New update video from WASP team on their multifunctional 3d printer which shows full overview of various features including wood, PCB and aluminium milling.
http://www.wasproject.it/
http://www.wasproject.it/
Showing posts with label Milling. Show all posts
Showing posts with label Milling. Show all posts
The FreeD handheld 3d manufacturing device
Innovative handheld 3d milling device. It is held in hand and computer controlled to stop when it reaches the outlines of the 3d object. It looks that the handheld 3d printer is also in making.
Update:
http://diy3dprinting.blogspot.com/2013/11/update-video-on-freed-handheld-router.html
Update:
http://diy3dprinting.blogspot.com/2013/11/update-video-on-freed-handheld-router.html
About Thread or what is mean by thread?
Threading:-
What is a Thread?
A thread is a raised, helical rib or ridge around the exterior of a cylindrically shaped object or the interior of a hole. Common threaded parts include screws, nuts, and bolts. Threads have two basic applications: fastening and the transfer or control of motionApplication:-
Threads have two basic applications: the transfer or control of motion and fasteningThread is one of the most used processes in mechanical field. In everyday life we come across through many type of components that have a thread in it. Take example of a pen cap or a water bottle etc.
Understanding a thread:
v The crest is the peak or top of the thread ridge that lies between two flanks. Its size and shape may vary depending on the thread type.
v The flank is an angled side of a thread. Threads have two flanks.
v The root is the bottom of the thread that lies between the flanks. Its size and shape also may vary depending on the thread type.
Type of thread:-
Depending on Geometry thread is classified into two categories. A) Straight threads B) taper thread.
Straight threads can be classified into single start or multi start threads.
Important parameters on the thread:-
- v The pitch point is the position on the thread where the distance between the flanks is equal in both the ridge and the groove.
- v The pitch diameter is the measured distance between the pitch points in the groove between the threads. It is one of the most important dimensions in thread inspection.
- v The depth is the length of the vertical space from the root to the crest of a thread.
- v The major diameter is the distance between the crests of a thread. It is the widest diameter on a thread.
- v The minor diameter is the distance between the roots of a thread. It is the smallest diameter on a thread.
- v Thread form which is the shape of the thread example 90 degree, 60 degree threads etc.
Start, Pitch, and Lead
Start:-
Start refers to the number of different individual threads that wrap around the cylinder. The number of threads equals the number of starts. It means how many start points are there in a thread.
Pitch:-
The distance from one thread crest to the next. For threads manufactured in inches, pitch is expressed in inches as a fraction. It is not the number of threads per inch, but the number "one" divided by the number of threads per inch. For metric threads, pitch is expressed in millimeters.Lead:-
Lead is the distance that a screw travels in one revolution. This distance is equal to the pitch of the screw multiplied by the number of starts on the screw. On a single-thread screw, the lead equals the pitch.
Threads can be manufactured in one of the below mentioned process.
- v Thread cutting and thread milling are cutting methods that use a single-point tool and multi-point tool, respectively, to create threads on a blank or work piece.
- v Thread rolling is a cold forming process that uses a die to deform metal and press it into the shape of threads. Figure 2 shows the mechanism that holds the dies.
- v Thread tapping uses a drill-like tool to either cut or form threads on the ID of a previously drilled hole.
- v Thread grinding uses an abrasive wheel to wear away material and create the thread. Thread grinding is the most precise method of producing threads
Threads may be cut using multiple methods. OD threads may be cut on a lathe or a mill. Both methods begin with a larger blank or work piece and use a cutting tool to remove material and shape the threads. In general, cutting threads is an efficient method, but it has its drawbacks. Cutting produces chips that can interfere with the threads, and the process can cause stress cracks in the metal.A lathe uses a single-point tool, to cut the threads into the blank or work piece, which is held either between centers or in a chuck. The cutting tool is fed into the blank and moved sideways along the rotating piece. On the first pass, the tool is often used to scratch the surface so that the operator can inspect the scratch and verify the tool settings. Then the tool makes multiple passes, cutting deeper each time the tool travels the length of the cylinder.
Milling is another form of cutting. Thread milling is performed similarly to lathe cutting except that a multi-point tool is used. Also, when using a mill, it is usually the tool, not the work piece, that rotates. Milling can be performed more quickly than other methods, but it is generally not recommended for manufacturing smaller threads.
