Alrighty, get ready for a long one...
I decided to take a break from the research project parts machining to do something fun. Went to the shop this weekend and made three neato perches for the finches. Ever since Charlie picked out his favorite spot on top of the kitchen cabinets, I decided I needed to create some custom perches for them. I am using paper towels up on top of the cabinets currently, but now instead, I can just stick one of these perches up there for him to sit comfortably and to catch all the mess. Then just rinse it off in the sink. Below is a series of pictures documenting the construction process.
1. I started by simply cutting out the shape I had in mind from paper just to get the approximate size I wanted for the perches. I then bent the paper where I wanted the folds. Again, this was just to see the approximate size first.
2. I then modeled similar dimensions in CAD (Computer Aided Design) using SolidWorks. This created the necessary STEP files to import into the CAM (Computer Aided Machining) software. I then programmed the CAM files using MasterCAM. This is what tells the machine where the part is in 3D space inside the machine, what tools to use, what RPM, when to use coolant, what paths the tools should cut etc. Essentially its the code telling the machine how to cut out the part. Lastly, I simulated the part machining process. This is an important step as it shows if I made any programming mistakes both with regards to the part and the machine. Its unfortunately possible to heavily damage the machine if you tell it cut in the wrong place or preform the wrong motion. These are SCARY powerful machines...
3. Once everything is coded, the machine has to be setup. All the tools are set and loaded into the machine and then the tools are precision probed inside the machine so the machine knows exactly where the tool is.
4. The machine also needs to know where the part (blank) is in the machine. We use ruby tipped probes that precision touch surfaces in the machine so it knows exactly where the part is in 3D space (X, Y, Z). This probe is grown molecule by molecule making its dimensions precisely controlled/known. Here I am probing the X coordinate in the first picture. In the second picture I am probing the Z coordinate using a precision block of known height. This is after I have cut custom jaw slots into the machine (The aluminum bars that are clamping on the block I am measuring). These are sacrificial jaws that are there to be intentionally or unintentionally cut into without permanently damaging the machine.
5. Once the machine is setup we can start machining parts. The first part we have to machine though is a fixture to hold the acrylic (Whole process is lengthy as you can tell). This is a half inch aluminum plate with holes drilled and tapped in it to hold down the acrylic blank while cutting.
6. Now that the fixture is made, after a few more adjustments (not pictured) an acrylic blank can be temporarily clamped to the fixture and the first part of the program run. This first part simply drills holes in the acrylic that align with the holes on the fixture so the acrylic can be bolted down in preparation for the rest of the program. Once bolted down, the clamps are removed and the acrylic is machined the rest of the way now that it is secured.
7. While the part was machining I snapped a few pics of the machine too. Here is the control console, HAAS VF2, and the row of all our VF2's. We also have a SMM, VF3 (BIGGER version of VF2), and a 5 axis for really complex stuff.
8. Once the part is finished machining, it is blown off to clear away any chips and all the machine coolant, and then unbolted. Now the part is still technically attached to the stock at this point. This is a method of machining where small "tabs" are left which are easily cut through and touched up by hand. For non precision parts, this is a great method and perfect for this application.
9. Here are the first looks at the part fresh out of the machine with the protective paper removed and the tabs cut and cleaned up with a file and steel wool.
10. I ended up cutting out three of these. One of each color. Blue, Green, and what the manufacture calls "Red" haha. The best part is, they are all florescent. The blue needs some encouragement from a UV lamp, but the green and red do just fine under regular light.
Max number of pictures added. Posting this first part now with an immediate followup. Stay tuned...
I decided to take a break from the research project parts machining to do something fun. Went to the shop this weekend and made three neato perches for the finches. Ever since Charlie picked out his favorite spot on top of the kitchen cabinets, I decided I needed to create some custom perches for them. I am using paper towels up on top of the cabinets currently, but now instead, I can just stick one of these perches up there for him to sit comfortably and to catch all the mess. Then just rinse it off in the sink. Below is a series of pictures documenting the construction process.
1. I started by simply cutting out the shape I had in mind from paper just to get the approximate size I wanted for the perches. I then bent the paper where I wanted the folds. Again, this was just to see the approximate size first.
2. I then modeled similar dimensions in CAD (Computer Aided Design) using SolidWorks. This created the necessary STEP files to import into the CAM (Computer Aided Machining) software. I then programmed the CAM files using MasterCAM. This is what tells the machine where the part is in 3D space inside the machine, what tools to use, what RPM, when to use coolant, what paths the tools should cut etc. Essentially its the code telling the machine how to cut out the part. Lastly, I simulated the part machining process. This is an important step as it shows if I made any programming mistakes both with regards to the part and the machine. Its unfortunately possible to heavily damage the machine if you tell it cut in the wrong place or preform the wrong motion. These are SCARY powerful machines...
3. Once everything is coded, the machine has to be setup. All the tools are set and loaded into the machine and then the tools are precision probed inside the machine so the machine knows exactly where the tool is.
4. The machine also needs to know where the part (blank) is in the machine. We use ruby tipped probes that precision touch surfaces in the machine so it knows exactly where the part is in 3D space (X, Y, Z). This probe is grown molecule by molecule making its dimensions precisely controlled/known. Here I am probing the X coordinate in the first picture. In the second picture I am probing the Z coordinate using a precision block of known height. This is after I have cut custom jaw slots into the machine (The aluminum bars that are clamping on the block I am measuring). These are sacrificial jaws that are there to be intentionally or unintentionally cut into without permanently damaging the machine.
5. Once the machine is setup we can start machining parts. The first part we have to machine though is a fixture to hold the acrylic (Whole process is lengthy as you can tell). This is a half inch aluminum plate with holes drilled and tapped in it to hold down the acrylic blank while cutting.
6. Now that the fixture is made, after a few more adjustments (not pictured) an acrylic blank can be temporarily clamped to the fixture and the first part of the program run. This first part simply drills holes in the acrylic that align with the holes on the fixture so the acrylic can be bolted down in preparation for the rest of the program. Once bolted down, the clamps are removed and the acrylic is machined the rest of the way now that it is secured.
7. While the part was machining I snapped a few pics of the machine too. Here is the control console, HAAS VF2, and the row of all our VF2's. We also have a SMM, VF3 (BIGGER version of VF2), and a 5 axis for really complex stuff.
8. Once the part is finished machining, it is blown off to clear away any chips and all the machine coolant, and then unbolted. Now the part is still technically attached to the stock at this point. This is a method of machining where small "tabs" are left which are easily cut through and touched up by hand. For non precision parts, this is a great method and perfect for this application.
9. Here are the first looks at the part fresh out of the machine with the protective paper removed and the tabs cut and cleaned up with a file and steel wool.
10. I ended up cutting out three of these. One of each color. Blue, Green, and what the manufacture calls "Red" haha. The best part is, they are all florescent. The blue needs some encouragement from a UV lamp, but the green and red do just fine under regular light.
Max number of pictures added. Posting this first part now with an immediate followup. Stay tuned...
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