CNC Router: Difference between revisions
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== CAMaster Stinger I CNC Router ==
[[File:CAMaster Stinger I CNC Router.jpg|thumb|upright=2|alt=CAMaster Stinger I CNC router, computer, and compressor|CAMaster Stinger I CNC router, computer, and compressor]]
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| colspan="2" | 15240 mm/min (600 in/min)
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! scope="row" |
| colspan="2" | 8890 mm/min (350 in/min)
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=== Reference Material ===
[https://
[https://www.cnccookbook.com/hub/speeds-and-feeds/ Feeds & Speeds
[https://www.
[https://drive.google.com/file/d/1q-PdAv_nw7_uOr-tP426cAEorOG3ylng/view?usp=sharing Download VCarve Pro v11.018 Trial] (CAD/CAM Software)
VCarve Pro Makerspace ID:
39330-F4690-16995-07DC5-70AEA-01778-91E18
=== FCFL References ===
[https://docs.google.com/spreadsheets/d/
[https://drive.google.com/file/d/1hwypOCyQ11mNdx32k812W3lDYDm5G8pF/view?usp=sharing FCFL CAMaster WinCNC post processor for Fusion 360] - "FCFL_CAMaster_wincnc_m3x_171014.cps" with Automatic Tool Changer disabled.
[https://drive.google.com/file/d/1e_epUuee_oOA-Cs6QrRGmAygsFLcqrwy/view?usp=sharing FCFL CNC Router Tool Library for Fusion 360] - Complete tool library ready to import into Fusion 360. This tool library is version 2024_06_21.
(DEPRECATED) [https://docs.google.com/spreadsheets/d/1OWSaMgkcoUyyKQk58nxxpIXn-BqWR1F2R01m_Mm7xRU/edit#gid=0 Old FCFL Bit Inventory] - Old spreadsheet. No longer in use.
== Materials ==
* Plastic: Acrylic (must be CAST acrylic), Delrin, polypropylene, etc.
* Metal: Aluminum, brass.
* Wood: Soft/hard grain wood, veneer wood (plywood, etc.).
* Foam: [https://www.generalplastics.com/products](Urethane foam) ("prototype foam") is OK; lower density gives more dust, and 18lb is recommended for CNC. You can [https://shop.sculpt.com/foam/urethane-foam/](buy it at Compleat Sculptor on 19th Street) or [https://www.mcmaster.com/tooling-foam/](McMaster-Carr). Despite what you might see on the internet, '''DO NOT''' use XPS insulation foam from Home Depot (it develops a static charge when cut, and clings to the exposed lead screws, requiring complete disassembly of the CNC to clean, and the dust is too light to be caught by the dust collector.)
== Bit Types ==
* Surfacing
* Flat endmill
* Ball nose end mill
* 3D carving (ball nose conical)
* V-groove
* Engraving
* T-slot
* Drilling bits
* Bull nose
* Drag
== Flute Types ==
* Straight - pushes against work - chips evacuated sideways. Good for hogging material. Poor cutting finish over spiral flutes.
* Spiral
** Up-cut - pulls up on work - chips evacuated upward. Best bottom finish. Good for hard/soft grain wood. Can be plunged straight down.
** Down-cut - pushs down on work - chips evacuated downward. Best top finish. Best for veneer wood (ex: plywood). Good for hard/soft grain wood. Use ramp when plunging.
* Compression - at cutting depth, pulls up on bottom of work and pushes down on top of work - chips evacuated towards center of cut depth. Good for hard/soft grain wood and veneer wood.
* O Flute - for acrylic and/or aluminum. Bits designed for particular material specified in tool bit inventory list.
== Getting Started ==
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Standard Disclaimers:
* Monitor your cnc job at all times
* Standard safety gear (safety glasses)
* Tie back hair
* No loose items
* Don't be inebriated
* Don't be stupid
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You must fully power cycle the CNC and reset the switch (twist) to use the CNC
* Make sure to wait for the spindle speed control panel to turn off before turning the CNC back on.
== Win CNC Control Software ==
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We have a Vcarve Pro Makerspace license and you can use it to prepare VCarve files (.tap) on your computer.
You can also use Fusion 360 to make the files. Fusion 360 tool library available [[CNC_Router#FCFL_References|above]].
