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Posts Tagged ‘Cutting’

This is a short video of my CNC-converted Grizzly Mill-Drill (Sieg Super X3) being used as a lathe to cut a switch knob for a PDP-7 computer. A 3/8″ 6061-T6 aluminum bar about 3″ long is mounted in a collet in the mill, and is driven past standard lathe tools mounted to the mill table. The spindle is running in reverse direction due to the orientation of the tools. I created a G-Code program by hand to make the two different tapers and cut off the knob at the end. Depth of cut was .010 because heavier cuts caused the rod to deflect too much. Spindle speed is about 800 RPM; cuts were made at 3 inches/minute except for the final cutoff, which is about .3 IPM. UPDATE: I have received a good number of questions about the videography. I used an HD camcorder (Sony HDR-SR11) which captures in AVCHD format. youtube will not accept AVCHD video, so I used a program called Free HD Converter from Koyotesoft.com to convert it to MP4 at 1280×720 resolution; which I was able to upload directly to youtube. Not much work all told, and the results speak for themselves. Of course, good even lighting and using a tripod are key to getting good video.

Originally posted 2010-02-22 21:34:40. Republished by Blog Post Promoter

The process of Waterjet cutting is fast gaining prominence due to its versatile and reliable approach. It does not involve any use of noxious gases or liquids. The procedure is environment friendly as it does not create hazardous materials or vapors. No heat effected zones or mechanical stresses are left on a waterjet cut surface. Water jet cutting has proved with its efficiency that it can give satisfactory results which other technology cannot. It can cut stone, glass or other material with finest accuracy and can also create different designs on the surface.

It is a unique technology with no adverse effects. It can be touted as the best alternative for laser cutting, flame cutting and plasma cutting. Even the material edge on which water jet cutting is performed is not distorted and is free of stresses.

It is an economical way to cut shapes of almost any complexity, in a very wide range of materials with no tooling costs. The unique process usually eliminates the need for secondary finishing processes.

Whether its metal or any other material, waterjet cutting is the most ideal solution. Seeing the advantages of waterjet cutting various sectors including automotive, military, aerospace, tile, stone cutting, food, textiles, rubber, foam, glass, and much more. Computer Numerical Control better known as CNC is also implemented in waterjet cutting. In this the user is required to sketch the design to which the material needs to be cut and the software for the CNC water jet cutting process follows it to cut the material to that particular shape. It results in smooth edges and hence does not need any finishing. There are various companies that offer the service of waterjet cutting.

Before finalizing the service provider it is very important to check the authenticity of the company and their track record as well. Hydro Lazer is one such company that offers high quality waterjet cutting services. With 30 years of experience Hydro Lazer has served different clients spread over various industries with ease and efficiency in waterjet services.

Cutting suspension brackets at SFR on a torchmate CNC plasma table. Filmed with a GoPro Hero Cam

Challenges and issues in technology upgrading from the corporate perspective has always been predominant and will continue to exist for many years to come. The challenges pertain to the five Ms: markets, men, machines, materials, and methods. For markets, there are problems of size (or the lack of) and the increasingly shortened life cycles. For men, there is a need to raise skills level and competencies, have suitable trainers, provide budgets and resources, and be able to retain the workforce in the industry. For machines, there are issues such as the high cost of capital, expensive testing equipment, rapid technology changes, restrictions imposed on the export of high-tech machinery, and long procurement times. For materials, there are limitations on the supply of specialized materials, difficulty in obtaining supplies in small quantities, high cost, and uncertain quality. For methods, the challenges are in the use of forecasting techniques and scenario analysis to assess market demands, emerging technologies, and product trends, and the receptivity of the workforce and companies to technology transfer and certification.

Precision engineering industry has evolved in order to support this everlasting demand of technology up-gradation. There is a progressive trend for product manufacturers to outsource more of their operations so that they can concentrate on their core strengths of design and development. This provides excellent opportunities for the more enterprising precision engineering companies to move up the value chain. A business model that is becoming increasingly common is one in which the product manufacturer nurtures of pool of supporting companies to form a manufacturing ecosystem. There are a number of important considerations for PE companies to adapt to such a symbiotic relationship.

In case studies of two precision engineering companies that have successfully leveraged investments in technologies and systems to grow into global players, it was analyzed that the companies have carefully balanced market needs with technology acquisition. Industry experts have provided insight into how the machine tool, tooling, and automotive parts industries underwent successful transitions from initial development through the growth period and finally entered the mature phase of mass production. From relatively modest beginnings, these three industries now command a significant share of the domestic and export markets. The precision machine tools and precision engineering have been identified as key industries, together with intelligent robots, flat-panel manufacturing equipment, and industrial machinery. Greater investments have to be made in human resources, R&D, innovation, logistics networks, and the living environment to create a steeper “smile curve” and ensure future prosperity.

However, if the management of sales channels is comparatively weak, priority should be given to the establishment of a global marketing strategy and there should be greater use of ecommerce as a means to facilitate the upgrading of enterprises. It has become evident that the factors that influence technological competitiveness are innovative products and processes, high quality, environmental awareness, product life cycle support, adaptability to change, error-free engineering, and manufacturing knowledge management. There has been a significant influence of IT systems on manufacturing from the 1970s to date with respect to themes, actors, and methods and tools. To meet the current challenges, we need strong leadership in decision making, giving priority to process innovation, and digitizing competitive knowledge. The emerging technologies that will be significant are life sciences, information and communications technologies, environmental technology, and nanotechnology. Manufacturing technology, infrastructural technology, and energy are important enablers.