To continue ……………
How to make Helical Interpolation Program
Helical interpolation:-
Producing a large-diameter hole is a common application for many shops, and there are numerous methods that can be used to achieve the end result. However, there are often numerous obstacles to completing the process cost effectively. Horsepower consumption is frequently a concern in these types of applications, especially on the more common 20 horsepower and below machine tools. These machines are capable of high speeds and feeds, but rigidity is sacrificed to the extent necessary to accomplish the quick movements. Using conventional means, making large diameter holes is hard on the machine...
Function and purpose:-
Command G02 or G03 with a designation for the third axis allows synchronous circular interpolation on the plane specified by plane-selection command G17, G18 or G19 with the linear interpolation on the axis.
Description:-
For helical interpolation, movement designation is additionally required for one to two linear axes not forming the plane for circular interpolation.
The velocity in the tangential direction must be designated as the feed rate F.
Programming Format:-
G17 G02 (or G03) X___ Y___ I__ J__ P__ F__ ;
Or
G17 G02 (or G03) X__ Y__ R__ P__ F__ ;
X = Arc ending point coordinates X axis
Y = Arc ending Point coordinates Y axis
I & J = Arc center Coordinates
P = Number of pitches
F = Feed rate
R = Arc Radius
Example:-
G28 U0. W0. Y0. ;
G50 X0. Z0. Y0. ;
G17 G03 X100. Y50. Z-50.0 R50. F1000.
Notes:-
Plane selection:-
As with circular interpolation, the circular interpolation plane for helical interpolation is determined by the plane selection code and axis addresses. The basic programming procedure for helical interpolation is selecting a circular –interpolation plane using a plane selection command (G17, G18 or G19) and then designating the two axis addresses for circular interpolation and the address of one axis for linear interpolation.
End milling helical interpolation calculation click Here
End milling helical interpolation calculation click Here
How to make Cylindrical interpolation G07.1 program
Cylindrical interpolation G07.1
Cylindrical interpolation function refers to a function by which the sides of a cylindrical workpiece are machined .the cylindrical interpolation function capable of programming in the form in which the sides of a cylinder are spread can very prepare programs including cylindrical cam grooving.
G07.1 C___ ; Cylindrical Interpolation mode ( C:Cylindrical Radius )
G07.1 C___ ; Cylindrical interpolation cancel mode
Detail:-
The moving distance of rotational axis commanded with an angle is converted to the linear distance on the circumference in CNC. After the conversion, linear interpolation or circular interpolation is given with the other axis .After the interpolation, the calculated movement is converted again to the moving distance of rotational axis.
Notes:-
1. Plane selection:-
Giving the circular interpolation between the rotational axis and other linear axis during cylindrical mode requires the command of plane selection (G17, G18, and G19).
Example:-
G18 Z__ C__ ;
G02 / G03 Z__ C__ R__;
2. Radius designation
The circular radius by word address I, J, or K cannot be commended during cylindrical interpolation mode. The circular radius is commanded by address R. the radius must be commanded not with angle, but with MM or Inch.
3. Tool nose radius compensation :-
Giving the tool nose radius compensation during cylindrical interpolation mode requires the command of plane selection as with the circular interpolation. However, giving the tool nose radius compensation requires start-up and cancel during cylindrical interpolation mode. Establishing a cylindrical interpolation mode with the tool nose radius compensation given does not provide proper compensation.
4. Positioning:-
Positioning cannot be accomplished during cylindrical interpolation mode. Positioning requires establishing a cylindrical interpolation cancel mode.
Notes:-
When the cylindrical radius is not commanded, a cylinder is defined taking as radius current value of X-axis when G07.1 is commanded.
How to make Spiral interpolation G02.1 G03.1 Program
Spiral interpolation G02.1 G03.1
Command G02.1 and G03.1 provide such an interpolation that the starting and ending points are connected smoothly for an arc command where the radial of the both points difference from each other
1. Circular movement directions of G2.1 and G3.1 correspond with those G02 and G03 respectively.
2. Radius designation is not available for spiral interpolation. The start and end points must lie on the same arc for a radius designation
3. Conical cutting or tapered threading can be done by changing the radial of the arc at its starting and ending points and designating a linear–interpolation axis at the same time.
Notes:-
When a radius is designated, this command will be regarded as a radius designated circular interpolation
Programming Format:-
Plane G17
G17 G2.1 or G3.1 X__ Y__ I__ J__ F__ P__
Plane G18
G18 G2.1 or G3.1 Z__ X__ K__ I__ F__ P__
Plane G19
G19 G2.1 or G3.1 Y__ Z__ J__ K__ F__ P__
Detail:-
X Y or ZX or YZ = Arc end point Coordinates
I J or K L or J K = Arc center coordinates
P : Number of pitches ( P can be Omitted If Equal to 0.)
