CNC overview process
Quick Explanation of the Process
This is how I view CNC Machining.I break it down into steps that I can remember easily. Now, they all interact, but it is good to keep them in boxes for simplicity sake. I also like to keep them in a logical, progression type order. Here they are: Design, CAD, CAM, Control and Machine.
Today you are going on a journey. You are going to learn about the basics of CNC.I trust you are as excited as I am about this subject.
I have been using CNC equipment in my home shop for six years now. The technology gets better and better every year. The software gets better every year. At one time large companies could only afford this technology.Now there are thousands of CNC machines working in shops like yours and mine.
There are basically five elements to a CNC Project that you need to know:
Design – thinking and planning what you want to build
Computer Aided Design – translating it into the computer
CAM – converting it into machine language
Controlling – directing your machine’s motion
Machining – building the part to specifications
These five elements are really the building blocks to a CNC project. As you see them above, that is generally the order people associate them in. For example, you can’t control until you have a design. You can’t use your CAM software before your CAD software.One of the things you need to take into account is how these different elements interact with one another.
Right now this may seem confusing. Over time, it will seem very basic. The more you use these elements with one another, the more their order will become second nature.
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You can join for Free and you get two free CNC ebooks. One is a GCode Quick Guide and the other is the CNC Info Site eBook. You will get access to the free CNC videos…Image to CNC Art when you join the community.
Why One Should Be Reading The 20gb Mp3 Player Review
If you are thinking about getting a discount mp3 player that you have come across there are some things that you are going to want to take into consideration. The first thing that you should really be considering is how much storage space you really need in a player. While the player that you are looking at seems to be a good deal, you may find something better if you are really not in need of such an excessive amount of storage space for your music. This is a personal choice and one that you should be thinking over for a good bit before you go spending all of your money on something that you could really do without.
So before you go and spend all of your hard earned money it would be a good idea to check out a 20gb mp3 player review or two. This will give you a good idea on whether or not that type of mp3 player is really something that you would want to have. Also, the 20gb mp3 player review that is brand specific is a great way to make sure that the overall product is something that is worth any money at all. Make sure that you are reading at least one good 20gb mp3 player review before you make your purchase.
Finding Good Mp3 Player Reviews That You Can Trust
Once you are finally ready to start paying close attention to a 20gb mp3 player review it is important that you are finding the right ones. There is absolutely no way that any company can make everyone out there happy so you want to make sure that the reviews that you are reading are true and to the point. Avoid the ones that appear to be someone who is just generally upset with the company for one reason or another because these people are most likely just blowing off steam and telling lies in order to make the company look bad.
Start your search on the Internet for a 20gb mp3 player review that you can trust. You will find once you find the reviews that there are a lot more then you probably thought there would be. This is typical so just try to surf through a few of them in order to find the most detailed ones. The detailed 20gb mp3 player review is what you would want to keep an eye out for and pay attention to. The more information you have the better off your choices will be.
Lost Foam Casting Process
Lost Foam Casting is a sub type of Investment Casting. This type of casting method uses foam pattern as the investment. This method benefits from the advantages of the foam properties helpful to make simple and cheap castings. These types of simple castings are impossible using the regular cope and drag method.
Here are the details of the Casting Process:
Foam Shaping: The original foam pattern of the Polystyrene is generally molded or carved.
Carving Polystyrene: What you want to do it to take either a traditional carving tool or one of the newer hot wire cutting tools to cut the formed foam. It can also be sanded easily.
Injecting Polystyrene in a Mold: Polystyrene contains pentane as a blowing agent and is commonly used for beads. The beads are pre-extended, stabilized and then blown into the mold to form pattern sections. A steam cycle forces the beads to expand fully, after this the fuse together and then it undergoes an in-mold cooling cycle. The final shape if very complex, then it is molded in sections. A cluster is formed by aging and gluing together the shaped foam sections.
Preparing Final Mold (Investment) for Metal Casting : Gates and Raisers are generally attached to the pattern, they are also the part of the casting as this helps reduce the shrinkage. Pouring, dipping or spraying are the different methods used for coating the foam cluster with ceramic investment. The reason for this coating is that it forms a barrier and helps to prevent the molten metal to penetrate or cause sand erosion while pouring. Structural integrity of the casting is protected thanks to the coating. The cluster when dried is backed up with un-bonded sand and is placed in a flask. Proper and uniform compaction is then achieved by performing mold compaction using a vibrating table. After all this process and after proper compaction, the mold is ready to be poured.