=== Post-processing ===
Use 'in' post-processor. Should already be set in VCarve.
== Preparing the Cut ==
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[[File:Air Compressor Switch.jpg|thumb|alt=Air compressor toggle switch (red)|Air compressor toggle switch (red)]]
1. Inspect the machine and bed for any debris, especially the ball screw
3. Turn on the air compressor (push red toggle switch backward). Only if necessary, adjust air compressor regulator to provide 60-80 PSI pressure to CNC if it has been changed. The CNC has a second regulator regulator for the air-assist and should already be at 40-45 PSI since no one changes it.
4. Turn on the Vacuum for dust collector.
=== Spindle Motor Bearing Warm-Up Procedure ===
[[File:Stinger I - Spindle Speed Control.jpg|thumb|alt=Spindle speed control (on front right of Stinger I)|Spindle speed control (on front right of Stinger I)]]
1. Remove dust collector boot from spindle.
2. Remove collet and collar from spindle and set aside.
3. Warm up spindle bearing using the speed control dial on front right of CNC router. This is required for the longevity of the spindle bearings. Spindle RPM digital readout (DRO) in thousands of RPM.
: (If the DRO reads "EF", this means the machine was turned on to quickly after power cycling due to the E-Stop being activated.)
* Step 1: 5k RPM for 5 mins
* Step 2: 10k RPM for 5 mins
* Step 3: 18k RPM for 5 mins
=== Zeroing Procedure ===
IMPORTANT NOTES:
* Must use sacrificial board underneath stock if cutting through stock completely.
* Must set Z zero at bottom of work if using multiple tools. You can set Z zero at top of work if just engraving with one tool or any case where the top stock reference is preserved.
1. Brush the bed clear of debris and remove any obstructions for the gantry.
2. Click “Initialize”. This will home the Z, X, and Y axes.
3. Attached collar to collet, begin thread to spindle, and insert first tool. Tighten collar with the two spindle wrenches.
5. Move gantry to back of machine with X & Y keyboard buttons.
6. Position stock squarely onto bed and clamp down. Remember to use sacrificial board underneath stock if cutting through stock completely.
7. Click “Laser On”.
8. Position laser light over corner of stock. Use the corner you chose when setting up CAM job.
10. Click "Zero XY". This will zero tool head in X and Y.
11. Connect touch plate, position touch plate on top of bed surface (or on top of stock depending on your CAM job setup), position tool over touch plate and click “Touch Top”. Keep your hand over the E-stop in case something goes wrong!
* For ‘Z0 at top’ jobs, plug in touch plate, position under tool and Press “Touch Top” button.
* For ‘Z0 at bottom’ jobs, Make sure no local Z is set. T codes in job trigger measure tool. Ensure job rapids clear all clamps. Type G92 to clear any stored settings
=== Securing the Stock ===
Spoilboard has 1/4”-20 threaded sockets for clamping stock. 3D printed clamps are available for clamping materials up to 1.4" thick.
Clamps:
[[File:FCFL CNC Router Clamps.jpg|thumb|alt=FCFL CNC Router Clamps in various clamping configurations.|FCFL CNC Router Clamps in various clamping configurations.]]
[[File:FCFL CNC Router Clamp Dimensions.png|thumb|alt=FCFL CNC Router Clamp Dimensions|FCFL CNC Router Clamp Dimensions]]
These can be used in creative configurations to secure your stock.
*Up to ~1.4" stock can be secured.
*Use whatever bolts listed next that work with your configuration.
*Whenever possible, position bolts as close to the clamping area as possible, so clamping force is maximized. Ideally, position the clamp with a downward slope towards the piece being clamped.
*Clamps can be stacked--see photo for ideas.
*Clamps can also be used to butt stock to prevent translation. In this configuration, other clamps need to be used to apply downward force.
*See [[CNC_Router#Replacing_3D_Printed_Clamps|Replacing 3D Printed Clamps]] for the files and print instructions.
