Paxton ActionLABS - San Dieguito Union High School Districtteachers.sduhsd.net/ssenese/CESMART MODULES AND... · process of design or conversion to CNC Code. ... you is Mastercam

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Day 1: Activity 2/ Computer Program Mastercam

In this activity you will become familiar with the concept of CAD/CAM manufacturing. While working through the Paxton ActionLAB program you saw many different CNC machines including a router very similar to the one in this module. You learned that machines are controlled by numbers and that there are people who program these machines.

In manufacturing today, more and more of the tasks that were previously accomplished by hand are being taken over by the computer. The result of this is more products of higher quality for you to enjoy, at a lower cost.

CAD/CAM stands for Computer Aided Design/Computer Aided Manufacturing. The router in this module is a CAD/CAM machine. The first part of CAD/CAM is CAD or Computer Aided Design and refers to the actual drawing, on the computer, of the part that you wish to produce. Mastercam is CAD/CAM software which means that you can draw the part you wish to make, tell the computer what you would like it to do with each line in the drawing, then (CAM) have the computer write the program that will direct the machine to make the part.

Because of security on the computer you are using, you will always save your drawings to a floppy diskette.

Your first project will be a Smiley Face just like the one pictured on the right. This activity will take more than one class period so be sure to save your drawing before you leave class for the day.

Materials Needed: Mastercam software Floppy diskette

Procedure: Before you begin, label your floppy diskette with you and your partner’s names. Place the diskette in the A: drive of the computer. Right-click on Start then click on Explore. Click on the A: drive. If there are any files already on the diskette delete them. Ask your instructor for help if you are not sure how to do this. You will be using this diskette all through this module, so don’t lose it! 1

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STEP 1: Minimize the Paxton ActionLAB program and return to the desktop.

STEP 2: Double-click the Mastercam icon on the computer desktop to launch Mastercam.

STEP 3: Before you can start designing or drawing your part, you need to know something about the Mastercam menu. Study the illustration below to learn where the features you will be using are located and what they accomplish.

Screen-Fit The Screen-Fit button will increase the size of

your drawing on the computer screen to the largest size that will fit. This makes seeing and working with the part easier.

Screen-UnZoom .8 The Screen-UnZoom .8 button will reduce the size of your drawing on the computer screen by one fifth. Again this just makes working with your drawing easier.

Main Menu The Main Menu button is used for two reasons. The first reason is that if you lose track of where you are in the menu, the main menu will bring you back to the root menu. The second reason is that you need to get back to the beginning of the menu to go on to the next task in the process of design or conversion to CNC Code.

Gview T In Mastercam you can look at your part from any side or in different views. You will use the Gview T button to start this process.

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Screen-Unzoom .8

Screen-Fit

Main Menu

Origin or Datum Point

Gview T

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Origin The Origin or Datum point is the zero, zero, zero of the design or actual part. Origin or Datum in CNC means the point from which all measurements or locations are made. Looking at the Smiley face from the front, the Datum point would be the front, left, top corner of the pine block. STEP 4: The first step in creating your design is to draw the

work piece, a piece of pine, in Mastercam. Click on the Create button on the Mastercam menu. Notice that when you do, a new set of choices will appear.

Information: Mastercam uses a layered menu system. What this means to you is Mastercam will offer a limited set of choices on the Main Menu. When you select an item like Create, a new set of choices will be shown to indicate the different things that you can create. You will keep selecting items from the menu until the computer has enough information to create your design. STEP 5: After you click on Create, click on Rectangle. STEP 6: Next click on 2 points. Notice the Dialog box at the bottom of the Mastercam screen is asking for the lower left corner of the rectangle. STEP 7: Type 0,0 (zero, zero) then press the Enter key. STEP 8: Now Mastercam wants to know where the upper right corner of the rectangle is located. Type 3.5,3.5 then press the Enter key. Mastercam will now draw the rectangle or in this case the square, but it is not in the center of the drawing field. STEP 9: Click on the Screen-Fit button then click on the

Screen-UnZoom .8 button. Your square should now be in the center of the drawing field and made larger to fit the screen. The square that you just created represents the pine block.

STEP 10: Looking at the smiley face, there is a square that is machined around the head of the smiley face. This is the next element that you have to draw.

STEP 11: Mastercam is still at the menu for Create>Rectangle>2 points and is again asking for the lower left corner of the rectangle.

Type .25, .25 then press the Enter key. STEP 12: Type 3.25,3.25 and press the Enter key for the

upper right corner. You should now have a square in a square just like the illustration on the next page shows.

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STEP 13: Now is a good time to save your drawing. Click on Main Menu, then File, then Save. An Mc9 window will open, use you and your partner’s first and last initials and period number for a file name i.e. BRJK1.

Navigate to the A: drive and click the Save button. If your drawing does not look exactly like the drawing to the left, you will need to start over.

STEP 14: The next step is drawing the head of the smiley face. Click on Main Menu then click on Create, then Arc, then Circ pt+rad

STEP 15: In the dialog box at the bottom of the screen, Mastercam is asking for the Radius of the circle. Type 1.25 and press Enter.

