Week 7

Testing Joints

Before making something I need testing the joints, we will use differents tolerances to see how this affects the stability and the dimentions and joints that will be usefull to build without glue or nails.

Knowing the machine

First of all this machine is known as a 2 1/2 axis machine, because it can make operations at differents depth, but it can't interpolate lines or curves on the Z axis planes, because of this the results of Z axis operations will be stepped.

Routers use a tool named Milling Cutter, they seems like drills, but they are a little different; thanks to this milling cutters can make operations in differents directions and details.

Generating G-Code

First of all we modified the vectors on Adobe Illustrator, here we can change parameters like male and female plugs dimensions

Open ArtCam and create a new file

Define the origin of the piece and the material's dimensions

Import the vector file and place them on the canvas how do you want to cut them

Select the thinning vector path and define the parameters like depth, vertical feed and tool

Then select the cutting vector path and define parameters like depth, tool and if you want bridges

Now you can simulate the paths and validate if all the parameters are ok, if not you can modify

If everything is alright you have to save the path, in this step you can change the execution order

Cutting process

After all we need to fix the material

Calibrate the router, moving X and Y axis to the origin that you have defined on ArtCam

When you are on the origin press the X0 and Y0 buttom on the router manual control

To calibrate Z axis we need to place a sensor under the tool and press the Z0 button to start the autocalibration process

Run the program from the software

Try and failure

On this part we decided to test how the joint's tolerance affects on the assembly process. We tested on vertical and horizontal joints.

For vertical joints we made 3 tests, with tolerances of 0mm, 0.3mm and 1mm. Only the last one fits.

For horizontal joints we made 2 tests, with tolerances of 0mm and 0.3mm. Only the last one fits.

Finally we made a last vertical test but with another kind of joint and with a tolerance of 0.65mm, the difference between this one and the one with 1mm, is that the 1mm fits looser than the other, so it feels a little less stable.