Automatic pouring is the preferred method in Lost Foam Casting . This is the most critical process and also a bit difficult than the traditional foundry practice. As there are no parting lines or fins to remove the cleaning is easier and requires far more less time and operations in the Lost Foam Casting process.
Advantages of Lost Foam Casting: Due to its unique properties, foam is easy to carve glue and manipulate. It also provides accurate dimensions as Lost Foam Casting is more accurate and effective than sand casting. There are no fins or parting lines the finishing process is easy and less time consuming. The elimination of cores makes complex casting designs easy. Lost Foam Casting also allows us to control the wall thickness and thus no core prints are required thus eliminating shifts or fins and also saves the trouble of sand mixing and core defects. As there are no drafts multiple levels of casting is possible. Precise gate and riser replacements are achieved. What is nice about Lost Foam Casting that sometimes, it is much easier to to cast items in this way versus other types of casting methods. Due to simpler process and easy finishing work, the process is very cost effective and lowers the overall price of the final product.
Metal Casting ZOne is a new community website all about Home and DIY Metal Casting. Come by today and join the site for free and you get a free Metal Casting Basics EBook just for signing up! Stop by the website MetalCastingZone.Com Today for your free Ebook on Metal Casting.
Training on CNC safety tips
Just about any topic that is covered about working in a shop should start with safety.Everyone safety should be the first thing you think about.CNC is not different than any other shop topic that you will encounter. In fact, the highest levels of safety awareness should be maintained when using a CNC machine.
CNC machines don’t have a mind of their own. A computer gives them a command and they execute it. They don’t care if they are cutting steel, aluminum, wood or your hand. They don’t differentiate between materials. You need to be aware of this.
When you are Learning CNC you should take it slow. Do tests on a small scale, then watch and learn what happens. For example, why don’t you let your machine “cut air” for a while when you first get it. You don’t need to put it right to work cutting material. Why not create a simple program, and let the machine cut the air instead of material. Better yet, why even run the spindle during the test.
Every CNC Machine has quirks that you need to learn.Every CNC machine has a different working window. Every CNC machine is just a little bit different then the rest of them.You should learn your machine before you put it to work.
Generally, with a CNC Mills, we are machining something. While machining, “chips” are being thrown off. Sometimes at a very rapid speed. Here is where safety glasses, face shields and material barriers come into play. Use them!The CNC machine doesn’t know that you are there. In the words of every boxing ref before a match, “protect yourself at all times!”
A few ideas to keep you safe in the shop:
Always read the instruction manual before using your machine
Always follow manufacturers recommendations
Always wear safety glasses
You need to wear the appropriate safety equipment for your job
Use shields and barriers while machining when it is appropriate
Test your machine before full production
Perform proper and routine maintenance on your machines
Perform checks on your machine for wear and damage
Always think safety!
CNC resource site:
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You can join for Free and you get two free CNC ebooks. One is a GCode Quick Guide and the other is the CNC Info Site eBook. You also get access to the Free Video Series…Image to CNC Art when you join the community.
Digital World Clocks Are Here To Stay
You can see digital world clocks in use in many places. Though they aren’t always digital, world clocks can be found helping business and consumers around the globe. What exactly is a world clock? What are some common uses? How can they be used by you, the average person?
What Is It, Anyhow?
Have you ever wondered what time it is in another place in the world? If you live in California, and your sister is in Japan, can you remember how many hours of difference there is in the time – and which way direction the difference is calculated – is she ahead of you? Or behind you in time? You probably want to know before you call her. That’s where a world clock comes in handy.
A world clock, whether digital, analog, or online, is a clock that displays the time all around the world, by stating the time in various cities. It can just show it in the cities that the need requires – like a train station that only tells times in cities that the trains are going to – or it can show times in many cities around the world. Some show the times based on which time zone the city is located in. Some show the time on a world map, others as a list. For some world clocks, like online, you can input the city you are interested in and it will tell you.
Uses In A Business Setting
World clocks, often digital, are found around the world in the business world. Many businesses rely on them for accuracy in their business dealings, like in an import/export type of business that needs to know the time in another area prior to making money transfers, phone calls, data feeds, meetings, etc. Some businesses don’t rely on them for a business purpose, other than to look professional and business-like. They can often be seen in the lobby of executive offices, as a wall clock.