STEP 16: Next, Mastercam will ask for the location of the center of the circle. Type 1.75,1.75 then press Enter. Notice that after you type the first number the name of the dialog box changes from “Circle, with Center/Radius: Enter the center point” to “Enter Coordinates.”

STEP 17: Click on Main Menu. STEP 18: Next you will add the small circle that will become

the eyes of your smiley face. Click on Create, then Arc, then Circ pt+rad.

STEP 19: Type .13 for the radius and press enter. STEP 20: Type 1.75, 1.75 for the center and press Enter. STEP 21: Click on Main Menu. STEP 22: Next you will need to copy the small circle and

move it to a new location. Click on Modify then Drag, then Chain.

STEP 23: Click anywhere on the small circle that you just drew.

STEP 24: Click on Done then click on Done again. STEP 25: A small Drag window will open. Click on Copy, then

click on OK. STEP 26: Click on the small circle and drag it to where you

want the first eye to be. Left click to set the circle. Mastercam is still in copy

mode so go ahead and set the second eye. STEP 27: After you set the second eye, press the Esc key on

your keyboard to exit the copy function STEP 28: You now have one too many circles. Click on Main

Menu then Delete. Next, click on the small circle that is where the nose of your smiley face will be to delete it.

STEP 29: Your drawing should now look like the drawing to the left. If it does not, you will need to delete any errors and redo.

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Information If your first eye is not where you want it or there are items you need or want to delete from your drawing here are a couple of ways to accomplish deleting items. 1. Click on Main Menu and click on Delete. Several choices are presented. 2. The easiest to use are Chain and Window. 3. To use Chain, first click on Chain then click on the item you wish to delete. The item will turn white. Click on Done and the item will delete. To use Window, Click on Window, make sure there is a + next to Inside, then left click above and to the left of the item or items you wish to delete. Drag the mouse to the lower right corner of the item or items you wish to delete and left click the mouse, the item or items will be deleted. STEP 30: When your drawing is correct, save your drawing.

Click on Main Menu, File then Save. Navigate to the A: drive. The system will ask if you want to overwrite your original file. Click on Yes.

STEP 31: The next element you will add to your drawing is the nose of your smiley face. Click on Main Menu to return to the root of the menu structure.

STEP 32: Click on Create, Line, then Endpoints. STEP 33: Drag your mouse to the point where you want the

nose to begin and left click. Drag your mouse to where you want the first line of the nose to end and left click. Without moving the mouse, left click a second time to start the second line of the nose. Drag the mouse to where you want the nose to end and left click. Your nose is complete.

STEP 34: Save your drawing. STEP 35: The last element of the smiley face is the mouth.

Click on Main Menu. STEP 36: Click on Create, Arc, then 3 points. STEP 37: To create an arc you will need to identify three points

on the smiley face for the arc to pass through. The points have to be located in a specific order for the computer to correctly draw the arc. First, click on your

smiley face where you want the upper left corner of the mouth to occur. Next, click where your want the bottom of the arc of the mouth to occur. Finally, click where you want the upper right corner of the mouth

to occur.

NOTE: If the mouth is not exactly what or where you want it, delete it and try again.

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STEP 38: Compare your smiley face to the illustration. If you are satisfied with how it looks, save your drawing.

STEP 39: Exit the Mastercam program. STEP 40: Remove your floppy diskette from the A: drive and

store it in a safe place. Conclusion: Today you have learned how to create rectangles, lines, arcs, and circles in Mastercam. You have also learned how to manipulate the different elements or geometry of your drawing by copying, and deleting different elements to achieve your final drawing. RETURN TO THE PAXTON ActionLABS PROGRAM

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Day 2: Activity 1

Use the first part of this period to finish drawing your smiley face.

Locate your floppy diskette and insert it in the A: Drive.

Procedure STEP 1: Minimize the Paxton ActionLABS program. STEP 2: Double-click on the Mastercam icon on your desktop

to launch the Mastercam program. STEP 3: Click on File then Get in the Mastercam main menu. STEP 4: Navigate to the A: drive and select your drawing file

and click on it to select it then click Open. STEP 5: Complete your smiley face by picking up where you

left off your last class period. When you have completed your smiley face save it by overwriting the original.