F : Rate of feed along the tool path
 |
| Spiral Interpolation |
More detail:-
Take care not to use radius designation (R) for spiral interpolation; otherwise a normal circular interpolation will be executed. It is not possible for a spiral interpolation the starting and ending points of which should have different center specified.
Example:-
Programming for spiral contouring with incremental data
Plane G17
Arc end point coordinates
X= 0.0 , Y = -15.0
Arc center coordinates
X= 0.0 , Y = 45.0 and pitch 2.00
Program :-
G00 X0.0 Y-45.0 ( Approach the start point )
G01 Z-0.5 ( in feed on the Z –axis )
G2.1 X0.0 Y-15.0 I0. J45.0 F300 P2. ( Spiral interpolation )
G00 Z3.0 ( Return on the Z axis )
Click Here
Click Here
Radius designated circular interpolation commands G02, G03
Radius designated circular interpolation commands G02, G03:-
Circular interpolation can be performed by designating directly the arc radius R as well as using conventional arc center coordinates (I, J, K)
Program format:-
G02 (G03) X__ Y__ Z__ R__ F__
X : X axis coordinates of the end point
Z : Z axis coordinates Of the end point
Y : Y axis coordinates of the end point
R : Radius of the arc
F : Feed rate
Example:-
G02 X100.0 Z50.0 R50.0 F10. ;
Detail:-
A semi –circle Or smaller will be generated if R is a positive Value.
An arc larger than the Semi-circle will be generated if R is a negative value.
Click Here
Spiral Interpolation G02.1 or G03.1
Click Here
Spiral Interpolation G02.1 or G03.1
G02 Circular interpolation CW , G03 -CCW Program Method
G02 Circular interpolation CW:-
The command below will move a tool along a circular arc.( CW )
Description:-
Once the G02 or G03 command has been given, this command mode will be retained until any other G-code command used to override the G02 or G03 command mode, that is , G00 or G01 of command given .
The direction of circular movement is determined by G02 / G03
G02: CW (clockwise)
G03: CCW (counterclockwise)
Program Format:-
G02 or G03 X___ Y___ Z__ I___ J___ K___ F___
X : Arc ending point coordinates , X axis ( absolute value )
Z : Arc ending point coordinates , Z Axis ( absolute value )
Y : Arc ending point Coordinates , Y Axis ( absolute value )
I : Arc Center , X axis ( radius command , incremental value of start point )
K : Arc center , Z axis ( incremental value of start point )
J : Arc center , Y axis ( incremental value of start point )
F : Feed Rate
Rotational direction
CW (G02) or CCW (G03)
Arc ending point coordinates
Given with address X, Z, Y, U, W, V.
Arc center coordinates
Given with address I, J, K (incremental dimension)
Feed rate
Given with address F.
Example:-
G02 X120.0 Z70.0 I50.0 F200.0 ; ( absolute data setting )
G02 U100.0 W-50.0 I50.0 F200.0 ; ( incremental data setting )
Notes:-
G02 or G03 during circular interpolation refers to the rotational direction in the right handed coordinates system when seen from the plus side toward the minus side of the coordinate axis perpendicular to the plane to be interpolated.
If the coordinates of the ending point are not set or if the starting and ending points are set at the same position, designating the center using address I, K or J will result in an arc of 360 degrees ( true circle )
More detail click here:-
Computer Numerical Control, CNC
CNC means Computer Numerical Control.
This means a computer converts the design produced by Computer Aided Design software (CAD), into numbers. The numbers can be considered to be the coordinates of a graph and they control the movement of the cutter. In this way the computer controls the cutting and shaping of the material.
CNC Coordinates
All the positions and motions of a computer numerical control (CNC) machine are understood in terms of numbers. Numbers describe the shape of the work piece, the movement of the cutting tool, the depth and speed of the cut, etc.
Figure 1
How exactly are numbers used in this way? The common system used to describe location is called the Cartesian coordinate system, which consists of a cubic grid of imaginary lines. The Cartesian system defines the location of a single point in three-dimensional space using three axes, which are shown in Figure 1. These axes are called the X-axis, Y-axis, and Z-axis, and each one indicates a particular direction.
An axis is an imaginary straight line. In the Cartesian system, the X-, Y-, and Z-axes meet at right angles. In other words, they join together like the corner of a box, as shown in Figure 2.
