a roughing pass:

Check the box forDo Multiple Z Passes

ZHeight of First Pass: -25

ZHeight of Last Pass: -25

* To optimise cutting speed, thedepth of the first pass could be setto half of the maximum cutting

depth as found above (when using 2passes with the same tool), or themaximum cutting depth of the partminus the maximum stepdown ofthe finishing tool (for instance 18mm for the V-Bit)



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AADPL CNC MANUAL 21

Choose an appropriate namefor the cutting operation andclick the Nowbutton to startthe generation of thetoolpath

Visually check if thetoolpath has been generatedin the right area (inside thevector initially drawn) and ifthe depths seem in order.

Choose Toolpaths and SaveToolpath as from the menu

In the dialog box, use theblack arrow to copy theselected toolpath from theleft to the right section



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AADPL CNC MANUAL 22

From the dropdown list,chooseRoland MDX500/650(*.mdx)and save your file to an

appropriate location

* For the big CNC machine in theAADPL, useCAMTech_CMC3 Toolchange MM(*.nc)


Save your ARTCAM project


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AADPL CNC MANUAL 23

Place a block of material onthe machine bed, afterchecking the bed is cleandust-free

Check if the measurementsof the block correspond tothe dimension set-up in theARTCAM project

Carefully align the materialwith the marked outline ofthe maximum cutting areaon the machine bed

When using double-sidedmilling, this line is animportant reference toensure both halves of themilled part will matchaccurately

CNC Milling: Machine Setup



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AADPL CNC MANUAL 24

Place 3 or 4 philipsheadwoodscrews (75 mm length)in the sides of the materialto fix the block securely onthe machine bed.

See p. 12 for guidelines

Apply pressure on the backof the battery screwdriver todrive the screws into thematerial

Do not let the screw bit spinaround in the screw head! Thiswill result in damaged screws whichmight cause difficulties whenremoving the block

Check if the block is tightlyfitted onto the bed if thereis a gap, unscrew the screwa few centimeters, andscrew back down

Make sure the area in whichthe screws are locatedmatches the outline of thecutting area as it is definedin the ARTCAM project.

Screws placed inside thecutting area will result in

the breaking of thecutting tool and otherpossible danger!



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AADPL CNC MANUAL 25

Open the spindle cover toremove the cutting tool

Carefully place the longspanner on the top of thespindle, and place the shortspanner on the nut

Letting the long spannerrest against the large beltwheel, move the shortspanner in a clockwisedirection

Remove the cutting tool, thenut and the collet

Clean the nut and collet onthe outside and inside byblowing air and/or using asmall brush

Be careful when handlingcutting tools as theymight be very sharp!

Nut

Collet

Cutting Tool



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AADPL CNC MANUAL 26

Place the collet in the nut bycarefully hooking the colletinto the concentric ringinside the nut

Screw the nut onto thespindle head by hand, fixingit loosely

Push the cutting tool intothe collet, fixing the nut byhand so the tool doesnt fallout

Make sure the length withwhich the cutter is placedinto the collet is 5-6 mmmiminum!

Be careful when handlingcutting tools as theymight be very sharp!



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AADPL CNC MANUAL 27

Using a tape measurer,check if the exposed lengthof the cutting correspondsto the maximum cuttingdepth as defined in the

ARTCAM project

Carefully place the spannersand tighten the nut, movingthe short spanner incounter-clockwise direction

Make sure the nut isfirmly tightened but donot use excessive force!

Close the spindle cover

If the cutting tool is tooshort, the nut might runinto the material or the

screws, causing anemergency stop, andpossible damage to thematerial and to themachine!



