Showing posts with label CNC Router. Show all posts
Showing posts with label CNC Router. Show all posts

Friday, June 28, 2013

Router Bits

Once you have your Industrial CNC Router running, you're ready to start thinking about your router bits. The Industrial CNC Machines use an ER-20 Spring collett (unless you have an Auto ToolChanger in which case you'll use BT-30's)


These collett's are available in a variety of Imperial and Metric sizes, which you'll match up with the shank of the bits you're using. If you're using a 1/4" collett, you'll need bits with a 1/4" shank.







For cutting, you'll most likely be using End Mill bits. They're similar in design to drill bits, except the have blades on the side to allow for horizontal cutting, rather than simply plunging up and down.  The two parts of the bit are the shank and the cutting area. Insert the shank only into the collett leaving the cutting area exposed.  For ideal results you'll want to use the shortest bit possible for the job as the longer it is the more tension is taken up by the bit and the more likely it is to snap.


There are many varieties of bits available, and specialized bits for any material you'll be cutting. For long bit life and the best cutting, you may want to consider some good carbide bits. In a pinch, the bits at your local Home Depot will work, but they won't last as long  or cut as cleanly. 

You'll find that there are many types of end mills available. The two main types are upcut and downcut. The upcut pulls waste out of the cut, while the downcut does the opposite. The downcut type leaves the top surface cleaner, while the downcut leaves the bottom cleaner. It should also be noted that the upcut endmill bit pulls up on your material so it's more important to have it held down securely.

For cutting wood, either can work, but for plastics and other materials you may want to go with an upcut to prevent wasted from melting into the path it left. There are also different flute patterns (single, double,  etc.) which are useful for better cleanup and finishes.

A straight end mill bit is useful for most cutting, but if you're planning to do any relief or 3D work, you can also consider a ball nose endmill bit. This is simply an endmill with a rounded tip, producing a smoother finish than the flat tip of the traditional endmill.



For finer detail, there are also engraving bits, which taper down to a point at the end, using different angles. These are great for text and very fine detail work, but keep in mind they're not designed for lots of straight cutting like end mill bits and they'll break easily if you ask too much of them.


Also popular is the V-Bit, which allows you to create a beveled effect of the edges of your cut without having to build it into your design. These are very useful for lettering and for borders. 



You may also want to fave a fly cutting/planing bit on hand if you have a lot of surfacing planned. This bit has a flat bottom designed for skimming the surface of your material. You can get them in very wide diameters, cutting down your work time, but again, it is not an endmill bit, and not for deep cutting.



Those are the basics. Of course there are many other specialty bits available, such as drag knife bit to allow your CNC to work like a vinyl plotter.

Here are some starting tips to help you get going (mostly for endmill bits)

1) Start out cutting the same depth as the diameter of your bit. (quarter in diameter, quarter inch deep.) As you get more comfortable, try cutting a little deeper. You should never cut more than 4x the diameter of your bit.

2) Make sure that you take the exposed length of your bit into account when cutting. For example, if your bit extends 2 inches from the collett, you cannot cut 2.5 inches deep.

3) Tighten the cap over the collett, after the bit is inserted. Make sure the collett is flush with the bottom of the cap.

4) Your bit should spin straight. If you see it wobbling when you turn on your spindle, it is not inserted correctly.

5) Consult your bit supplier's charts for recommended feedrate/RPM for diferent materials. Wood, Acrylic, Aluminum and other materials all have their own needs for ideal cuts.

6) Use the shorteset bit possible for the cut to decrease possible deflection.

7) Use the largest diameter bit possible to cut deeper and reduce work time.

8) Keep your bits clean after use to extend tool life.








Thursday, January 10, 2013

Reverse Axis Direction


If any axis on your Industrial CNC Router is moving the wrong way, changing direction is very simple. In Mach3 Go to CONFIG/HOMING/LIMITS and find the row for the axis you would like to change.

In the first column on the left, labelled REVERSED, simply check or uncheck the box, whatever is the opposite of the current setting.

That axis will now move the opposite way. See picture below:


Motor Tuning


For your Industrial CNC Router to cut accurately, the motors need to be tuned. Basically this means that every step sent from the computer to the machine needs to translate correctly to the units you measure with (inches or millimeters.) When motors are tuned properly the machine will cut the distance your job requires.

You will start out with your X and Y axis at around 2,000 steps per unit. And your Z axis at around 4,000 steps per unit. These are ballpark numbers, so some tuning is required. Fortunately Mach has an automated motor tuning feature that will make this easy. Go to the "SETTINGS" tab and you'll find it right over the RESET button.



Note: You will need either a digital movement gauge or a tape measure before going further.

Click on the SET STEPS PER UNIT button, and a pop up window will appear asking which axis you would like to calibrate.

Select an axis

Another window will then pop up asking how far you would like each axis to move.

Enter a number (inches)

Be advised that when you enter a number it will then move the spindle that distance (or what it thinks is that distance.) The longer the distance the more any inaccuracy will be noticeable, so use a large number but make sure the spindle is far enough to the the left or front that it can travel that distance.

As soon as the movement is done, another window will appear to ask you how far the machine actually moved.

Enter in the actual distance it moved. Make sure to add the diameter of your bit.

Mach will then suggest a number for your steps per unit. Accept it and Mach will automatically calibrate the axis to that setting.

You can also change the setting manually by going to Config/Motor Tuning



You can also change your travel speed here by adjusting the sliders on the bottom and right side of the chart.

Switching from Millimeters to Inches in Mach 3 Software

Here are the steps to switch from Millimeters to Inches using Mach 3 Software for your Industrial CNC Router.

1) Switch from "Program Run" tab to the "Settings" tab. Select "Inch" by pushing the "Units" button,



2) Return to the "Program Run" tab and select "Config" from the title bar, and then "Select Native Units" from the drop down menu. 


3) A warning box will come up, click "OK" 


4) Another box will appear. Select "Inches"

5) Go to "Config/Motor Tuning" and verify that X, Y, and Z are tuned for Inches.

Friday, November 9, 2012

Sending CAD files to your CNC Router


If you're using a design program already, such as Corel, Adobe, Autocad, TurboCad, etc., you can generate designs, but can't save your files as g-code, the only language your Mach 3 Software understands to control your Industrial CNC Router.

In order to turn your files into g-code you need what's called a "post processor" a program from which you can take your Vector file, add cutting information (feedrate, cut depth, etc.) and then convert it to G-Code which the Mach 3 software understands.

I typically recommend Vectric Software for this. You can find them at http://www.vectric.com. They have user friendly programs for many purposes, with capabilities from simple cutting operations, all the way up to complex 3D designing. Vectric Cut 2D is a simple and powerful program and a perfect way to get started. Once you've mastered it, you can always upgrade to their top of the line programs, V-Carve Pro and Aspire. If you have a CAD/CAM background already you may want to start with at least V-Carve Pro.

Step by step:

1)From your design program, (Adobe, Corel, etc.) export your file as a .dxf file. (you can also use other file formats such as .eps and .ai. Be advised that using other types of files may not open up in the Vectric software.) Make sure to save the file somewhere you'll remember, like on a thumb drive.

2)Open the Vectric program and open the .dxf file into Cut2D.

3)Using the "Tooling" Menu on the Right Hand Side of the screen, add cutting information (depth, tool diameter etc.)

4)Save as a g-code file by clicking the floppy disk icon. Make sure to Select  "Mach 3 Arcs/Inch" Save the g-code (it'll be a .txt file) to your thumb drive.

5)Open the G-code .txt file in Mach 3

You are now ready to cut the file in Mach 3.