RETURN TO THE PAXTON ActionLABS PROGRAM

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Day 2: Activity 2/Simulating-Rendering

One of the many advantages of combining Computer Aided Design (CAD) with the machining or manufacturing process (CAM) is the ability of the computer to take the drawing that you have created along with the cutting instructions that you provide and creating a rendering-simulation or three dimensional picture of the completed part. In Activity 1 you saw the smiley face to the right several times as you worked your way through the activity. This is actually a rendering of the part made by the computer. This particular rendering was done using a program called TurboCAD. TurboCAD is a program very similar to the Mastercam program that you are using. A rendering shows the designer what the finished part will look like when it is actually manufactured. A rendering also shows the programmer how the part will machine and show any major errors in the manufacturing process. Before the computer can do a rendering or simulation of your smiley face it must know exactly how you want each line or piece of geometry machined. The way you will do this is to define the tool path for each line in your drawing. You can think of a tool path as the path the tool will make as it cuts. If you have ever sawed a board in half, the cut is the tool path. If you have ever drilled a hole in a piece of material, the hole that the drill made is its tool path. Materials Needed: Mastercam software Floppy diskette Procedure: Before you begin, place your floppy disk in the A: Drive STEP 1: Minimize the Paxton ActionLABS program. STEP 2: Double-click on the Mastercam icon on your computer

desktop to launch the Mastercam program. STEP 3: Click on File then Get. Navigate to the A: Drive. STEP 4: Click on your drawing file to highlight it then click on

Open. STEP 5: Click on Main Menu to return to the root of the menu

structure. STEP 6: Click on Toolpaths then Contour. STEP 7: Click on Window.

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DAY 2 Information There are several ways to define toolpaths for the computer. For the smiley face you will cut the path in a single pass and all paths will be cut to the same depth. Further, all of the cuts will place the center of the cutting tool on the center of each of the lines. Because of this you can use the Window function in Mastercam to tell the computer that each line is to be cut in one pass to the same depth. This will save a lot of time. STEP 8: Click in the upper left corner of your drawing inside of

the large square but outside of the smaller square. STEP 9: Drag your mouse to the lower right corner of your

drawing inside of the larger square but outside of the smaller square. A white square will appear on your drawing as you drag your mouse just like the

illustration to the left. STEP 10: When you have the white square in the lower right

hand corner, inside of the large square but outside of the smaller square, left click the mouse.

STEP 11: Click anywhere on the smaller square. Your entire smiley face will turn white. Click on Done.

STEP 12: A new window will open. This is the first of two windows that will allow you to set up the machining parameters. In the Tool Parameters window, change the Length offset to 0, Feed rate to 10, Plunge rate to 2, Retract rate to 2, and the Tool diameter to .125. Delete anything that appears in the Tool Name box. Place a check mark in the boxes at the bottom of the window for Home pos…, T/C Plane, Misc values, and Tool Display. Your Tool Parameters window must exactly match the example to the left.

STEP 13: Click on the Contour Parameters tab. STEP 14: In the Contour Parameters window, change the

Clearance to .2 and select Absolute. Deselect Retract. Change the Feed plane to .2 and select Absolute. Change the Top of stock to 0.0 and select Absolute. Change the Depth to -.125 (be sure to place the minus (-) sign in front of the .125). Set the Compensation type to Off and deselect Lead In/Out. Your Contour Parameters window must exactly match the example to the left.

STEP 15: Click on OK.

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STEP 16: Your smiley face should now look just like the example STEP 17: Click on Main Menu to return to the root of the menu structure. STEP 18: Click on Toolpaths then click on Job Setup. STEP 19: You will be inputting many settings. You must be very careful or the part will not machine correctly. STEP 20: Click and hold on the red + in the middle of the square and

drag it to the far left hand corner. STEP 21: Click on the Select origin button. When your drawing

window opens, click on the lower left hand corner of the large green square.

STEP 22: Click on the Select corners button. When your drawing window opens, click on the lower left hand corner of the large green square then click on the upper right hand corner of the large green square. This will identify your pine block for the computer.

STEP 23: In the box below the Z dimension, type .75 then press Enter. This will tell the computer how thick your pine block is. STEP 24: Place a checkmark in the box next to Display stock. STEP 25: In Stock origin window at the left of the Job Setup window,

verify that the X, Y, and Z values are set to 0.0. STEP 26: Finally, at the bottom of the Job Setup window, locate the Post Processor window. Verify that MPTECHNO is selected as the post processor. If it is not, click on the button to the right of the post processor and select MPTECHNO.PST from the list that opens. STEP 27: When your setup matches the example exactly, click on

OK. STEP 28: After your have completed this step, your smiley face comes back with the tool paths drawn just like the example to the right. If your smiley face has the original tool paths, click on the Screen-Repaint button and it will change to match the example. You can see in this example where the toolpaths are located but what will the part actually look like when it is machined? The last steps before machining the part will be to have the computer generate the code necessary to machine the part and have the computer run a simulation or rendering so you can verify the program is correct. STEP 29: Click on Operations. STEP 30: In the Operations Manager window, first click on Select All

then click on Post. The Post Processing window will open. You need only confirm that the Active Post is set to MPTECHNO.PST then click on OK.

STEP 31: Mastercam will ask you to save your program. Save it to the A: drive.

STEP 32: The next window that opens is a Programmer’s File editor window. The text in this window is the actual program that will drive the machine to manufacture your smiley face. Close this window by clicking on the X in the upper right hand corner of this window.

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DAY 2 STEP 33: In the Operations Manager window, click on Select All then click on Verify.