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AADPL CNC MANUAL 28

Using the handheldcontroller, position the toolat the machine origin:

- press MENU

- dial to MACHINE-XY- press ENTER

Move the tip of the cuttingtool onto the FRONT-LEFTcorner of the material, toset the user 0,0,0 point

- Select [Return to Main]- press Z- dial to move the tool- press RATE to change thespeed and accuracy

- repeat for X and Y

Visually check if thecenterline of the cutting toolis ACCURATELY placed atthe edge of the material in Xand Y directionCheck if the end of the toolis placed directly on top ofthe material



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AADPL CNC MANUAL 29

Check if the coordinatesystem is set to USERIf not, press COORDSYSTEM

Set the user 0,0,0 point tothe current position of thetool:- press X- press/hold ORIGIN untila beep can be heard

- repeat for Y and Z

Failure to set the 0,0,0point correctly will resultin damage to thematerial or machine!

Carefully close the machinecover



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AADPL CNC MANUAL 30

Read the followingsection through BEFOREstarting the machiningoperation!

Start the VPanel application

Click OK

The VPanel interface willappear

This interfaces allows formoving the cutting toolaround before cutting,setting the user origin pointand adjusting certain valuesduring the cutting processMost functions can also be

performed using thehandheld controller

1. At Overrides, dial the topvalue down to 30 %

2. Click on the Cut button

3. Click on the Open Filebutton

4. Select the right toolpathfile and click Open

CNC Mill ing: Starting the Milling Process

CNC Milling: Starting the Milling Process

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AADPL CNC MANUAL 31

Click Apply and Output

Make sure the machine isset-up correctly andsafely, as this will start

the machining process!

Make sure the areaaround the machine isclear and proceeddirectly to the next step:

Keep your finger on thePAUSE button of thehandheld controller incase anything seems tobe going wrong

As the machine is startingand moving towards thefirst cutting position, checkvisually if everything seems

as planned in the ARTCAMfile.- check if the cutting tool ifnot going to hit any screws- check if the cutting depthis not lower than expected- check if the pressure onthe cutting tool is not toohigh

If the first few passes of thecutting tool have beencompleted without anyproblems, CAREFULLY dial upthe feedrate by pressingOVER RIDE until the indicatorarrow is located at the linemarked with XYZ

Dial the feedrate up to 100%

Make sure NOT to dial theoverride function up anddown when the arrow is atthe spindle speed S !!

This can immediatelydestroy the cutting tooland the material!



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AADPL CNC MANUAL 32

Stay with the machine atall times while it is inoperation!

If you need to leave the

room, use Pause and Move.Move to Viewfrom theVPanel application to pausethe milling operation

Press the red emergencystop button at the frontof the machine in caseanything seems to begoing wrong

Leave the handheldcontroller in a securelocation



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AADPL CNC MANUAL 33

Use MENU and >VIEW tomove the machine bed intoviewing position, at the frontof the machine

Use a hoover to removewaste material on top andaround the model

Inspect the model and themachine including thecutting tool

CNC Mill ing: After the cutt ing has finished

CNC Milling: After the Cutting has Finished


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AADPL CNC MANUAL 34

In ARTCAM, hide theroughing toolpath byunchecking the name in theToolpaths tab

Create a new Machine Relieftype toolpath using thesame vector as previouslyused to mark the cuttingareaThe material thicknesssettings will still be thesame as in the roughingtoolpath

Check if the Machine Safevalues are still set to 25 mmfor Safe Z and Home Z

At the tool selection chooseunder the V-Carvingcategory the Small V-Bit 6mm 90 degree

Click Edit

CNC Milling: Setting up the Finishing Path

3D Milling: Finishing Pass Setup


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AADPL CNC MANUAL 35

Change the settings for theV-Bit as following:

Rate Units: m/min

Included Angle: 20Stepdown: 18

Stepover: 0.5Spindle Speed: 15000Feed Rate: 4.5Plunge Rate: 2.5

By clicking on the tool namethe settings can be slightlyadjusted for this particularprojectThe stepover can for instancebe adjusted to set-up abalance between the desiredquality and speed:

Stepover value:

0.9 mm good fast0.5 mm better slow0.3 mm best very slow

Use the mouse cursor toread out the Z-depth valuesof the darkest/lowest areasusing the 2D view

