Aadpl CNC Manual 2010

AA Digital Prototyping Lab
CNC Machining Manual
AADPL CNC MANUAL
Contents
1. Important Health and Safety Warnings 2. Preparing Files 3. ARTCAM + Machining 3D Milling 4. ARTCAM + Machining 2D Cutting 5. Tips and Tricks (3) (8) (11) (42) (52)
AADPL CNC MANUAL
Important Health and Safety Warnings

1. Important Health and Safety Warnings 2. Preparing Files 3. ARTCAM + Machining 3D Milling 4. ARTCAM + Machining 2D Cutting 5. Tips and Tricks
AADPL CNC MANUAL

Improper use of the CNC machine can cause serious health risks and risk of damage to the machine. If you are using the CNC machine, you are responsible for the safety of all people and equipment affected by using the machine. Only persons with proper training and up-to-date knowledge of the safe operation procedures should use the CNC machine. You can only use the materials that have been designated as safe to use, as posted in the Digital Prototyping Lab.
AADPL CNC MANUAL

If you are in doubt about the safe and proper operation of the laser cutting machine you MUST ask for assistance before operating the machine.
Failure to operate the CNC machine in a safe and responsible way might result in serious consequences such as being held liable for damages and being banned from using the machine in the future.
AADPL CNC MANUAL
Preparing Files at Home

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Procedure
How to submit files to the DPL The CNC machines at the DPL are operated by the Digital Prototyping Lab staff. AA Students can submit 3D models for production in one of the machines at the lab between 10.00 am and 1.00 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 of the date and time your model will be finished, please be aware that there usually is a waiting time between 1 and 8 working days (in busy periods). Planning the size of your model The 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 length of the cutters. (*We have one cutter with a length of 75mm for use in the big CNC machine, with a diameter of 12 mm.) When considering sizes for a model produced in the big CNC machine it is advisable to work with the standard sheet sizes of high-density foam to avoid waste of material and high purchase cost: The high-density foam comes in sheets of 1500x500x50 mm. Other materials that can be used in the CNC machines are: MDF Plywood Bluefoam Other types of soft foam Cast-acrylic Modelling wax All materials except high-density foam need to supplied by the individual student or can be ordered through the DPL. In all cases when considering materials other than high-density foam it is strongly recommended to discuss your project with the DPL staff beforehand. In the DPL are also sample boxes of several different types and grades of medium and high-density foams available. Cost of Materials Two grades of high-density foam are usually kept in stock at the Digital Prototyping Lab (M300 and 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 block 500x400x50 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
AADPL CNC MANUAL
File Preparation
General file preparation To enable the translation and the preparation of your 3D model into ArtCam (the CNC toolpath preparation 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 be submitted 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 different cutters: 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 of the 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 contain intersecting 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 features undercuts these will not be machined.
A properly prepared file in Rhino

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Double-Sided Milling Models which feature complex geometries or openings can sometimes be produced by machining from a block of material from both sides. The digital files need to produced in a particular way so that the material can be rotated in the machine while keeping the model firmly 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 knife or a dremel, and the attachment points are then sanded to make the geometry look continuous. 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 all directions -Include a frame around the parts to be milled, with a minimum thickness of 20 mm and a height 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, height of 50 mm; -Place these bridges at regular intervals around all edges of the model, so that there is nowhere any 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 to intersect the geometries. (Leave a distance slightly smaller than the size of the intended drill bit in between the bridges and the part to allow easy cutting and finishing after the pieces have been milled.)
A file prepared for double-sided milling

2D Cutting The CNC machine can be used for various other operations such as 2D cutting, drilling, area clearing (like engraving) and text or pattern engraving. These operations can be performed on flat sheet materials such as plywood, MDF or acrylics, or in combination with 3D milling. For instance 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 accurate results. To prepare files for these procedures a 2D drawing is needed with a rectangle marking the outline 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 area engrave 7 mm down; - Each shape that will be cut or areas that will be engraved to a certain depth needs to be marked with a single, closed polyline (this needs to be CHECKED use the selectOpenCurves command 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 the edges of the sheet;
A file prepared for 2D cutting