STEP 34: In this window you will be able to simulate your smiley face. The default for this window is top view and while it will show the path of the cutter it will not show depth. Locate the Gview: button at the left

of the screen. Yours will have either a T or I next to it. Click on the Gview: button and a new set of menu items will open at the top of the menu list. Click on Isometric.

STEP 35: Center the block by clicking on the Screen-Fit button then click on the Screen-Unzoom .8 button.

STEP 36: In the control window that overlays the block, move the slider control to the far left. Click on the Play button to see your smiley face be cut.

STEP 37: If you have followed all of the instructions, your smiley face will look very much like the Example to the left. If you cannot get the part to machine

correctly, you will need to delete your smiley face from your floppy diskette and start over.

STEP 38: Exit the Mastercam program. STEP 39: Remove your floppy diskette and store it in a safe

place. Conclusion: In this activity you learned what a rendering or simulation is and why it is important. You also learned how to create a program that will allow the router in your module to cut your smiley face.

RETURN TO THE PAXTON ActionLABS PROGRAM.

Day 2 Activity 3/Problem Solving Coordinates

For the last two class periods you have been inputting numbers into your smiley face drawing and expecting the computer to know what to do with the numbers. Mastercam uses a Cartesian coordinate system to identify where elements are to be placed. Sounds confusing but actually you have used a Cartesian coordinate system many times. If you have ever created a graph for a math or science class you have probably used a Cartesian coordinate system. Locating a place on a road map uses a Cartesian coordinate system. Here’s how it works. The numerical control system uses a grid with two lines crossing each other. Industrial standard calls the horizontal line the X-Axis and the vertical line the Y-axis. Where the two lines cross is the Datum or 0,0 point. The depth of cut represents the Z-Axis and the third 0 in the diagram. A two number pair defines a specific point on the grid. The first number is for the X-Axis; the second number is for the Y-Axis. Zero is written (0,0). “X plus” is to the right of absolute zero and “Y plus” is toward the top of the Datum. The Cartesian coordinate system has four sections called quadrants. Most Computer Numerical Control Programs are programmed in the upper right quadrant which is called the first quadrant. X is movement to the left or right and Y movement is up or down as shown in your drawing. Let’s start using the Cartesian coordinate system to read a map. Locate the US map in your module and respond to the following questions in your Journal. 1. Find the map of the United States in your module work

area. 2. Locate the following cities on the map and enter the X and

Y coordinates in your journal. Note: X will be a number and Y will be a letter.

Chicago, IL

Miami, FL

Portland, OR 3. What is the largest city in quadrant D-7? 4. What river is running through coordinate F-7? RETURN TO THE PAXTON ActionLABS PROGRAM


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Datum or 0,0,0

Z-Axis

X-Axis

Y-Axis

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Day 3: Activity 2/Machining a Part

In this activity you will machine the smiley face that you have designed. Materials Needed: Mastercam software Techno GCODE Interface software (2) 3 ½ X 3 ½ X ¾ pine blocks Router Floppy diskette Shop Vac Procedure: Before you begin place your floppy diskette in the A: Drive. STEP 1: Minimize the Paxton ActionLABS program. STEP 2: Load the pine block into the router using the procedures

you learned in the video. Note: If the spindle of the router is in the way, make sure the power to the router is turned on then launch the Techno GCODE Interface program from the desktop icon and select Jog. Using the jog arrows you may jog the cutter out of the way.

STEP 3: Turn the power to the router on by first twisting the red emergency knob on the front of the machine to the right to make sure it is disengaged then press the green power button.

STEP 4: Click on the Techno GCODE Interface shortcut on the desktop to launch the Techno GCODE

Interface program. STEP 5: To load your program, click on the Translate/Execute button. A

folder will open, navigate to the A: Drive. Select and open your file.

STEP 6: After you open your file a new window will open that will allow you to set the conditions under which your part will be machined. Click on the Jog button.

STEP 7: Use the Up and Down arrow keys to move the cutter on the Y-Axis and the Left and Right arrow keys to move the cutter on the X-Axis. The + and – keys will raise

and lower the cutter. You can slow the jog speed down by clicking on the – button next to Speed.

STEP 8: Jog the cutter to the front, left, top corner of your pine block. The cutter should just touch the top of the surface.

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STEP 9: Once the cutter is at the zero position, click on the Zero button and set all axes to 0 by selecing Zero All.

STEP 10: Click on Exit Jog to return to the Translate/Execute window. Check to make sure that the X, Y, and Z positions are set to 0.

STEP 11: Close the cover to the router. STEP 12: Click on the Preview to see how the part will be

machined. STEP 13: Signal your instructor to check your setup. STEP 14: Exit the preview screen. STEP 15: Click on the Start button to machine your part. STEP 16: After your part is machined, click on the Jog button

to move the cutter out of the way and remove your part. STEP 17: Your partner can now load his pine block and

machine his part by following steps 1-13. STEP 18: After the parts are machined, locate the vacuum and

clean out the inside of the router. STEP 19: Remove your floppy diskette and store it in a safe

place.