Enter the maximum cuttingdepth needed in both inputfields at the Do Multiple ZPasses section


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AADPL CNC MANUAL 36

Enter an appropriate namefor the toolpath operationand generate the toolpathby clicking Now

Use Toolpaths, SaveToolpath as to save thetoolpath to the desiredlocation

Use a comprehensive file-naming format



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AADPL CNC MANUAL 37

In the machine, open thespindle cover and use thespanners to loosen the nutand remove the cutting tool

Leaving the nut and collet inplace, the finishing tool canbe inserted by hand

Check if the exposedlength of the tool iscorrect in relation to themaximum cutting depthas set-up in ARTCAM

Firmly tighten the nutwithout applying too muchpressure

Close the spindle cover


* If other cutting tools such as a 3mm End Mill are being used, itnecessary to switch the collet


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AADPL CNC MANUAL 38

Use the handheld controllerto move the cutting tool tothe USER-XY

Without changing the Xand Y position, move thetool down so the tip of thecutter is just touching thetop of the material

Set the current position to 0by pressing Z andpressing/holding ORIGINuntil a beep can be heard

At the VPanel application,click on the Cut button

Delete the previous toolpathfile and open the finishingtoolpath file

ClickApplyand Outputwhen ready to start themachining process


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AADPL CNC MANUAL 39

Using the VPanel screen orthe handheld controller tostart the machining at 30%speed OVER RIDE

Check if the first passes arebeing machined properly

Dial the speed up to 100 200% while the finishingpass is being machined



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AADPL CNC MANUAL 40

Similar to when theroughing pass finished:

Use MENU and >VIEW tomove the machine bed into

viewing position, at the frontof the machine

Use a hoover to removewaste material on top andaround the model

Inspect the model and themachine including thecutting tool

CNC Mill ing: After the cutt ing has finished



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AADPL CNC MANUAL 41

The following proceduresare not optional but crucialfor the proper maintenanceand reliable working of themachine

Remove the cutting tool

Hoover inside the machinecover to remove all wastematerial and dust aroundthe CNC bed and from themachine itself

Hoover inside the spindlecover to remove any dust

CNC Milling: Cleaning Up



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AADPL CNC MANUAL 42


2. Preparing Files



5. Tips and Tricks



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AADPL CNC MANUAL 43

Prepare files in Rhino usingclean, closed polylinesorganised in separate layersdepending on the intendedtoolpath operation

Use a rectangle in thedefault layer to indicate thematerial that will bemachined

Use Export Selectedinstead ofSave as to makesure no other geomtriessuch as hidden lines,surfaces etc are beingincluded in the file

Use the DXF format and the2004 Naturalfile formatsetting

2D Cutting: ARTCAM Setup



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AADPL CNC MANUAL 44

Start a new project inARTCAM using thedimensions of the materialthat will be machined

Use Vectors, Import fromthe menu to import the DXFdrawing

* This menu option will only beavailable when the 2D view is active

Click OK



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AADPL CNC MANUAL 45

Note that the drawingappears centered on theworkspace, and the layersfrom the Rhino drawinghave imported as well

Scoring Toolpath:

Switch of the visibility for alllayers except the one forscoring to enable easyselection of objects

Select the linework that willbe machined as scoringlines

Choose the Machine AlongVector option from theToolpaths tab

Enter the desired FinishDepth for instance 1 mm

Select the V-Bit 6 mm 90degree from the toolslibrary and edit itsspecifications as on page 35

Specific parameters can bechanged after the toolselection check thesettings in relation to thematerial suggestions as onpage 53

(In this example plywood isbeing used)



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AADPL CNC MANUAL 46

Setup the material thicknessas the real thickness of thepiece that will be machined

Choose Top Offset as 0.0

Choose a suitable name forthe toolpath operation andclick Now

Switch to the 3D view tovisually check if the toolpathhas been generatedcorrectly



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AADPL CNC MANUAL 47

Drilling toolpath:

Lock the layers that havebeen processed and switchon the visibility for the layer

named drilling

Select all objects on thelayer

Choose the Drilling iconfrom the Toolpaths tab

Check the Finish Depth andselect the cutting tool suchas the 6 mm End Mill

Some parameters of the toolcan be changed afterselecting it:

Change the plunge rate tothe correct valueconsidering the materialthat is being drilled (Seep53)

In this example forplywood: 1.5 m/min



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AADPL CNC MANUAL 48

Enter a name for thistoolpath operation and clickNow

Switch to the 3D view tocheck whether the drillingtoolpath has been generatedcorrectly

Area Clear Toolpath:

Lock the previously usedlayers and change thevisibility for the Text layer

Select only the text vectors

For engraving areas usingjust their outlines select theArea Clear icon from theToolpaths tab



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AADPL CNC MANUAL 49

Enter the desired FinishDepth

For areas with small detailsuch as text, choose the V-

Bit cutting tool

(For larger areas choose anEnd Mill type tool)

Set the stepover to a valueslightly smaller than thediameter of the tool

Choose between a RasterorOffsetoperation to calculatethe toolpaths

Click Now

Zoom in to areas with smalldetails to inspect whetherthe toolpath has beengenerated correctly

Outline Cutting Toolpath:

Lock previously used layersand switch on the layer forOutline Cutting

(Switch off the visibility ofthe finished toolpaths in 2Dfor easy selection ofadditional vectors)

Select all applicable vectorsand choose 2D Profilingfrom the Toolpaths tab



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AADPL CNC MANUAL 50

Check the Finish Depth andselect a cutting tool such asthe End Mill 6 mm

After selecting the toolchange the parameters forStepdown and Feed Rateinto the value applicable tothe material being cut(See p53 for guidelines)

In this example for 12 mmplywood:Stepdown 4 mm

Feed Rate 2.5 m/min

* This means there will be 3 passesof 4 mm down towards cuttingthrough the full 12 mm thickness

Choose a suitable name forthe toolpath operation andclick Now



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AADPL CNC MANUAL 51

Save the toolpaths asdescribed in the chapter 3DMilling

Position the material and

execute the cuttingoperations as described inthe chapter CNC/3D Milling,making sure the locations ofthe screw fixing does notintersect with the areas inwhich will be machined


2D Cutting operationscan produce loud noiselevels or high frequencysounds!

Do not continue withnoisy operations in theCNC machine withoutproper ear protectionequipment for both

yourself and other peoplesharing the same space!


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AADPL CNC MANUAL 52


2. Preparing Files



5. Tips and Tricks



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AADPL CNC MANUAL 53

Guidelines for Toolpath settings

Different materials and different cutting toolsEach material should be used with specific maximum values for toolpath parameters. Thesevalues are indicative only! The operator of the CNC machine is at all times responsible forthe safe operation including checking and if necessary adjusting the settings for the toolpathoperations.

Tips and Tricks

5.5

3.5

5.5

4

1

0.9

25

20

18

End Mill 6 mm

End Mill 3 mm

V-Bit 1 mm

M-450

(pink foam)

7.5

4.5

7.5

4

1.5

0.9

25

20

18

End Mill 6 mm

End Mill 3 mm

V-Bit 1 mm

M-300

(yellow foam)

Maximumfeedrate

(m/min)

Maximumstepover

(mm)

Maximumstepdown

(mm)

Cutting toolMaterial

3D MILLING

5.53.5

5.5

41

0.9

2520

18

End Mill 6 mmEnd Mill 3 mm

V-Bit 1 mm

MDF

2.5

-

4.5

3

-

0.7

6

do not use

9

End Mill 6 mm*

End Mill 3 mm

V-Bit 1 mm

Acrylic

2.5

-

4.5

3

-

0.7

6

do not use

6

End Mill 6 mm

End Mill 3 mm

V-Bit 1 mm

Plywood

2.5

2.5

1.5

1.0

End Mill 6 mm

End Mill 3 mm

End Mill 6 mm

End Mill 3 mm

M-300

M-450Plywood

Acrylic

MDF

Plunge Rate

(m/min)