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CNC Milling: General Setup

Understanding toolpath setup Setting up the toolpaths in a correct way is important to ensure there is no risk of damaging the 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, cutting speed, stepdown and stepover settings, depending on the type of material being used, the characteristics of the geometry and the finish quality that is appropriate.
screws in the sides border all around different methods of fixing a piece of material on the machine bed
blocks to hold the piece
Cutting tools There is a wide range of different cutting tools to choose from, with tools made in different diameters, shape design, cutting flute geometry and material properties. The most common types used in architectural prototpying are End Mills for roughing and 2D cutting 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 in total (given that a certain length needs to be used to fix the cutter into the spindle of the machine). The length of the cutting area within the tool determines how deep the material can be cut in one 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 is often 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 be set when using a rastering toolpath operation this is called the stepover. When rastering, the tool will move through the material in a zig-zag movement from left to right and back, stepping back a small distance each time the tool starts a new line. The maximum stepover distance cannot be greater than the diameter of the tool, and usually a percentage of the diameter is recommended to release the pressure on the drill.
General Setup
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Setting up a multi-pass toolpath In any CNC-milling project where the total cutting depth is more than the maximum stepdown value 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 a depth of 25 mm at one time.
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First pass of the 6 mm End Mill taking away the top 25 mm of material around the part that is being machined
Second pass of the 6 mm End Mill taking away any material between 25 and 50 mm (or less) of material, measuring from the top surface Finished part after it the boundary of material that had been left to secure the block in place while machining, has been cut off
Roughing and finishing toolpaths Some cutting tools are better at take material away quickly, while others are better to give the final part a highly detailed finish. Taking the first layers of material away, which is called roughing, 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 separate tool, depending on the shape characteristics of the part and depending on the detail size.
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Traditional setup of roughing toolpath, using a 6 mm End Mill and two passes of -25mm and -50 mm, and a 4 mm stepover
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Finishing toolpath setup using a V-Bit set to -50 mm maximum Z-depth and a 1 mm stepover
Time-saving setup using a roughing pass with the 6 mm End Mill for only the top 25 mm down; and a finishing pass to mill the last 15 mm away while doing the finishing (Geometry checked in relation to the maximum stepdown of the V-Bit)
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General Setup
Double-sided milling setup For projects which need milling from both sides the toolpath setup is similar to single-sided milling, but repeated for both top and bottom side. Depending on the desired level of detail and surface finish smoothness, either one or both surface 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 frame around the part as reference
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 AADPL CNC MANUAL 14
CNC Milling: ARTCAM Setup
When setting up a project for CNC Milling it is of crucial importance to relate the settings 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 the properties of the cutting tool need to correspond to the settings in ArtCam. Any discrepancies between these settings will result in errors which can cause damage to the workpiece and to the machine! It is important to prepare the setup of a CNC project using the following instructions in a CONCENTRATED and PRECISE manner. Double-check all the settings if necessary before starting the actual machining process.
Open ArtCam and start a new Project. From the File menu, choose New, Model
Input the size of the block of material that will be placed in the machine, in mm and oriented the same way as when standing in front of the machine
3D Milling: ARTCAM Setup
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An empty workspace will appear switch between 2D and 3D using the icon above the viewport
Use Relief and Import 3d Model from the menu to load a digital model Use the Center button to place the model on the workspace, use precise placement from one of the corners of the model if necessary
Use the scale input fields if necessary to match the dimensions of the digital model to the size of the material If necessary, unlink the Zsize to stretch the model to the maximum height of 50 mm.
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Use the Paste button to apply the digital model into the workspace If necessary, this can be done several times to create multiple copies of the same file in one workspace If the Paste function is used mistakenly, close this window and use Relief, Reset from the menu
Switch to 2D and use the Greyscale from Composite Relief button to create a snapshot of the model in topview
Use the Create Rectangle tool under Vector Tools to mark the area which will be machined Make sure this rectangle does not overlap with the area that will be used to place screws in the material for fixing it onto the bed of the machine Instead of a rectangle, circular or freeform shapes can be used
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Select the Toolpaths tab and choose the Machine Relief button under 3D Toolpaths to start the setup of the toolpath
Choose Selected Vector as the area to machine
Under Machine Safe Z type 25 mm at the fields for Safe Z and Z Home Position (This is the safe height which at with the cutting tool can travel around above the material)
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At the Tool section, use the Select button to access the ArtCam library with cutting tools For the initial milling procedure choose the End Mill 6 mm type cutter
Make sure the settings for the tool are exactly as shown here: Tool Units: Rate Units: mm m/min
Stepdown: 25 Stepover: 4 Spindle Speed: 15000 Feed Rate: 5.5 Plunge Rate: 2.5
Click Setup under Material to define the material thickness
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Make sure the following options are defined: Material Thickness: 50 (-or less, corresponding to the actual material) Top Offset: 0 (recommended to save milling time change to Bottom Offset if necessary) Material Z Zero: Top
Use the move cursor to hover over the different colored areas of the model in 2D view to check the cutting depths at the bottom of the window (Check whether the darkest color areas dont exceed the expected cutting depth)
Set the multi-pass settings for a roughing pass: Check the box for Do Multiple Z Passes ZHeight of First Pass: -25 ZHeight of Last Pass: -25
* To optimise cutting speed, the depth of the first pass could be set to half of the maximum cutting depth as found above (when using 2 passes with the same tool), or the maximum cutting depth of the part minus the maximum stepdown of the finishing tool (for instance 18 mm for the V-Bit)
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Choose an appropriate name for the cutting operation and click the Now button to start the generation of the toolpath
Visually check if the toolpath has been generated in the right area (inside the vector initially drawn) and if the depths seem in order. Choose Toolpaths and Save Toolpath as from the menu
In the dialog box, use the black arrow to copy the selected toolpath from the left to the right section
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From the dropdown list, choose Roland MDX500/650 (*.mdx) and save your file to an appropriate location
* For the big CNC machine in the AADPL, use CAMTech_CMC3 Toolchange MM (*.nc)
Save your ARTCAM project
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CNC Milling: Machine Setup