Personal Uses For World Clocks
Many of us have used a world clock at one time or another, for the fun of it, if nothing else. If it is a digital world clock, it can tell in numbers what time it is in another part of the world. Isn’t everyone intrigued by looking at the time in another place….”So, it is 9:00 here on a Thursday night, but it is tomorrow afternoon where she lives? Wow!” It can be difficult to wrap one’s mind around, but seeing the numbers on a digital world clock can help.
Where To Find A World Clock
World clocks are easily accessible. You can buy one in a store, or online. They come as either analog or digital world clock types. Or you can buy software to install a world clock on your computer. You can also access online world clocks that are free, often with just as many “bells and whistles” as one you would purchase. It is worth looking online before parting with your money.
Figure out The Basics of Metal Casting
Home Metal Casting is known and loved for the high temperatures, glowing molten metal, and the possibility to make nearly anything. Metal and their alloys are not the only things that can be used in casting. Casting in plastic, most notably resin casting, is becoming popular with artists and jewelers looking for something odd and unique.
Resin casting does not involve the use of furnaces, crucibles, or casting sand. In fact all one really needs for resin casting is a mold, some resin (of course), and time.
There are actually two forms of resin casting. The first kind is the one that more closely resembles metal casting, uses a mold and even gates and runners if it’s complex enough. The second type of DIY Metal Casting is simply incasing an object in the resin. An example of this is using an ice cube tray and placing an object like a small pendant in one of the tray’s cavities and then filling it with the resin solution. After the resin dries you can pop it out of the tray. The pendant is now encased in hard plastic. This form is usually employed by jewelers and crafty moms but tends to be fun for everyone no matter age or experience. At the very least it’s a great way to get rid of some of the clutter around your house and disguise it as art. Your imagination is the only thing that limits what you can cast in resin.
Resin casting using mold is generally used by those who work with models and miniatures. Resin casting is a great way to make several pieces at once so you can avoid shelling out money you may not have and waiting several weeks for delivery of your items. Who has that kind of time anymore?
Like Metal Casting , resin casting will require you to build a mold. If you are fortunate enough then you can easily find pre-made molds, especially if you are working with miniatures. If you don’t feel like buying these pre-made molds or just like doing things the hard way, then you will have to make the mold yourself. Don’t worry, it’s still fun.
You will need to find a molding box this will hold the rubber that will be used to make the actual mold until it dries. Many who work with smaller objects find that working with toy building blocks to create this molding block work extremely well and will provide added convenience. A wooden box will work as well, of course. The box, or flask, will not have a top or bottom, just the four walls. Place molding clay at the bottom of the flask and insert your original. Make sure to add a way for the resin plastic to enter the mold. The funnel or cup as some casters call it should be put at the very top of the mold. You are going to prepare the silicone rubber and catalyst which will be used to create the mold. Follow the instructions on the labels since each type will vary. A process called degassing can be used which will remove all the air bubbles from the rubber. This is a fun process involving a vacuum pump.
Slowly pour the rubber into the flask, covering the original. This can take up to a day to dry, so be patient. Remove the molding clay and repeat the process using the bottom part of the flask, or drag. You should have two parts now, with the original in the middle. When dry, remove the mold from the box and very carefully split the mold to remove the original.
Place the mold back together and prepare the resin solution, follow the instructions to the letter. The resin should be poured into the top of the mold where you put the cup. The set time for the resin should be stated on the bottle, but for most it will take up to 30 minutes. In order to remove the cast you need to crack the mold open when you are ready to see your cast.
Resin casting can be a great family craft project but just make sure to follow all of the safety guidelines. This type of casting can still be dangerous even though you are not dealing with molten metals. Often times, the solutions and chemicals used in resin casting are poisonous if consumed. Not to mention that resin casting can be a bit smelly so working outside or in a well ventilated room is advisable.
Metal Casting ZOne is a new community website all about Home and DIY Metal Casting. Come by today and join the site for free and you get a free Metal Casting Basics EBook just for signing up! Come by MetalCastingZone.Com Today for your free Ebook on Metal Casting.
Let’s look at a G-Code program
Next, we are going to go through an example of cutting out a 2” square with a CNC Plasma. Then we will look at the G-Code to see what is happening.
