Embedded Files
Objectives For This Project:
Understand what milling machines are and what they are used for
Learn the difference types of milling machines that exist and how they can be used in engineering
Become fluent with using design software for milling machines and Bantam software (for running the machines)
Different Types of Milling Machines & Abbreviations:
Lathes: Rotates a workpiece around an axis
Milling: Uses rotary cutters to remove material
3D Printers: Layered additive manufacturing
Routers: A power tool with a rotating blade
Plasma Cutters: Ionized gas to cut materials
CNC: Computer Numerical Control
CAD: Computer Aided Design
CAM: Computer Aided Manufacturing
DNC: Direct Numeric Controls
MDC: Manufacturing Data Collection
OEE: Overall Equipment Effectiveness
Project Overview:
On the dog tag section, we reviewed the process of using Corel Draw, like in Thinking Out of the Box. Like in the other unit, we also reviewed converting text to curves, vector vs. raster lines, and exporting the design. Using the small milling machine was also a review from Current Affairs. The dog tag printing process also called for a workflow, another skill that was readdressed. The chocolate mold designing process was where we were introduced to new material. In the past, such as in Plane and Simple and our Fusion 360 Deep Dives, we had only worked in the Design workspace of Fusion 360, and never the Manufacturing. This time, in the Manufacturing workspace we learned how to create a toolpath using the 3D Pocket (and Adaptive Clearing) and how to run a simulation of it. This project also brought the larger milling machine into our repertoire. For the package design, we again were brought back to Corel Draw. This time around, the focus was more on vector vs. raster lines. For this section, we reviewed how to use the large laser cutting machine and how to import the design into it and prepare the machine for cutting.
↪ Dog Tag Outline
↪ Original Dog Tag design
↪Final Dog Tag design
In order to create the final dog tag design, I needed to use the Text Tool. After I typed in "Biscuit" I rotated the text by 90° by inputting 90 next to the ↺ symbol. Text needs to be converted to curves, so I did that by going into
Objects ↪ Convert to Curves (Ctrl+Q)
I then went online to choose a clip art I liked, and ran it through remove.bg. I copied and pasted the image into my design. The image needed to be vector, so I went into
Trace Bitmap ↪ Outline Trace ↪ Detailed Logo
IMG_0521.mov↪ Printing gone wrong
Problems I Encountered:
The issues I had in the design section of the process was fine design lines. Thus, I had to change the font into one that had fewer fine lines. I also had to change my biscuit images to different ones which also had fewer fine lines.
In the printing process, I made a placement mistake (as seen to the left) where, had the printing continued, the text would have gone over the keychain hole. I noticed that and stopped the milling process. To fix this, I had to go back into the printing settings and adjust the x-position of my design. To the right, I have my final, successful print.
IMG_0523.MOV↪ Printing gone right
Workflow:
Acquire the 80° bit and nitto tape
Turn on the milling machine
Open the Bantam software
Go into change in the upper right corner and change the bit
Using the wrenches, loosen the opening
Inset the bit and tighten the opening (first manually and then with the wrenches)
Click locate tool and the tool will lower to the point it touches the spill board
Measure the dimensions of the dog tag
Input these values for Material Size (width X height Y Thickness Z)
Attach double sided tape to one side of the dog tag
Measure the thickness of the tape
Enter that value as Z for Material Placement
Place the dog tag on the bottom left corner of the landing Pad
Click "Rehome" on the software
Ensure the design placement aligns with where the actual tag is by adjusting X and Y settings as needed
Ensure "Engrave" is selected
Click "Start Milling" to begin the milling process
Afterwards, use a tool to scrape the dog tag and tape off
Clean the dog tag (with a paper towel) and the machine (with a vacuum)
Chocolate Mold Designing:
For this section I used the 3D pocket in the Manufacturing workspace of Fusion 360. First, we set the origin point to be the upper left corner of the box. Then, we set up the tool library, which we had to download into the database. The bit used was the 1/8 Ball End bit. After that, we finished the toolpath with the 3D pocket clearing.
↪ Original hand-drawn design
↪ Fusion 360 design
IMG_0710.mov↪ Simulation video of the toolpath
IMG_0693.MOV↪ Video of milling the wax mold
Problems I Encountered:
At first, we used the 3D Adaptive Clearing as outlined in the tutorial site. When we did the toolpath this way, the simulation was acting above the topmost plane. Then we used the 2D Pocket, which went into the wax block, but it was not saving properly. Finally we did the 3D Pocket which gave use both the correct simulation and was able to be saved as .gcode. However, when milling the block, the projected time it would take to finish was around 6 hours. This was because of the depth of our design. As seen in the time lapse video, the real time we were able to print was only 19 minutes.
Software Difference:
This software was different because we had to input the dimensions of wax block and didn't need the Z value as while milling the dog tag.
↪ Final wax mold
Package Design:
↪ Hand-drawn design
↪ CorelDraw design outline
↪ CorelDraw final design (with the logo)
Package Laser Cutting:
IMG_0347.MOV↪ Video of laser cutting our design
↪ Final put together package
↪ Our mold in our packaging
Overall Problems Encountered:
The first time we laser cutted our design, the vector lines did not go deep enough, and we could not remove it from the sheet. That was when our power setting was set to 50, and when we re-cut our design, we changed that value to 70, and it cut more cleanly.
More pressingly, our design did not finish getting cut. It was because we placed our design too low, and the machine could not go further and had to stop. On our second try, we moved our design to the middle of the machine, to ensure boundary issues did not occur again.
IMG_0345.mov↪ Video of the laser cutting issue
↪ The unfinished packaging
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