Bolts:
* [https://www.boltdepot.com/Product-Details.aspx?product=1280 Machine screws, Phillips flat head, Stainless steel 18-8, 1/4"-20 x 1"]
* [https://www.boltdepot.com/Product-Details.aspx?product=1282 Machine screws, Phillips flat head, Stainless steel 18-8, 1/4"-20 x 1-1/2"]
* [https://www.boltdepot.com/Product-Details.aspx?product=1283 Machine screws, Phillips flat head, Stainless steel 18-8, 1/4"-20 x 2"]
Flat Washers:
* [https://www.boltdepot.com/Product-Details.aspx?product=2948 Stainless steel 18-8, 5/16"]
T-Nuts:
For spoil board.
* [https://www.boltdepot.com/Product-Details.aspx?product=10484 T-Nuts, Stainless steel 18-8, 1/4"-20 x 5/16"] - 115 needed.
== The Cut ==
[[File:Dust collector.jpg|thumb|alt=Dust collector and power switch (on right side)|Dust collector and power switch (on right side)]]
WEAR EYE PROTECTION. Wear earmuffs to protect your ears. Make sure hair is tied back and loose sleeves are pulled back.
Lookup the required chip load for your material based on the tool's diameter! You'll need this to be able to calculate proper speeds and feeds.
See this [https://cutter-shop.com/chip-load-chart/ Chip Load Chart]
Spindle speeds typically 7k-18k RPM.
Typical feed rate ~200-300ipm.
Calculate feed rate with this formula:
(Feed rate) = (Chip load) x (Number of Flutes) x (Spindle RPM)
Better to begin at lowest end of recommended
* the finish deteriorates because of vibration of the cutting tool
* tight radii causes the machine to adjust to a slower speed
* the part moves
Make sure to attach dust boot and turn on dust collector before cutting, or else use the shop vacuum tube without dust boot.
== After the Cut, Clean Up ==
# Rotate spindle RPM knob fully counter clockwise (0 RPM).
# Power off CNC router by twisting power switch.
# Turn off air compressor (pull red toggle swithch forward).
# Turn off dust collector.
# Vacuum up all leftover debris and dust. Anything left behind can build up into a fire hazard or gunk moving parts.
# Carefully put away bits into the numbered tool location they came from.
# Put tool boxes, clamps away, and safety gear back.
== Maintenance ==
=== Greasing Parts ===
=== Replacing the Spoil Board ===
Threaded holes are 4" apart.
=== Calibrating Tool Measure Plate ===
Only after resurfacing the spoil board, the tool measure plate position on the lower right of the machine needs to be recalibrated with the 'Calibrate Switch' button--this is a '''required and critical step'''. This button should '''not''' be used at any other time. This distance is the difference between the top of the tool measure plate and the top of the spoil board. The machine needs to know this height difference so tool measure operations are correct.
Follow these instructions exactly:
* Attach a tool to the spindle
:* Any tool will work, but using the standard 1/4” flat end is ideal
* Turn off all soft limits with G-code L21
:* This allows the ability to jog the Z past the Z bottom soft limit
* [https://youtu.be/zhRtr7aMlVw Jog the bottom of the bit down to the spoil board]
:* Jog the bit bout 1 inch over the spoil board
:* Switch the speed to move by 0.1" steps (not using fast, medium, or slow)
:* Jog the bit to about 1/4 inch from the spoil board, then switch the speed to move by 0.01" steps
:* Use printer paper under the bit and move it back and forth
::* Lowering the Z until the bit just barely snags the paper. There should be room enough for the paper to drag under the bit.
* [https://youtu.be/r9-QHmy459o Click the 'Calibrate Switch' button]. The Z lower bound is now one paper width above the spoil board (~0.004" or 0.1mm). We do this to minimize cuts into the spoil board that we prefer to resurface as rarely as possible.