RETURN TO THE PAXTON ActionLABS PROGRAM

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Day 4: Activity 2/Name Plate Purpose: The purpose of this activity is to introduce you to the engraving capability of the CNC Router and Mastercam software. Each student will engrave a nameplate. You will learn how to create, scale, and center text on a project In this activity you will begin your second project, a nameplate, similar to the one on the right. You will revisit some of the skills you learned while making the smiley face and learn several more. Among the new skills will be scaling or proportionately changing the size of an element or elements, how to fillet or round a corner and how to add text to a project. In the first activity each instruction was written as a separate step. Now that you have some experience with the Mastercam program, we will reduce the number of steps. In this activity, when a series of menu selections is necessary to get to a point where you will be adding an element to your design, the menu items will be presented in a series of clicks separated by a coma. For an example, look at step 3 on the next page Create, Rectangle, 2 points. To complete this step you would click on Create then Rectangle, then 2 points. Using this format will greatly reduce the number of individual steps. Each person in the module will be making an individual name plate. To save time once the material has been defined and the border created you and your partner should save that drawing under two separate file names i.e. BR1 and JK1. You will have two class periods to complete this project. Remember to save your work at the end of the period. Materials Needed: Mastercam software Floppy diskette

Procedure: Before you begin place your floppy diskette in the A: Drive STEP 1: Minimize the Paxton ActionLABS Program. STEP 2: Click on the Mastercam icon on your desktop to

launch the Mastercam program.

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STEP 3: Click on Create, Rectangle, 2 points. STEP 4: Type 0,0 then press the enter key. STEP 5: Type 8, 2.5 then press the enter key. STEP 6: Type .25,.25 then press the enter key. STEP 7: Type 7.75,2.25 then press the enter key. STEP 8: Click on Main Menu. STEP 9: Click on Screen-Fit, Screen-UnZoom .8. STEP 10: Compare your drawing with the drawing to the left.

If yours does not look the same you will need to go back and try again.

Fillets and Rounds

In manufacturing, very often a sharp corner is eased by putting a radius or a bevel on the edge or corner. This process is called filleting or rounding. Filleting or rounding can be done for several reasons, it may improve the appearance of a product, make the product safer by removing a sharp corner, or it may actually make the product stronger. STEP 11: Click on Main Menu, Create, Fillet, then Radius. STEP 12: If the Fillet radius is not already .25” then type .25

and press the enter key. STEP 13: You will be filleting the smaller inner rectangle so

click on one side of the smaller rectangle then click on one of the sides that connects to it.

Mastercam will put a .25 or ¼” radius on that corner. Continue the process until all four corners have a fillet.

STEP 14: Compare your drawing with the one to the left. If yours does not exactly match, you will need to go back and try again.

STEP 15: Save this drawing twice. Save the drawing to the A: Drive. Use your initials for the first save then select Save and use your partner’s initials for the second save.

Adding Text

When adding text to a project there are a number of things that need to be considered. What size font should be used? When the part is being machined, what is the shape and diameter of the cutter? How far apart should the letters be placed so they do not run together? How will I center the text on the part? What font (Gothic, Roman, Script, Italic, Bold) styles will work with the size of cutter and size of the letters?

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All of these items must be taken into consideration to manufacture a satisfactory part. The nameplate you are making measures 8 X 2.5” but the actual area you have for your text is 7.5 X 2” because of the .25” border. The cutter you will be using is 1/8” in diameter so it does not allow for a lot of fancy lettering like Old English.

For your nameplate you will use Times New Roman, Italic letters that are 1” tall. STEP 16: Click on Main Menu. STEP 17: Click on Create, Next Menu, Letters, Truetype. STEP 18: In the Fonts window that opened up select Times New

Roman, Italic, 72 point (Size) then click on OK. STEP 19: Type your name in the Letters box. STEP 20: In the Create Letters window, confirm that your name

is spelled correctly, Height is set to 1.0, Alignment is horizontal, and Spacing is set to .2. Then click on OK.

STEP 21: Select a point a half inch above the left hand corner of the large rectangle and click. This will position your text above the drawing of your nameplate so you can see how the text will fit. It is probably too large as it is in the example to the right.

Scaling One of the many advantages of the computer is its ability to scale or change the size of a drawing element without your having to delete and redo until you get the text to fit. To scale your text you will first have to identify it as a single element of your drawing.

STEP 22: Click on Main Menu. STEP 23: Click on Xform, Scale, Window, Inside. STEP 24: Click above and to the left of your text, next click below

and to the right of your text to create the window. Your text will turn white.

STEP 25: Click on Done, then Sketch. STEP 26: Click just below and to the left of the first letter in your

name. A scale window will open. Type .75 in the Scale Factor box. Click on OK. This will reduce your text by 25%. Press the Esc key on your keyboard and

click on Screen-Repaint. STEP 27: If it appears that your text will now fit on the nameplate

as the example on the right does, go on to the next section. If it is still too large repeat steps 22-25 and in the Scale Factor box enter .9. This will reduce the size an additional 10% and you can repeat this until your text fits. If you have a really long name you may have to shorten it by using only your first initial. If reducing your name made it too small, scale to 1.10. This will increase the size by 10%.