Place a block of material on the machine bed, after checking the bed is clean dust-free
Check if the measurements of the block correspond to the dimension set-up in the ARTCAM project
Carefully align the material with the marked outline of the maximum cutting area on the machine bed When using double-sided milling, this line is an important reference to ensure both halves of the milled part will match accurately
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Place 3 or 4 philipshead woodscrews (75 mm length) in the sides of the material to fix the block securely on the machine bed. See p. 12 for guidelines
Apply pressure on the back of the battery screwdriver to drive the screws into the material
Do not let the screw bit spin around in the screw head! This will result in damaged screws which might cause difficulties when removing the block
Check if the block is tightly fitted onto the bed if there is a gap, unscrew the screw a few centimeters, and screw back down
Make sure the area in which the screws are located matches the outline of the cutting area as it is defined in the ARTCAM project.
Screws placed inside the cutting area will result in the breaking of the cutting tool and other possible danger!
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Open the spindle cover to remove the cutting tool
Carefully place the long spanner on the top of the spindle, and place the short spanner on the nut Letting the long spanner rest against the large belt wheel, move the short spanner in a clockwise direction
Remove the cutting tool, the nut and the collet Clean the nut and collet on the outside and inside by blowing air and/or using a small brush Be careful when handling cutting tools as they might be very sharp!
Cutting Tool
Nut
Collet
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Place the collet in the nut by carefully hooking the collet into the concentric ring inside the nut
Screw the nut onto the spindle head by hand, fixing it loosely
Push the cutting tool into the collet, fixing the nut by hand so the tool doesnt fall out Make sure the length with which the cutter is placed into the collet is 5-6 mm miminum! Be careful when handling cutting tools as they might be very sharp!
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Using a tape measurer, check if the exposed length of the cutting corresponds to the maximum cutting depth as defined in the ARTCAM project
If the cutting tool is too short, the nut might run into the material or the screws, causing an emergency stop, and possible damage to the material and to the machine!
Carefully place the spanners and tighten the nut, moving the short spanner in counter-clockwise direction Make sure the nut is firmly tightened but do not use excessive force!
Close the spindle cover
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Using the handheld controller, position the tool at the machine origin: - press MENU - dial to MACHINE-XY - press ENTER
Move the tip of the cutting tool onto the FRONT-LEFT corner of the material, to set the user 0,0,0 point - Select [Return to Main] - press Z - dial to move the tool - press RATE to change the speed and accuracy - repeat for X and Y
Visually check if the centerline of the cutting tool is ACCURATELY placed at the edge of the material in X and Y direction Check if the end of the tool is placed directly on top of the material
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Check if the coordinate system is set to USER If not, press COORD SYSTEM Set the user 0,0,0 point to the current position of the tool: - press X - press/hold ORIGIN until a beep can be heard - repeat for Y and Z Failure to set the 0,0,0 point correctly will result in damage to the material or machine!
Carefully close the machine cover
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CNC Milling: Starting the Milling Process