:* The command log will first asks you to jog the bit to the bed, which is already completed
:* This step will start the process to reset the Z bottom at the current position of the bottom of the bit
* Press 'enter' then the command log will say it will now use the Measure Tool feature and to ensure it can move freely
:* This step will take into account the length of whichever tool used
* Press enter and the machine will move up to the Machine Z0 (the Z top hard limit), then move to the tool measure touch plate to measure the tool
:* The machine knows the location of Machine Z0 and the Measure Tool operation allows the machine to figure out where the Z bottom limit is, relative to the machine Z0
* After the Measure Tool operation is completed, the Z bottom limit has been set
* Test if the calibration has worked
:* Click the Park button to move the spindle to the Machine X0 Y0 Z0
::* This should be off the edge of the spoil board
:* Jog the bit downwards towards the bed
::* This should trip the Z bottom soft limit when the bottom of bit is just below the spoil board (0.01" below the spoil board)
=== Compressor/Air Tank Draining ===
=== Replacing 3D Printed Clamps ===
[[File:FCFL CNC Router Clamp image.png|thumb|alt=FCFL CNC Router Clamp render|FCFL CNC Router Clamp]]
STL file:
* [https://drive.google.com/file/d/1FmcfCsJWTyyqtVQ97TQotZL2cJ2FVKzq/view?usp=sharing FCFL CNC Router Clamp STL]
Print settings:
* Position model on its side (bolt direction horizontal to bed)
* Material: PLA+
* 0.8 nozzle
* 0.2 layer height
* 10 walls
* 50% infill, cubic subdivision
* Generate support everywhere
* Skirt
=== Replacing 3D Printed Dust Collection Boot ===
[[File:Dustboot1.jpg|thumb|alt=Dust boot|FCFL Dust Collection Boot]]
NOTE: This file's geometry tolerances need adjustment (boot groove & magnet holes). It may work on some printers and not on others, so be prepared to modify as needed (either physically or digitally). Holes for the M3 retaining pins were an after-mod, so are not included in the file and need to be manually added later.
This part can be printed as one piece or as two separate pieces.
* Full STL file requires a large printer:
** [https://drive.google.com/file/d/13Dxwsi6C2WWSWrQ5LSA_VqfQnIbXf5Xv/view?usp=sharing CNC Dust Boot Full.stl]
* Separate STL files can be done on any Ultimaker or similar printer:
** [https://drive.google.com/file/d/1rEx6f0t3lkniwuvnSYDCObXyN7-Jj_53/view?usp=sharing CNC Dust Boot Half A.stl]
** [https://drive.google.com/file/d/1wl_y9x7eB8jHbfCK3BMTucW-wmBR_UFu/view?usp=sharing CNC Dust Boot Half B.stl]
Print settings:
* Position model on its back (dust boot grooves facing upward)
* Material: PLA+
* 0.4 nozzle
* 0.15 layer height
* 6 walls
* 12 top & bottom layers
* 30% infill, cubic subdivision
* Generate support everywhere
* Skirt
Hardware:
* [3x] - 1/4" x 1/2" cylinder neodymium magnets
Assembly:
# Super glue the two halves together
# Press in the magnets. The magnets should be about flush and in the same plane as the top surface of the boot.
# Glue the magnets in place.
# Install the brushes. No glue is needed. Will need to modify to fit. Clamp to press in bristles in place.
# Drill holes to allow for M3 retaining "pins" to fit in.
== Troubleshooting ==
=== Spindle
Hit reset button on spindle controller console. Check that speed control knob is fully clockwise.
If there's an error code on the spindle's DRO, you can power cycle the machine (wait until the DRO LED's turn off). You WILL have to re-initialize and re-home your job though!
=== WinCNC Won't Start ===
Restart software.
=== Z Limit Error ===
The 'Calibrate Switch' button was probably clicked on accident. See section [https://wiki.fatcatfablab.org/wiki/CNC_Router#Calibrating_Tool_Measure_Plate Calibrating Tool Measure Plate] for help.
''Only use this method if you are experiencing all the known issues below.''
'''Known Issues'''
* The Touch Top and Measure Tool feature works without errors
* Before loading any G-Code, the Z Soft Limit is exceeded without the tool being close to the spoil board
== Pinned Items from Slack #cnc and Other References ==
[https://www.endmill.com.au/blog/what-the-flute-a-comprehensive-guide-to-cnc-router-bits/ Comprehensive Guide to Router Bits]
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VCarvePro (Windows) FatCatFabLab serial: 39330-F4690-16995-07DC5-70AEA-01778-91E18
== CNC Router Quick Reference Checklists ==
[[File:CHECKLISTS for Stinger Router.pdf|thumb|center|175px|alt=CHECKLISTS for Stinger Router|CHECKLISTS for Stinger Router]]
== CNC Router Maintenance Log Sheet ==
Replacement CNC Router Maintenance Log Sheets can be found here:
[[File:CNC Router Maintenance Log Sheet.pdf|thumb|center|175px|CNC Router Maintenance Log Sheet]]
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