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Moving your Text STEP 28: Click on Main Menu to return to the root of the

menu structure. STEP 29: Click on Main Menu, Modify, Drag, Window,

Inside. Create a window around your name by clicking above and to the left of your name and below and to the right of your name.

STEP 30: Click on Done. STEP 31: A Drag window will open. Verify that Move and

Translate are selected and click on OK. STEP 32: Click on the first letter of your name and move it onto the workpiece, centering it as best you can, then click to place your name. STEP 33: If you have been successful your drawing will now be similar to the example at the left. STEP 34: Save your drawing to your floppy diskette. If time permits your partner should now work on their

nameplate.


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Day 5: Critical Writing – Narrative

Directions: While your partner is completing the test on the computer, you will complete the critical writing activity on a separate page supplied by the instructor. When you have both finished this activity, trade places. You will now complete the test on the computer and your partner will complete the critical writing activity. Critical Writing: The Training Director at the D & M Metal Fabrications plant was given your name as a resource. They are searching for consulting advice to develop a training program for their employees. The plant is in the process of updating the manually-operated metal machinery with CNC equipment. Their employees will need to be trained in the principles of CNC and how to operate the new equipment. You were listed as a possible consultant on the project because they were told you are currently learning about CNC principles and how to operate a CNC router. The Training Director wants your opinion on the direction of the training. Your job is to describe the steps you have taken in your own education and what has worked best for you in the learning process of the CNC machine. Paragraph One: Explain the principles of CNC and the capabilities of the equipment. What experience or background did you have before beginning the Computer Numerical Controlled module that helped prepare you to use the equipment? Paragraph Two: Describe the learning process you have gone through to understand CNC. Explain what areas you feel you need additional information on and what sequence of events your training has taken. RETURN TO THE PAXTON ActionLABS PROGRAM.

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CNC ROUTER

Day 6: Activity 1 Engraving the Name Plate

In this activity you and your partner will finish placing text on your name plates, convert the drawings to CNC code, and render the part to verify that it is ready for manufacturing. Materials Needed: Mastercam software Floppy diskette Procedure: Before you begin place your floppy diskette in the A: Drive. STEP 1: Minimize the Paxton ActionLABS program. STEP 2: Double-click on the Mastercam icon on the desktop

to launch the Mastercam program. STEP 3: Click on File, Get, and navigate to the A: Drive.

Load either your file or your partner’s file. STEP 4: Use the first part of this period to finish placing text

on your nameplates. STEP 5: When the drawings for both nameplates are finished

and saved, exit the Mastercam program. AFTER COMPLETING THIS ACTIVITY, CONTINUE TO

ACTIVITY 2 IN YOUR MODULE GUIDEBOOK.

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DAY 6

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Day 6: Activity 2

Engraving the Name Plate In this activity you and your partner will render your nameplates to verify they will machine properly and you will machine the part. Materials Needed: Mastercam software (2) 8” X 2.5” X .75” pine blocks Router Floppy diskette Shop Vac Procedure: Before you begin, place your floppy diskette in the A: Drive. STEP 1: Minimize the Paxton ActionLABS program. STEP 2: Click on the Mastercam icon on the desktop to

launch the Mastercam program. STEP 3: Click on File, Get, then navigate to the A: Drive, and

load either your or your partner’s file. STEP 4: Both nameplates should look similar to the example

to the right. STEP 5: Click on Main Menu, Toolpaths, Contour, and then

Window. STEP 6: Create your window by clicking above and to the left

of the filleted rectangle, then below and to the right of the filleted rectangle.

STEP 7: Click anywhere inside of the filleted rectangle and your name and the filleted rectangle will turn white.

STEP 8: Click on Done. STEP 9: In the Contour window that opens change Len. offset

to 0. Delete anything in the Tool name box and set the Feed rate to 10, Plunge rate to 2, Retract rate to 2, and the Tool dia to .125.

If they are not already there, place a checkmark in Home pos., T/C plane, Misc values, and Tool display. Compare your tool parameters window with the one on the right.

STEP 10: Click on the Contour parameters tab. STEP 11: In the Contour parameters window, set the

Clearance to .2 and select Absolute. Deselect Retract, set Feed plane to .2 and select Absolute. Top of stock must be 0.0 and Absolute selected.

Set Depth to -.1 (make sure to use the minus sign (-) in the Depth box) and select Absolute. Deselect Lead in/out and finally turn the Compensation type off.

continued…

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STEP 12: Compare your Contour parameters window to the example at the Left.

STEP 13: When your settings match the example, click on OK. STEP 14: Your drawing will come back to the surface with the

toolpaths drawn on your nameplate. You cannot really tell from this view how the finished product will look so the next step will be to verify the part.