Read the following section through BEFORE starting the machining operation! Start the VPanel application Click OK
The VPanel interface will appear This interfaces allows for moving the cutting tool around before cutting, setting the user origin point and adjusting certain values during the cutting process Most functions can also be performed using the handheld controller
1. At Overrides, dial the top value down to 30 %
2. Click on the Cut button 3. Click on the Open File button 4. Select the right toolpath file and click Open
4 3
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Click Apply and Output Make sure the machine is set-up correctly and safely, as this will start the machining process! Make sure the area around the machine is clear and proceed directly to the next step:
Keep your finger on the PAUSE button of the handheld controller in case anything seems to be going wrong As the machine is starting and moving towards the first cutting position, check visually if everything seems as planned in the ARTCAM file. - check if the cutting tool if not going to hit any screws - check if the cutting depth is not lower than expected - check if the pressure on the cutting tool is not too high If the first few passes of the cutting tool have been completed without any problems, CAREFULLY dial up the feedrate by pressing OVER RIDE until the indicator arrow is located at the line marked with XYZ Dial the feedrate up to 100% Make sure NOT to dial the override function up and down when the arrow is at the spindle speed S !! This can immediately destroy the cutting tool and the material!
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Stay with the machine at all times while it is in operation! If you need to leave the room, use Pause and Move. Move to View from the VPanel application to pause the milling operation Press the red emergency stop button at the front of the machine in case anything seems to be going wrong
Leave the handheld controller in a secure location
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CNC Milling: After the cutting has finished

Use MENU and >VIEW to move the machine bed into viewing position, at the front of the machine
Use a hoover to remove waste material on top and around the model Inspect the model and the machine including the cutting tool
CNC Milling: After the Cutting has Finished
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CNC Milling: Setting up the Finishing Path