2” Square G-Code:
The numbers on the left of the G-Code are the sequence numbers of the code and the order it will be executed in. I have added notes after different actions to let you know what that line of code means. My note starts with a “-“ then continues. A “-“ means nothing in G-Code Programming.
N0000 (Filename: 2INSquare.txt) – Name of File
N0010 (Post processor: Plasma.post) – Name of Post Processor Used
N0020 (Date: 8/1/2007) – Date G-Code was generated
N0030 G20 (Units: Inches) – Measurement Units Used
N0040 G53 – Machine co-ordinate system
N0050 G90 – Absolute Programming
N0060 G40 – Tool radius compensation off
N0070 F1 – Feedrate of 1” per min
N0090 (Part: Square) – name of the part
N0100 (Process: Plasma, DEFAULT, Plasma, 0.01 in kerf) – Tool to be used
N0110 G00 – Go to Home
N0120 X0.1113 Y-0.0904 – Move to this exact X, Y position
N0130 G04 P2000 – Pause for 2 seconds, this is in milliseconds
N0140 M03 – Fire the plasma torch
N0150 G04 P500 – Pause for .5 seconds, this is in milliseconds
N0160 G03 X0.0000 Y-0.0050 I-0.1113 J-0.0298 F40.0 – move to this X, Y position in an arcing movement at a feedrate of 40 inches per min
N0180 G01 Y2.0000 – Travel in the Y+ direction for 2 inches to X0, Y2
N0200 G01 X2.0000 – Travel in the X+ direction for 2 inches to X2, Y2
N0220 G01 Y0.0000 – Travel in the Y- direction for 2 inches to X2, Y0
N0240 G01 X0.0000 – Travel in the X- direction for 2 inches to X0, Y0
N0250 G03 X-0.1113 Y-0.0904 I0.0000 J-0.1152 – move to this X, Y position in an arcing movement
N0260 M05 – Turn off the plasma torch
N0270 G04 P2000 – Pause for 2 seconds, this is in milliseconds
N0280 G00 – Move to Home
N0300 M30 – End Program
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Creative designing and CNC artwork
What I used to do…
I was living in the past before I found design software. I would actually hand lay out a template on a piece of paper. Then cut it out. Next, I would tape the design onto a piece of steel and trace around it with a Sharpe Marker. Finally, I would cut out the piece I wanted.
No matter what, it was never exact. There would always be something wrong. Things like wavy lines, gouges and “unique parts” were the norm. Measurements were never as exact as I would have liked either. That usually caused some fit-up issues, followed by some grinding. If you know anything about fabrication, grinding is the enemy of your time.
Why use creative design software?
I knew there had to be a better way so I found some design software to try out. Yes, it does take some time to learn. Think about it, like anything else in life, something that is worth it takes some time. This is also the situation of taking one step backwards to move ten steps forward.
Here are some advantages of using Design Software:
Saved file you can use over and over
Transferred the unique design to other people
Can use exact measurements
Repeatability in design
Here are some disadvantages of using Design Software:
Cost money
Takes time to learn
May not be the quickest way of making something if it is a “One Off”
My Definition of Design Software
If you are an engineer, you will probably consider CAD Software as design software. That is true. But what I am talking about here is “Creative” Design Software. These software packages are used by creative types for print, web design and logo design.This software is great for creating CNC artistic designs that flow in some way.
Design software can be boiled down to what it is good at. If you want to make a square with a hole in it or a triangular gusset, then CAD type design software works great. If you want to cut out a Cowboy on a Horse, then “Creative” Design Software is the only way to go.
Here are some examples of work for “Creative” Design Software:
Plasma Art
CNC Plasma Art
Signs
Engraving
CNC Information Free Community Site:
If you would like to know more about CNC, head on over to http://www.cncinformation.com
You can join for Free and you get two free CNC ebooks. One is a GCode Quick Guide and the other is the CNC Info Site eBook. You also get access to the Free Video Series…Image to CNC art work when you join the free CNC community.
What is CNC Controlling
What is CNC Controlling
Since we are dealing with machines that do work for us, we need to control those machines somehow. We need to control them for safety reasons as well. If you give a machine improper commands it can easily get out of control and cause harm to you or the part you are machining. We want to give good commands to our CNC machines, at the right times so they are not “out of control”.