STEP 15: From the main menu select Job Setup. STEP 16: Just like you did with your smiley face, click on the

Select origin button and click on the lower left hand corner of the large rectangle in your drawing. Next click on Select corners then click on the lower left hand

corner of the large rectangle. Click on the upper right hand corner of the large rectangle. Click on the red + in the middle of the gray square and drag it to the far left hand corner of the square. In the box below the Z

dimension of the square, type .75 and place a checkmark in the box next to Display stock. In the X, Y, and Z boxes below Stock Origin, verify that all re set to 0.0. If they are not, change them. In Post Processor,

make sure that MPTECHNO is selected. STEP 17: When your Job Setup window matches the example

to the left, click on OK. STEP 18: From the Main Menu, click on Operations. STEP 19: Click on Select All then Post. STEP 20: In the Post Processing window that opens, you need

only verify that MPTECHNO.PST is selected. Click on OK.

STEP 21: Mastercam will ask you to save your drawing. Save it to the A: drive.

STEP 22: A Programmer’s File Editor window will open showing you the G code program that was written for your nameplate. Click on the X at the upper

right hand corner of the window to close it. STEP 23: You should now be back to the Operations Manager

window. Click on Select All then click on Verify. STEP 24: You will now be in the simulation window. Click on

the Gview: button at the bottom of the Main Menu list. A new list of choices will appear at the top of the menu list. Click on Isometric.

STEP 25: Using the Screen-Fit and Screen-Unzoom .8 buttons, center your workpiece in the simulation window.

STEP 26: Click on the run button to simulate your nameplate.

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STEP 27: If you have followed all of the instructions correctly, your nameplate will resemble the example to the right.

STEP 28: Save your part to the A: Drive. STEP 29: Trade places with your partner and help him finish

his nameplate. TECH TIP: Mastercam has a habit of remembering settings for drawings. If your nameplate does not simulate properly it is easier to start the toolpath process over than trying to correct it. To do this, click on Main Menu, Toolpaths, new and repeat the toolpath process. STEP 30: Once both nameplates have been successfully

simulated, ask your instructor for two pieces of pine ¾” X 2 ½” X 8”. Exit the Mastercam software.

STEP 31: With the power to the router turned on, open the cover to the router and mount one of the blocks on the table of the router.

STEP 32: Close the cover. STEP 33: Launch the Techno GCODE Interface program by

clicking on the desktop icon. To load your program, click on the Translate/Execute button. A folder will open; navigate to the A: Drive. Select and open your file.

STEP 34: Click on the Jog button and allow a few seconds for the machine to initialize.

STEP 35: Using the left and right, up and down, and +/- buttons, jog the cutter to the front, left, top corner of the work piece. The cutter should just touch the top of the block.

STEP 36: In the jog window click on the Zero button then Zero all.

STEP 37: Exit jog and click on Preview. STEP 38: Signal your instructor to check your setup. STEP 39: Click on the Exit button. STEP 40: Click on Start to machine your part. STEP 41: Your partner will now repeat the setup and run their

nameplate. STEP 42: When both nameplates are done, exit the Techno

GCODE program. Then Locate the vacuum in the module and clean the

router.

continued…

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Conclusion In this activity you have taken skills that you have learned from earlier activities and added new skills to create a finished nameplate. You have learned to add text to a project as well as scale and move it. RETURN TO THE PAXTON ActionLABS

PROGRAM.

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Day 7: Activity 1/ Finishing the parts

Purpose: The purpose of this activity is to aquaint you with the final step in the manufacturing process, applying a finish to your parts. Materials needed: Paints Paint brush Sanding block Sandpaper Stain Paper towel Smiley Face project Nameplate project Procedure: STEP 1: If you or your partner have not finished machining both

projects, you will need to do this now. Return to the previous activity and resume where you left off at the end of the last class period.

STEP 2: Locate a sanding block and piece of sandpaper. STEP 3: Carefully sand the face and all four edges of both projects.

Take care to only sand with the grain of the wood especially on the face or engraved surfaces of your projects.

STEP 4: Find a used piece of sandpaper, fold it one time and carefully sand inside the features cut by the mill to remove any “fuzz” left by the cutter.

STEP 5: Select the color you wish to use to color the tool paths and a small paintbrush.

STEP 6: Carefully paint the tool paths on your project taking care to get as little paint on the surface as possible. It will not be possible to completely avoid getting paint on the surface. However, the less you get on the surface now, the less you have to sand off later.

STEP 7: While your first project is drying, finish sanding and start painting your second project.

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DAY 7

Rendering

Actual project after

painting but before

sanding


CNC ROUTER

STEP 8: After the paint is completely dry on the first project, sand off any paint that may have gotten on the surface of the project. The paint must be completely dry before you sand.

STEP 9: Locate the container of stain in your module and a paper towel.

STEP 10: Make sure the stain is well stirred then fold the paper towel and dip a corner of the towel in the stain.

STEP 11: Wipe the stain onto all surfaces of the project. Be careful not to use so much that it runs into the areas that you have painted. If you are not happy with your results, you can re-sand the piece and re-finish it.

