Composites

Assignment

This assignment I decide to experiment with the strong material , and the work with the composites, Due the flexibility of the materials.

Testing Model in Rhino

We did a Simple model in rhino transforming the surfaces in a mesh > Export > STL data > Binary System

Conda Cam

Open the model pressing the option (model Laden)

Make model visible

Sometimes when you open the model you see only the lines going to Ansicht > Ausblenden > Model you can activate the view of your model.

Rough Milling

Z ebenen Schuppen, you can give the settings for the first can begin from the black point that you localize in the top part of the model, you can see that the model is contain in a block in the block, which is your material. You have to place your model in the machine. If you set the 0 point in the top of part of the model you have to set the Z 0 of your machine in the top part of your material !! don't forget it!

Milling Parameters

Fräsparameter in this panel you can play with the precision of the rough cut, extracting your material quickier, (if dependes with which material are you using for milling.)

Abstand: is the meassure between the each pass, that means that each pass is around5 mm, if this is wood or metal you can consider a less distance, in order to avoid damages in the bit (middle of the bit diameter.)

Offset

Annährungshöhe ist the distance between the material, that the bit taketo go to the other pass, in this occasion we use a small distance in between of 5 mm, in case of milling and other material to avoid some damages please increase this distance.

(for this traces the machine moves 1000 rpm, it is slow, it means if you have a big distance it will takes more time to mill the hold piece )

Vorschub / Speed and Feed rate

You can change the settings for both jobs to have better results (faster , finer,) but you can work with the same settings

Spindeldralzahl: spindle speed

Arbeitsvorschaub: the speed when the tool is doing the passes in the material

Anfahrvorschaub: speed, when the tool going inside in the material

Tool panel

in this panel you can select one of the bit that we have in our Fab Lab. In case that you change your bit You have to set the new parameters.

You can select which kind of bit you are using that depend which job are you doing, (cutting, engraving, pocket, finishing, etc).

Durchmesser: diameter

Auskraglänge: projection length. the length between the coil and the end of the tool.

Scheidenlänge: sheath length. Is the length of the spiral of your tool

Werkzeug Nr: If your machine can not change the tools automatically and has only one tool please select the tool "0".

if your machine can change the tool automatically , please verify it in your machine- which number is the tool that you want to use.

Fine Cut

Komplettschichten: milling the rest of material

number of the number of the bit

Milling parameters

For a smooth surface you can select around 0.02 mm to have an extremely soft surface

Offset 2

In this window you have a second offset that work for right lines

Milling Layers

Bereicheingrenzung: reduce the area of milling, to decrease the time of the job , and to work with short tools, you can use this option.

Tool

Verify and select the right tool number if your machine has multiple tools.

Almost ready to mill.

At this moment we have 2 jobs the rough and the fine milling jobs. please check both jobs. in order to generate the G code in the postprocessor.

Post Processor

Select the Postprocessor ausgabe, afterward you will see window with to option

Driver: 1. select the driver for the postprocessor for our machine e(sign easy master pro, which is MasterPro ATC_3D. 2

Select the partition that you can save your data and the name it

G-code ready

After the Postprocessor generates the G-code, you can proceed to simulate the milling process with the play function in the top of the window right.

Simulating the process

Diameter

Meshmixer

For smooth your model you can press the option Select and transform your model a little bit.the idea is not damage the anatomy of the hand , only to smooth the edges.

To cut the hand in a right edge you can use the “Plane Cut”.

Symulating the process

for cutting the hand in a right edge you can use the  > Plane Cut

Offset

In case of doing a negative form you can generate an offset expanding the dole homogeneously.

you can see that there is overlapping of forms. that will be difficult to reparet.

Rhino

Rough Cut

1,5 mm between the pases.

Fine Cut

0,02 precision

Detail hand

.

Protecting the hand with "holzheim"

Holzheim: product for paste wood !, it was not enough you have to be careful that the product is homogeneously spread in the model, otherwise will take years to be dry.

Protecting it wih

Because the Resins that we use could react in contact of the water. also you can apply a little bit vaseline or oil for separating the resin with the alufolie

Components for casting

Both components are Polyurethane - casting resins flexible, it take like a 30 min to solidify the material

For Component A and B you can use 50% to 50%. for more information you can see the Datasheet 

Making the positive

As we see the model have some problems due to the position and anglen of cutting, it makes ta that the am is deep but in the fingers there are less material.

After solidifiing

Positive and negative

The Polyurethane made a wire surface, destroying the cnc Model. :( , some reflection I have a "killing insects Tool!"

I decided to do a new model that illustrate more the form of a orthotics.