Figure 2
CNC Code Letter addresses Meaning in Fanuc Control
Letter addresses
Some letter addresses are used only in milling or only in turning; most are used in both. Bold below are the letters seen most frequently throughout a program.
Variable | Description | Corollary info |
A | Absolute or incremental position of A axis (rotational axis around X axis) | |
B | Absolute or incremental position of B axis (rotational axis around Y axis) | |
C | Absolute or incremental position of C axis (rotational axis around Z axis) | |
D | Defines diameter or radial offset used for cutter compensation | |
E | Precision feed rate for threading on lathes | |
F | Defines feed rate | |
G | Address for preparatory commands | G commands often tell the control what kind of motion is wanted (e.g., rapid positioning, linear feed, circular feed, fixed cycle) or what offset value to use. |
H | Defines tool length offset; Incremental axis corresponding to C axis (e.g., on a turn-mill) | |
I | Defines arc size in X axis for G02 or G03 arc commands. Also used as a parameter within some fixed cycles. | |
J | Defines arc size in Y axis for G02 or G03 arc commands. Also used as a parameter within some fixed cycles. | |
K | Defines arc size in Z axis for G02 or G03 arc commands. Also used as a parameter within some fixed cycles, equal to L address. | |
L | Fixed cycle loop count; Specification of what register to edit using G10 | Fixed cycle loop count: Defines number of repetitions ("loops") of a fixed cycle at each position. Assumed to be 1 unless programmed with another integer. Sometimes the K address is used instead of L. With incremental positioning (G91), a series of equally spaced holes can be programmed as a loop rather than as individual positions.G10 use: Specification of what register to edit (work offsets, tool radius offsets, tool length offsets, etc.). |
M | Miscellaneous function | Action code, auxiliary command; descriptions vary. Many M-codes call for machine functions, which is why people often say that the "M" stands for "machine", although it was not intended to. |
N | Line (block) number in program; System parameter number to be changed using G10 | Line (block) numbers: Optional, so often omitted. Necessary for certain tasks, such as M99 P address (to tell the control which block of the program to return to if not the default one) or GOTO statements (if the control supports those).N numbering need not increment by 1 (for example, it can increment by 10, 20, or 1000) and can be used on every block or only in certain spots throughout a program. System parameter number: G10 allows changing of system parameters under program control. |
O | Program name | For example, O4501. |
P | Serves as parameter address for various G and M codes |
|
Q | Peck increment in canned cycles | For example, G73,G83 (peck drilling cycles) |
R | Defines size of arc radius or defines retract height in canned cycles | |
S | Defines speed, either spindle speed or surface speed depending on mode | Data type = integer. In G97 mode (which is usually the default), an integer after S is interpreted as a number of rev/min (rpm). In G96 mode (CSS), an integer after S is interpreted as surface speed—sfm (G20) or m/min (G21). See also Speeds and feeds. On multifunction (turn-mill or mill-turn) machines, which spindle gets the input (main spindle or sub spindles) is determined by other M codes. |
T | Tool selection | To understand how the T address works and how it interacts (or not) with M06, one must study the various methods, such as lathe turret programming, ATC fixed tool selection, ATC random memory tool selection, the concept of "next tool waiting", and empty tools. Programming on any particular machine tool requires knowing which method that machine uses. |
U | Incremental axis corresponding to X axis (typically only lathe group A controls) Also defines dwell time on some machines (instead of "P" or "X"). | In these controls, X and U obviate G90 and G91, respectively. On these lathes, G90 is instead a fixed cycle address for roughing. |
V | Incremental axis corresponding to Y axis | Until the 2000s, the V address was very rarely used, because most lathes that used U and W didn't have a Y-axis, so they didn't use V. (Green et al 1996 did not even list V in their table of addresses.) That is still often the case, although the proliferation of live lathe tooling and turn-mill machining has made V address usage less rare than it used to be (Smid 2008 shows an example). |
W | Incremental axis corresponding to Z axis (typically only lathe group A controls) | In these controls, Z and W obviate G90 and G91, respectively. On these lathes, G90 is instead a fixed cycle address for roughing. |
X | Absolute or incremental position of X axis. Also defines dwell time on some machines (instead of "P" or "U"). | |
Y | Absolute or incremental position of Y axis | |
Z | Absolute or incremental position of Z axis | The main spindle's axis of rotation often determines which axis of a machine tool is labeled as Z. |
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