STEP 12: Repeat the sanding and finishing process for the second project.

Conclusion: In this activity you have learned that the process of finishing a project is just as complex as the design and manufacturing.


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Finished project

Rendering


CNC ROUTER

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DAY 10

Day 10: Critical Writing – Persuasive

Directions: While your partner is completing the test on the computer, you will complete the critical writing activity on a separate page supplied by the instructor. When you have both finished with this activity, trade places. You will now complete the test on the computer and your partner will complete the critical writing activity. Critical Writing Your mother works for D & M Metal Fabrications. Her position is to design and manufacture all metal turning ordered from the plant. The plant is in the process of updating the manually-operated metal machinery with CNC equipment. Your mother wants your opinion on the CNC Router because the plant will soon be replacing her manually-operated machine. She is somewhat stressed about this change because she does not think she will be able to keep up with the orders coming into her department. Your job is to persuade your mother to accept the change while keeping her stress level to a minimum. Paragraph One: List the advantages and disadvantages of using manual equipment and then list the advantages and disadvantages in using CNC equipment. Justify each disadvantage in the CNC list to convince your mother the long-term benefits will prove beneficial to her career and stress level. Paragraph Two: Describe the advantages of using CNC equipment in terms of cost saving, mass production, accuracy, speed, and efficiency. Expand on each topic using research you have collected to support your argument.

continued...


CNC MILL

DAY 10

Narrative/Persuasive Pre-Writing to Writing Process Follow this process when writing your narrative or persuasive assignments. Prewriting: Plan your writing by thinking about the topic and your purpose. Are you explaining or arguing a point of view? A narrative piece requires you to describe in order. Persuasive writing requires you to first state your point of view, then tell why you think it is correct and present facts to support your opinion. 1. Identifying – Choose the main elements you wish to write about. There should not be more than three. 2. Drafting – Jot your ideas down in rough form. 3. Revising – Change and improve the rough draft. Get rid of unnecessary parts. Add important material based on your writing goal – to explain or defend. 4. Proofreading – Correct any errors in spelling, punctuation, and clarity. Care should be taken to make the writing communicate clearly. 5. Publishing – After final editing, finish the writing and make it available for others to read. Edit your piece one more time before you rewrite (publish it) for the audience to read. AFTER COMPLETING THE CRITICAL WRITING AND THE POST TEST,

FINISH YOUR DESIGN BRIEF.

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Design Brief #1 Introduction The Round Tu It Novelty Company is looking for a small company to make short runs of a trivet they plan to use for sales promotions. While simple in design it must be very precise and all must be exactly the same. The company considered making them out of plastic but found the cost of the mold prohibitive and the number of units they would have to purchase to be more than they could use. The wife of the company president thought wood trivets stained and finished would be very attractive and make a favorable impression on their clients. The only requirements for the trivet are that they be made of wood, 3 ½ X 3 ½ X ¾”, and that they be finished in a two tone color scheme. Your Task Your job is to determine how long it will take your employees to produce the trivets in batches of 50. You will also have to produce 2 prototype pieces in different color schemes to present to the president’s wife. You will need to determine how you will price the trivets for the Round Tu It Company. Take into consideration how long it will take to do the initial design work, machine 50 pieces, finish the pieces and the cost of the materials and labor. Materials In this design brief you and your partner will need the following materials:

CNC module, computer, and associated equipment

Mastercam 9 software

Techno GCODE Interface software

2 pieces ¾ x 3 ½ x 3 ½ pine

Router Historical Research You can use the Internet, books, magazines, hardware stores, and lumber companies to conduct research for the design brief. 1. What additional materials will your need to produce this part? 2. How can you determine the manufacturing costs and an appropriate profit margin? 3. Will additional equipment or supporting equipment need to be purchased to fill these orders? 4. How much does the pine stock cost? 5. Can you purchase pine in lengths that have one dimension already cut for you?

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Parameters The final presentation must include the following:

1. Two trivets manufactured out of wood and completely finished; 2. A cost analysis worksheet itemizing all of the costs; 3. A time analysis worksheet detailing the time commitment from the order to the client’s

receipt of the order; 4. A presentation illustrating the finished part and a manufacturing plan must be provided

to the client at the conclusion of this design brief. Evaluation You and your partner will be evaluated by the following criteria:

1. Appearance: Is the overall appearance of your product acceptable and of an appropriate quality for distribution?

2. Process and Planning: Did the team provide ample evidence of planning and preparation? (including rough sketches)

3. Cost Analysis: Did the team provide the client with a cost analysis worksheet detailing the time and material cost

involved in manufacturing the trivets? 4. Presentation: Did the team present and communicate the product in a professional

manner? 5. Historical Questions: Did the team provide adequate responses to the questions

outlined in the “historical research”?

V. 3.0

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copyright protected including but limited to student guidebooks, graphics, tests, rubrics, videos, and instructor and student orientations.

®

DB2

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