The programming language that these cnc machines use is called GCode G-code has been around since the early 60’s. There are a number of variations of G-code, but most are very similar to one another. See the previous section for a sample of G-Code.
We need a computer to interact with our CNC Router. Our computer will send signals to our CNC machine. In-between our computer and our CNC machine sits a controller. A controller converts commands into signals that are used to control the motion of our machine.
As these signals are sent out of the controller, they go to either stepper or servo motors. This is how we create motion. These cnc motors drive our various axis on our machine. While we are moving our axis, there is generally a cutting tool of some sort removing material. This is the machining process coupled with CNC.
Here is a brief description of the two types of motors generally used in CNC:
Stepper motors:
Simple design
Very easy to use
Generate torque at low rpm
Do not know their position in relation to the program
Servo Motors:
Generate torque at high RPMs
Generally need gearing of some sort to be effective
More sophisticated
Can maintain their relative position, thus, they can be more accurate
CNC Machine Controllers
Controllers generally stand alone near the CNC machine. They act as a translator between your control computer and your CNC machine. Generally, they add quite a bit of cost to a CNC machine as well. Controllers can cost anywhere from $1000-$20,000 or more depending on their sophistication.
CNC Community Site:
If you would like to know more about CNC, head on over to http://www.CNCInformation.com You can join for Free and you get two free CNC ebooks. One is a GCode Quick Guide and the other is the CNC Info Site eBook. You also get access to the Free Video Series…Image to CNC Art when you join the community.
What is Metal Casting and how does it Work
Casting can be defined as a process of manufacturing, which implies pouring of a ‘liquid’ material into ‘A Mold’ containing a desired shaped hollow cavity, and then made to solidify. The next step is to take the formed casting and break it out of the mold so you can complete the process. The use of casting is ‘forming hot liquid metals’ or numerous metals that are cooled after having the components like clay, plaster, concrete, and epoxies mixed. Complex shapes are normally made by casting, as other methods are not feasible. Casting came into being around 6000 years ago. ‘Copper Frog’ is the most ancient casting existing till date since 3200 BC. The process of casting has two distinct subdivisions: non-expendable and expendable mold casting.
‘Non-expendable’ mold casting: This technique is inclusive of at least 4 distinct methods: continuous, centrifugal, die, and permanent casting.
Continuous casting: Continuous Metal Casting can be defined as a refined process of casting for high-volume, continuous production of ‘metal sections’ with constant cross-section. The pouring of molten metal into a water-cooled, open-ended copper mold takes place. This allows a ‘layer’ of ‘solid metal’ to be formed above the ‘still-liquid’ center. Continuous casting is widely accepted due to its cost-effectiveness. The metals continuously cast are aluminum, copper, and steel.
Centifugal casting: Centrifugal DIY Casting is independent of both-pressure and gravity. This is because its own ‘force feed’ is created by the way of using a ‘temporary sand mold’ in ‘spinning chamber’ at 900 N. Lead time is variant with respect to application. True- and semi-centrifugal processing allow 30 to 50 pieces/hr. The batch processing has an upper limit of around 9000 Kg (practically). Before, this method that is being discussed was used to Cast Railroad Wheels. A company knows as Krupp is who it was developed by. It had a German origin. Jewelry is normally cast by this method.
Die-casting: Die Metal Casting can be defined as a process of ‘forcing molten metal’ into cavities of mold under high pressure. Aluminum, Copper and Zinc are what really make up most of these castings. It is even possible to make die castings of metal. The method of die casting is used where finer parts are needed.
‘Permanent Mold Casting’: This casting is made up of non-ferrous metals. It requires some time to set up (some weeks), after which the production rate of about 5 to 50 pieces/hour-mold is achieved. The coating of ‘acetylene soot’ is applied to steel cavities. This helps in removing the work piece easily and promoting longer life (of tools). Permanent molds possess a limited life span. For worn molds, replacement or refinishing is required.
Expendable mold casting: ‘Expendable Mold casting’ can be referred to as a standard classification inclusive of the following:
Sand casting: It is amongst the simplest and most popular casting types used since ages. It involves very small size operations. The bonding of sand takes place by use of clays (as in ‘green sand’) or ‘polymerized oils’, or ‘chemical binders’. Recycling is easily possible.
Plaster casting (for metals): There is no difference between plaster casting and sand casting, except the fact that plaster is used in place of sand. Similarly, there are also plastic and concrete castings.
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