In ARTCAM, hide the roughing toolpath by unchecking the name in the Toolpaths tab
Create a new Machine Relief type toolpath using the same vector as previously used to mark the cutting area The material thickness settings will still be the same as in the roughing toolpath Check if the Machine Safe values are still set to 25 mm for Safe Z and Home Z
At the tool selection choose under the V-Carving category the Small V-Bit 6 mm 90 degree Click Edit
3D Milling: Finishing Pass Setup
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Change the settings for the V-Bit as following: Rate Units: m/min
Included Angle: 20 Stepdown: 18 Stepover: 0.5 Spindle Speed: 15000 Feed Rate: 4.5 Plunge Rate: 2.5
By clicking on the tool name the settings can be slightly adjusted for this particular project The stepover can for instance be adjusted to set-up a balance between the desired quality and speed: Stepover value: 0.9 mm good fast 0.5 mm better slow 0.3 mm best very slow
Use the mouse cursor to read out the Z-depth values of the darkest/lowest areas using the 2D view Enter the maximum cutting depth needed in both input fields at the Do Multiple Z Passes section
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3D Milling: Finishing Pass Setup AADPL CNC MANUAL 35
Enter an appropriate name for the toolpath operation and generate the toolpath by clicking Now
Use Toolpaths, Save Toolpath as to save the toolpath to the desired location
Use a comprehensive filenaming format
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In the machine, open the spindle cover and use the spanners to loosen the nut and remove the cutting tool
Leaving the nut and collet in place, the finishing tool can be inserted by hand
* If other cutting tools such as a 3 mm End Mill are being used, it necessary to switch the collet
Check if the exposed length of the tool is correct in relation to the maximum cutting depth as set-up in ARTCAM Firmly tighten the nut without applying too much pressure Close the spindle cover
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Use the handheld controller to move the cutting tool to the USER-XY
Without changing the X and Y position, move the tool down so the tip of the cutter is just touching the top of the material Set the current position to 0 by pressing Z and pressing/holding ORIGIN until a beep can be heard
At the VPanel application, click on the Cut button Delete the previous toolpath file and open the finishing toolpath file Click Apply and Output when ready to start the machining process
1 3
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Using the VPanel screen or the handheld controller to start the machining at 30% speed OVER RIDE Check if the first passes are being machined properly
Dial the speed up to 100 200% while the finishing pass is being machined
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CNC Milling: After the cutting has finished

Similar to when the roughing pass finished: Use MENU and >VIEW to move the machine bed into viewing position, at the front of the machine
Use a hoover to remove waste material on top and around the model Inspect the model and the machine including the cutting tool
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CNC Milling: Cleaning Up

The following procedures are not optional but crucial for the proper maintenance and reliable working of the machine Remove the cutting tool
Hoover inside the machine cover to remove all waste material and dust around the CNC bed and from the machine itself
Hoover inside the spindle cover to remove any dust
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2D Cutting: ARTCAM Setup