Cutting toolMaterial

DRILLING

5.5

4.5

2.52.0

4.5

25

25

66

15

End Mill 6 mmM-300

M-450

PlywoodAcrylic

MDF

Maximumfeedrate

(m/min)

Maximumstepover

(mm)

Maximumstepdown

(mm)

Cutting tool

(do not use EndMill 3 mm)

Material

2D CUTTING


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AADPL CNC MANUAL 54

Tips and Tricks

Toolpath SimulationArtCam includes a feature that allows for the digital simulation of the CNC milling process,allowing to anticipate tool movements and to evaluate finished surface quality.

Tips and Tricks

With a toolpath selected,

click the SimulateToolpath icon at theToolpaths tab

Click OK and use the arrowsto run the simulation atnormal or maximum speed

After the simulation hasfinished, zoom in to inspectthe surface quality inrelation to the stepovervalues used


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AADPL CNC MANUAL 55

Tips and Tricks

These guidelines are for advanced users only up to date knowledge of the machine and/orArtCam is required.

Double-sided Milling CalibrationBlocks are always rotated around the Y-axis, just like flipping the page of a book -make sure

the digital model is rotated in the same way in the ArtCam setup.Accurate placement of the block on the machine is crucial for a good match of the separatehalves of the milling operation. Use the marked outline on the machine bed for reference in theY direction.As the actual sizes of polyurethane blocks may vary, use the following procedure to calibratethe model in the X direction:-before starting the roughing pass, move the machine manually to a 0,250,0 position(assuming the use of a 500 mm wide block of high-density foam);- turn on the spindle (press SPINDLE) and dial the spindle speed up to maximum;- with a RATE of 100X, drill slowly down into the material up to -25 mm depth- move the tool back up to above the material and switch off the spindle- after finishing the top toolpaths, flip the block over and repeat the above 3 steps;- measure the distance in X-direction between the two marked grooves;- if the top groove is displaced towards the LEFT, reset the user-XY after moving the tool in X-direction with the measured distance;- if the top groove is displaced towards the RIGHT, use Model, Set Position in ArtCam andinput the measured distance at the X position as negative value. Regenerate the toolpaths.

Projecting a line pattern or text onto a 3D milled surfaceGenerate a 3D milling toolpath operation as normal and machine the part accordingly. -Generate a 2D toolpath as normal using imported vectorwork such as lines, curves or text andtoolpath operations such as Machine Along Vector.-With this toolpath selected in the Toolpaths tab, click the icon Toolpath Transform:

- At the bottom of the Toolpath Transform options, click Project On Relief:

Tips and Tricks


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AADPL CNC MANUAL 56

Custom G-Code

These guidelines are for advanced users only up to date knowledge of the machine and/orArtCam is required.

Scripting G-CodeFollowing is an example of a valid G-Code for the MDX-540 generated with ArtCam.

Note the units are set as 100 units per mm.

;;^IN;!MC1;!RC15000;

V50.0;^PR;Z0,0,10500;

^PA;V49.8;Z14742,19128,4400;

V49.8;Z14742,19128,-2500;

V75.7;Z14744,19329,-2500;Z23322,8924,-2500;Z15291,15793,-2500;Z14742,19128,-2500;

V49.8;Z14742,19128,4400;

V49.8;Z0,0,4400;!MC0;H;

All coordinates in the body of the G-Code should be within the maximum bounding box of theMDX-540: X,Y,Z = 50000,400000,5000

Tips and Tricks

switch on

spindle speed

rapid move speedgo home (0,0 XY and maximum Z height)

rapid move speedmove to first coordinate at safeZ above milling trajectory

plunge speedmove straight down to cutting depth

machining speedcoordinates along trajectory of milling

plunge speedmove straight up to safeZ above material

rapid move speedgo home (0,0,safeZ)switch off


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Documents

Aadpl Cnc Manual 2010