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howto:rowland_jwx-10_setup [2014/04/22 10:46]
tpack
howto:rowland_jwx-10_setup [2014/04/22 12:02] (current)
tpack
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-===== Experiments so far ====== 
  
-  * Engraving onto timber (pine) using Dr.Engrave. Very light "​MHV"​ in middle caused by not tightening the grub screw on the engraver tool. Tool was not being pushed into the material. Deeper cuts resulted in champered edges - not optimal.\\ {{:​projects:​roland-jwx10:​etching.jpg?​200}}\\ \\ 
-  * Milling the "​fan"​ model supplied with ModelA software. Available tools are a 3mm flat end mill (1/8" shaft) with about a 6mm cut length. The finer 1mm flat end mill only has about a 3mm cut length - so I had to reduce model height in Z to allow for fine cutting with the 1mm endmill without having the shank hitting the top of the fan blades (see middle diagram in figure 2 below).\\ {{:​projects:​roland-jwx10:​photo.jpg?​400}} {{:​projects:​roland-jwx10:​android(1).jpg?​200}}\\ \\ 
-  * Balsa (middle and right examples in images above) - Machined using 1mm flat endmill. Too soft, doesn'​t hold details and burrs easily. Thin vertical fans don't have any structural strength so break easily - especially across the grain. Android logo example (right image above) was OK as didn't have small thin details (apart from the antena) - Mill could be good to create architectural model panels (to be tested).\\ \\ 
-  * Pine (left example in image above) - Good detail, but thin fan blades across the grain are not very strong. Model was scalled down for this example - so details even finer. 3mm end mill couldn'​t get into gaps between blades in middle of model. Left of image shows "​roughing"​ process, and right shows "​finishing"​ process. Could be a great technique for making custom boxes for machine tools etc. or moulding patterns into timber sections, draw handles or similar.\\ \\ 
-  * Polycaprolactone (image below) - Thermosetting plastic - melts at 60 degrees C - tool heats up plastic too easily, remelting microchips into a burr that have to be cut out regularly as they clog up the cutter - not very clean result. Solution may be to slow down cutting speed and speed up XY cutting speed - was using 6000 rpm at 18 mm per second XY.\\ {{:​projects:​roland-jwx10:​thermo.jpg?​200}} \\ Links: \\ http://​australianrobotics.com.au/​sites/​default/​files/​Polycaprolactone%20techniques%20v1.pdf \\ and \\ http://​www.robotroom.com/​Prototype-Plastic.html\\ https://​en.wikipedia.org/​wiki/​Polycaprolactone\\ \\          * UHMWPE plastic (image below) - works similar to above. Changed tool settings to 6000 rpm and increased XY speed to 24 mm/sec. Better result but still showing a burr and strips. Material is easy to cut with a knife - but not with available hand saws. Feels a bit like Nylon. \\ {{:​projects:​roland-jwx10:​uxx.jpg?​200}}\\ http://​www.plasticsmag.com/​features.asp?​fIssue=Sep/​Oct-03&​aid=3862 recommends the following: "​Milling:​ Cutters designed for machining aluminium give the best results. Cutting speeds of 600 to 1,800 feet per minute are suggested [3048 to 9144 per second ??], with a feed rate of approximately .01 inches per revolution. Router bits work well for slotting and light milling."​\\ https://​en.wikipedia.org/​wiki/​Ultra-high-molecular-weight_polyethylene\\ \\ 
-  * Acrylic - (to be tried 23/4/2013) 
-    * Resin sample from Chris Wolfe - (Smooth-Cast 300 = diphenylmethane dilsocyanate) white resin with black pigment. Good quality result - some bubbles in resin that are visible in machining (see far wall detail in right image). Not very strong material though - as evidence by breaking of thin fan blades - though this could have been a function of the speed of the cut.\\ {{:​projects:​roland-jwx10:​resin(1).jpg?​200}} {{:​projects:​roland-jwx10:​resin_detail(1).jpg?​140}}\\ \\ 
-    * Wax - some small samples blocks with kit - will order some test materials for maching. 
- 
-===== Issues/​Questions ===== 
- 
-  - How to hold models to allow for ease of lift of with positive replacement 
-    * double sided tape is "​prefered"​ method apart from wax ring/tube and small vice mount. 
-    * would prefer a positive hold method to hold model material and "​mount"​ and to allow lift off and replacement as some models may take multiple sessions to complete. 
-    * have started using a thin MDF backing board as would allow mills to cut all the way through the material (into the MDF) without hitting machine bed. 
-  - Production techniques 
-    * how to easily reset the Z zero position when changing between larger roughing bits and smaller finishing desk. 
-    * use mill to create a mould for silicon - to be used for casting resins and wax models for lost wax etc. 
-    * need vacum machine to produce clean models and furnace for copper alloys (brass/​bronze),​ alumninum, and precious metals (gold/​silver). 
-    * direct milling of suitable plastics,​ suitable non-ferrous metals (aluminium, brass etc) and precious metals (??) 
-  - Modelling techniques 
-    * Blender (free/open source) has modelling tools and can output suitable file for input into Modela 
-    * Also has new 3D Printer output tools 
- 
-{{:​projects:​roland-jwx10:​03-endmill-view.jpg?​nolink&​600}}\\ 
-Figure 1 - Anatomy of an End Mill\\ 
-Image from Michal Zalewski'​s "​Guerrilla guide to CNC machining"​ 
- 
-{{:​projects:​roland-jwx10:​05-reach.jpg?​nolink&​600}}\\ 
-Figure 2 - Interference of model with mill shank - need to introduce 
-draft angle.\\ 
-Image from Michal Zalewski'​s "​Guerrilla guide to CNC machining"​ 
- 
-===== Links ===== 
- 
-Roland Product page http://​rolanddg.com.au/​engineering/​milling-machines/​jewela-jwx-10-desktop-engaver 
- 
-MHV Member David put me onto Michal Zalewski'​s excellent article "​Guerrilla guide to CNC machining, mold making, and resin casting"​ at http://​lcamtuf.coredump.cx/​gcnc/​full/​ - well worth a read.  
- 
-Tips and Tricks section of Roland'​s web site - http://​tipsandtricks.rolanddga.com/​category/​milling/​ 
- 
-Modela Cutting Tips - Roland Support - Wish I'd seen this early on...\\ 
-http://​support.rolanddga.com/​docs/​Documents/​departments/​Technical%20Services/​Manuals%20and%20Guides/​SupDoc_Modela_Cuttip.pdf 
- 
-===== Sources for end mills and materials ===== 
- 
-M&G in Fyshwick very helpful with materials and have selection of plastics on hand or can get in, including offcuts "out the back". Materials available are: Acetal (White and BlackUV stabilised),​ Delrin, Bakalite, UHMWPE, Teflon and C100 an oil filled plastic available in lots of profiles and suitable for bearings and axels. 
- 
-Bought a selection of ball endmills from xxxxx in Fyshwick. Very helpful. Purchased imperial mills with a 1/8" shank as that is the available collet size with Mill. Can purchase a 3mm collet from Roland - so will do this as 1/8" = 3.175mm > too much slack for 3mm shaft mills. 
howto/rowland_jwx-10_setup.txt · Last modified: 2014/04/22 12:02 by tpack