Prepare files in Rhino using clean, closed polylines organised in separate layers depending on the intended toolpath operation Use a rectangle in the default layer to indicate the material that will be machined
Use Export Selected instead of Save as to make sure no other geomtries such as hidden lines, surfaces etc are being included in the file
Use the DXF format and the 2004 Natural file format setting
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Start a new project in ARTCAM using the dimensions of the material that will be machined
Use Vectors, Import from the menu to import the DXF drawing
* This menu option will only be available when the 2D view is active
Click OK
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Note that the drawing appears centered on the workspace, and the layers from the Rhino drawing have imported as well
Scoring Toolpath: Switch of the visibility for all layers except the one for scoring to enable easy selection of objects Select the linework that will be machined as scoring lines Choose the Machine Along Vector option from the Toolpaths tab
Enter the desired Finish Depth for instance 1 mm Select the V-Bit 6 mm 90 degree from the tools library and edit its specifications as on page 35 Specific parameters can be changed after the tool selection check the settings in relation to the material suggestions as on page 53 (In this example plywood is being used)
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Setup the material thickness as the real thickness of the piece that will be machined Choose Top Offset as 0.0
Choose a suitable name for the toolpath operation and click Now
Switch to the 3D view to visually check if the toolpath has been generated correctly
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Drilling toolpath: Lock the layers that have been processed and switch on the visibility for the layer named drilling Select all objects on the layer Choose the Drilling icon from the Toolpaths tab
Check the Finish Depth and select the cutting tool such as the 6 mm End Mill
Some parameters of the tool can be changed after selecting it: Change the plunge rate to the correct value considering the material that is being drilled (See p53) In this example for plywood: 1.5 m/min
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Enter a name for this toolpath operation and click Now
Switch to the 3D view to check whether the drilling toolpath has been generated correctly
Area Clear Toolpath: Lock the previously used layers and change the visibility for the Text layer Select only the text vectors For engraving areas using just their outlines select the Area Clear icon from the Toolpaths tab
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Enter the desired Finish Depth For areas with small detail such as text, choose the VBit cutting tool (For larger areas choose an End Mill type tool)
Set the stepover to a value slightly smaller than the diameter of the tool Choose between a Raster or Offset operation to calculate the toolpaths Click Now Zoom in to areas with small details to inspect whether the toolpath has been generated correctly
Outline Cutting Toolpath: Lock previously used layers and switch on the layer for Outline Cutting (Switch off the visibility of the finished toolpaths in 2D for easy selection of additional vectors) Select all applicable vectors and choose 2D Profiling from the Toolpaths tab
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Check the Finish Depth and select a cutting tool such as the End Mill 6 mm
After selecting the tool change the parameters for Stepdown and Feed Rate into the value applicable to the material being cut (See p53 for guidelines) In this example for 12 mm plywood: Stepdown 4 mm Feed Rate 2.5 m/min
* This means there will be 3 passes of 4 mm down towards cutting through the full 12 mm thickness
Choose a suitable name for the toolpath operation and click Now
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Save the toolpaths as described in the chapter 3D Milling Position the material and execute the cutting operations as described in the chapter CNC/3D Milling, making sure the locations of the screw fixing does not intersect with the areas in which will be machined
2D Cutting operations can produce loud noise levels or high frequency sounds! Do not continue with noisy operations in the CNC machine without proper ear protection equipment for both yourself and other people sharing the same space!
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Guidelines for Toolpath settings

Different materials and different cutting tools Each material should be used with specific maximum values for toolpath parameters. These values are indicative only! The operator of the CNC machine is at all times responsible for the safe operation including checking and if necessary adjusting the settings for the toolpath operations.
3D MILLING
Material Cutting tool Maximum stepdown (mm) 25 20 18 25 20 18 6 do not use 6 6 do not use 9 25 20 18 Maximum stepover (mm) 4 1.5 0.9 4 1 0.9 3 0.7 3 0.7 4 1 0.9 Maximum feedrate (m/min) 7.5 4.5 7.5 5.5 3.5 5.5 2.5 4.5 2.5 4.5 5.5 3.5 5.5
M-300 (yellow foam)
End Mill 6 mm End Mill 3 mm V-Bit 1 mm End Mill 6 mm End Mill 3 mm V-Bit 1 mm End Mill 6 mm End Mill 3 mm V-Bit 1 mm End Mill 6 mm* End Mill 3 mm V-Bit 1 mm End Mill 6 mm End Mill 3 mm V-Bit 1 mm
M-450 (pink foam) Plywood
Acrylic
MDF
2D CUTTING
Material Cutting tool (do not use End Mill 3 mm) End Mill 6 mm Maximum stepdown (mm) 25 25 6 6 15 Maximum stepover (mm) Maximum feedrate (m/min) 5.5 4.5 2.5 2.0 4.5
M-300 M-450 Plywood Acrylic MDF
DRILLING
Material M-300 M-450 Plywood Acrylic MDF
Tips and Tricks
Cutting tool End Mill 6 mm End Mill 3 mm End Mill 6 mm End Mill 3 mm
Plunge Rate (m/min) 2.5 2.5 1.5 1.0
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Tips and Tricks

Toolpath Simulation ArtCam 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. With a toolpath selected, click the Simulate Toolpath icon at the Toolpaths tab
Click OK and use the arrows to run the simulation at normal or maximum speed
After the simulation has finished, zoom in to inspect the surface quality in relation to the stepover values used
Tips and Tricks
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Tips and Tricks

