7. CNC-Machine¶
This week I worked on defining my final project idea and started to getting used to the documentation process.
CNC Machine Bed¶
The goal is to create a design suitable for CNC machine use. The difference between the laser cutter and CNC machine is the bed size were laser machine width is less than 900 mm. For bigger design such as furniture it is more suitable to use CNC for efficient results.
Creating design
Thinking process¶
First Idea¶
I wanted to create something artistic and a décor piece were you can present it in my living room. Visit
Second Idea¶
Then I changed my mind and decided to create a parametric seat for kids. Visit
When I saw the video I think that I want to more original work so I remembered that in winter my shoe wears increases comparing to summer so my shoe rack is not enough to carry more than 12 shoes and I have in total 22 shoe wear. Therefore I decided to create parametric shoe rach design according to your bed-work.
Rough Idea (Inspired by Ikea)¶
Main Components 2 Side panel (same design) Shoe rack design 1 (150 mm height and light due to pattern cut) Shoe rack design 1 (Solid no patter, heavier for larger shoes because there is no height limit)
To make the wood lighter some pattern cut need to be placed according to the length of the rack. The width of the rack I kept is fixed as recommended (300 mm).
When I saw a video I said whet if I make the joint in patter were I have different spaces between the rack minimum of 100mm (suitable for kids shoe) and 2nd option 210 mm (suitable for adults shoe wear such as sneakers and high-heel)
Using Fusion 360¶
Design Set-up¶
Create the bed sheet¶
Create component (Layout and Assembly) to have different configuration of your design
Side Panel¶
Activate Layout by clicking on the circle
Sketch Design Parts components
Create a sketch in Desired Plane
Create border using Square construction Line
Create Parameter for width and Length of the Shoe panel
Joint-test From testing and my desired design is to make theses joint easily put together and removed without excessive force and at the same time they are stable.
The best fit was less by 0.1 mm in height and width (39.9 in width + 11.9 in thickness)
Create Desired Shape¶
Width (50mm) not parametric only the leg height
For the joint holes place them in desired place and constraint them with fixed dimension using the construction lines.
Extrude 1¶
All body including hole
Extrude 2¶
holes cut but not all through create 3 mm wall (9 mm pocket for 12mm material thickness)
Creating Pattern + Parameters using logic and fusion 360 help built in functions
Chose feature<click on holes ‘extrude 2’ < Axis use Y-axis < Distance and Quantity use parameters
Fillet¶
To create smooth angle surface in the corners
Move and Copy¶
Modify<Move and copy < use setting above to create 2nd component (tick create a copy)
Create Shoe Rack¶
Use construction Line To create intersection Line and create parameters Using combination of fixed values and parametric values is essential to ensure that there is no error in the design, such as width of panel can be fixed to 300 mm and the space between the border and the cut through rectangular cut should be fixed to prevent intersection (25 mm from all sides)
Extrude 1¶
Extrude 2¶
Holes cut all through (12mm material thickness) Create a Pattern for the Hole + Parameters
Adjusting distance is essential to ensure there is no wrong placed cut.
Move and Copy¶
Do it multiple times to create rack 2 , rack 3 and rack 4. Modify<Move and copy < use setting above to create 2nd component (tick create a copy)
Check Bedwork + Layout
Assembly
Activate ‘Assemble:1
Move and Copy
Create a copy of each in the assembly make any changes in position while using joint doesn’t affect the component position in the layout. Move all required component to a different place to assemble them.
Joint
Choose first component joint face
Choose second component joint face
Positioning
Fix position by holding the blue circle to adjust the rotational angle
Assembly
Other components Joint They follow the same exact procedure after finishing this will be the final assembly
Parametric
These are the design adjustable parameters (above parameters used for final assembly)
Another Versions Larger version with thinner material thickness (10 mm)
Smaller version with thicker material (18 mm)
Larger Joint width is needed to support heavier material
CNC-Machine Process
Adjusting the work material
Unscrew the board
Keep the screw for later
Place new MDF wood boar (12mm in thickness above the scrap board)
Screw back the board
CNC- computer program setting
Bed work setup¶
Draw the offset in the bedword
Offset setting by 20 mm
Width and height of the bed work (2440mm X 1220 mm)
Open file¶
Import vector
Open the desired file and drag it to bed work
Tabs¶
Adding taps to put the cut in place while cutting
Placement of taps
Cut depth¶
To ensure that cut is all through we put the depth of cut equal to material thickness + 1 mm. Moreover, this message appears to ensure that there a scrap board beneath to prevent damage.
Toolpath function¶
Create path
Using built in function use ‘pocket toolpath’
Create a pocket of depth 9 mm (3 mm wall)
Closer look of toolpath
Check the order of toolpath list
Add dog-bone fillet for easier fit
Error – drill bit example¶
Error we select the wrong drill mill diameter 8mm instead of 6mm diameter drill bit.
We choose the correct drill bit
Final Shape¶
Final shape before cut including the path of cut
Save¶
File>Save>Save to ‘all’
Important instruction¶
electrical current
Check if the machine electrical current is responsive
Safety + work instruction¶
Wear glasses Wear long sleeves, pant and shoes Stay 1 meter at least from the machine Click ‘red button’ in case of any disfunction.
Check XYZ¶
Use Fablab recommendation
Cutting¶
Start¶
Results¶
Cutting result (break the taps using file tip)
Check fit¶
The fit was good (I forget to take picture because I rush into finishing process)
Finishing Processes¶
Filing¶
filing the tabs to create flat edges
Sanding¶
Sanding is a processed to creates pores in the material to get a better paint finish.
For the side panels I used different grade to see the difference I used 800 CW first and it wasn’t sufficient therefore I used a rougher grade 100 CW
For the rack I want a smooth finish so I used 800 CW
Applying Primar¶
Coating first after painting for 1 hour for the primary to dry I realized that I use too much primar for the first side panel
There is some imperfections in coating I flipped it and did the same process again
I used 100 CW to remove excess coating of the heavy sprayed side panel and 800 CW for the other side
Coloring¶
I used 1 can of 400 ml spray paint and it wasn’t enough to cover all the required area
I went back to the work shop to find a suitable color to use. I decided to use ‘chrome’ spray paint and add star effect to the side panel
I bought 2 400 ml black spray paint to cover the back side and added the same effect using chrome spray paint’
The sides were bit challenging in coloring so I decided to cover it with electrical tape (black tape) other option is to sand sand from the colors and make as neat as possible by showing the mdf wood texture.
Assembly
Using a soft head hammer helped a lot in installation + Help from my colleague Ammar
Self-Review¶
The final shape is good for my first time but there is some improvement I should work know such as using a clear coat after final paint and try to color the sides for better general shape. The fit is great but I should find a way to make it more rigid.
Add new component¶
As my classmate Ammar suggested that designing support to maintain stability is essential