These guidelines are for advanced users only up to date knowledge of the machine and/or ArtCam is required. Double-sided Milling Calibration Blocks 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 separate halves of the milling operation. Use the marked outline on the machine bed for reference in the Y direction. As the actual sizes of polyurethane blocks may vary, use the following procedure to calibrate the 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 Xdirection with the measured distance; - if the top groove is displaced towards the RIGHT, use Model, Set Position in ArtCam and input the measured distance at the X position as negative value. Regenerate the toolpaths. Projecting a line pattern or text onto a 3D milled surface Generate 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 and toolpath 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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55
Custom G-Code
These guidelines are for advanced users only up to date knowledge of the machine and/or ArtCam is required. Scripting G-Code Following 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;
switch on spindle speed rapid move speed go home (0,0 XY and maximum Z height) rapid move speed move to first coordinate at safeZ above milling trajectory plunge speed move straight down to cutting depth machining speed coordinates along trajectory of milling
plunge speed move straight up to safeZ above material rapid move speed go home (0,0,safeZ) switch off
All coordinates in the body of the G-Code should be within the maximum bounding box of the MDX-540: X,Y,Z = 50000,400000,5000
Tips and Tricks
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Copyright 2010 AA Digital Prototyping Lab
This manual is copyrighted and intended for use solely in the Architectural Association School of Architecture and the AA Digital Prototyping Lab. Nothing out of this manual can be reproduced in any form without permission. More information can be found at www.digitalfabrication.net First edition written in Feb2010 by Jeroen van Ameijde The writers and publishers accept no liability for damages occuring when using this manual. Example CNC model designed by Lydia Kim, Costanza Hageman and Joao Bravo da Costa as part of AA DRL Parametric Urbanism v.2.0, 2006/2008
Disclaimer
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AA Digital Prototyping Lab

CNC Machining Manual

AADPL CNC MANUAL

AADPL CNC MANUAL

Important Health and Safety Warnings

AADPL CNC MANUAL

Important Health and Safety Warnings

AADPL CNC MANUAL

Important Health and Safety Warnings

AADPL CNC MANUAL

Preparing Files at Home

AADPL CNC MANUAL

AADPL CNC MANUAL

A properly prepared file in Rhino

A file prepared for double-sided milling

A file prepared for 2D cutting

Preparing Files at Home

AADPL CNC MANUAL

CNC Milling: General Setup

blocks to hold the piece

AADPL CNC MANUAL

Roughing pass with a 6 mm End Mill

Finishing pass using a V-Bit

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

CNC Milling: ARTCAM Setup

3D Milling: ARTCAM Setup

AADPL CNC MANUAL

3D Milling: ARTCAM Setup

AADPL CNC MANUAL

3D Milling: ARTCAM Setup

AADPL CNC MANUAL

Choose Selected Vector as the area to machine

3D Milling: ARTCAM Setup

AADPL CNC MANUAL

Click Setup under Material to define the material thickness

3D Milling: ARTCAM Setup

AADPL CNC MANUAL

3D Milling: ARTCAM Setup

AADPL CNC MANUAL

3D Milling: ARTCAM Setup

AADPL CNC MANUAL

Save your ARTCAM project

3D Milling: ARTCAM Setup

AADPL CNC MANUAL

CNC Milling: Machine Setup

CNC Milling: Machine Setup

AADPL CNC MANUAL

CNC Milling: Machine Setup

AADPL CNC MANUAL

Open the spindle cover to remove the cutting tool

CNC Milling: Machine Setup

AADPL CNC MANUAL

CNC Milling: Machine Setup

AADPL CNC MANUAL

Close the spindle cover

CNC Milling: Machine Setup

AADPL CNC MANUAL

CNC Milling: Machine Setup

AADPL CNC MANUAL