My homebuilt cnc machine cutting out some mdf parts

opposite end of the tube which i can not have. If i hire this out to someone with a cnc system how much less torch slag will i have if any?

Originally posted 2009-10-01 18:18:18. Republished by Blog Post Promoter

Laser cutters work by focusing a beam of light, or laser, on a focused site on a piece of material in order to slice through it rather than using a solid object, like a blade, to cut the object. A computer system enabled with vector graphical software is also necessary. Commands are given to the laser cutter through software which translates design geometry to numerical CNC machine code. A laser can also take input from drawings developed with the aid of computer-aided design (CAD) software.

Laser Cutting Machine Configurations

The configurations of the machine are defined based on the way the laser beam will hit the object to be cut. There are three main configurations that act on two axes, the X and the Y. The first configuration is referred to as moving material. In this setup, the material to be cut is put beneath the cutter head. The second configuration is the hybrid laser. The table and the cutter head operate in opposing directions, giving the best stability of the beam’s path. The third configuration is the flying optic configuration, employed by Maloya, where the cutting head is the piece of the machine that is moving. The object being cut is static and this type of setup creates neat work. Its rate of motion is also the fastest among the three setups. The flying optic system also does not require clamping down the material being cut, aiding in the speed of the workflow. There are also machines utilizing up to six axes.

Workflow with Laser Cutting Technology

Loading and unloading can take up valuable production time but the speed of laser cutting can make up for this. The unnecessary need for material clamping can also save time. Another consideration is if the laser cutter can be left on. Workers may have to turn off the power to take materials out of the machine and interrupt the flow of cutting.

Lighting is also important in a manufacturing environment. Light emitting diode (LED) lighting is becoming more popular for saving energy. More green ways of lighting these types of environments are becoming available such as controlling lighting with fluorescent lights by having them turn off through motion sensors.

Laser Cutting Equipment and Maintenance

With the money spent on laser cutting machines, sufficient upkeep can ensure that they operate optimally and safely. Undesirable cuts can be produced if the machine is not running at its peak performance level. Process control such as checking cutting nozzles, lenses and additional optics should be done on a frequent basis. Simply making regular checks on their alignment can save many headaches later. Air sources can affect focal lenses of the laser cutter. Making sure the lenses are clean is of utmost importance. Operators can tell if a focal lens is dirty by visual inspection and checking it with a polarizer. A lens can then be cleaned with alcohol and fine tissue or replaced. Laser optical components are in the category of consumables. Maintenance of chiller units is also important. They should be started prior to cutting. A laser cutter will not be as fast if it has not been maintained. Replaceable parts should also be kept available if they are needed. Keep exhaust systems up to par as well.

Training on Laser Cutting Systems

Laser cutter training should include hands-on and classroom training. It should involve basic operation of the laser cutter such as how to start and shut down the machine, how to properly use the cutter and programming of the machine, safety and maintenance. Oftentimes the supplier of a machine will provide training to the purchaser. Other training involves how to create drawings and load them into the laser machine, scaling, and rotation. Other things to be learned are file usage, code, databases, laser tables and metrics. Users of laser cutters should also understand CAD and computers. One should understand how to measure thicknesses of materials in relation to whether the laser cutters can cut them effectively. A user should also be able to read blueprints. Users need to be trained in quality control and geometric tolerance to know the how precise the laser cutter can get. Material Requirements Planning (MRP) involves planning everything needed for a job as well as inventory taking. Software is used for these tasks. Proper training on these systems is essential as the common problem with them is the data often is erroneous. Some of these errors can be eliminated through training.

One should be able to use measuring tools such as calipers or a vernier caliper which can offer more accurate measurements. Other basic tools someone should be able to use are a ruler, protractor, compass and basic mathematical tools.

Quality Control

In order to keep improving workflow processes, Corrective Action Requests (CARs) and Corrective Action Notifications (CANs) can be done. This involves problem reporting, the cause of the problem, and future problem preventions. There is workflow quality management software that will handle this. For example, if something happens, a notification in a certain form such as an email will go out to a person who handles that problem. The action will then be taken to correct the problem.

Much knowledge and skill is needed to use a laser cutter. Having the wherewithal to operate the laser cutter correctly in a proper environment will keep a machine working optimally on many projects for a long time to come.

3D scan and cutting of a marble head on a 5 axis CNC machine using Scantech’s 3D Scanner and Copying CAD/CAM CarsoLathe – www.scantech.com

Laser cutters operate by focusing a beam of light, or laser, on a pinpointed site on an object in order to cut it rather than using a solid object, like a blade, to cut the object. A computer system with vector graphical software will also be needed. Instructions are given to the laser cutter through software which deciphers design geometry to numerical CNC machine code. A laser can also take in data from drawings made with the help of computer-aided design (CAD) software.

Configurations of Laser Cutting Machines

The configurations of the machine are characterized based on the way the laser beam will come in contact with the material that will be cut. There are three main setups that work on the X and Y axes. The first configuration is referred to as moving material. In this setup, the object that will be sliced is placed below the cutter head. The next setup is the hybrid laser. Both the table and the cutter head move in opposite axes, offering optimal stability of the beam’s path. The third configuration is the flying optic setup, used by Maloya, where the cutting head is the part of the machine that is in motion. The object being cut is static and this type of configuration produces very clean work. Its rate of motion is also the quickest among the three setups. The flying optic system helps in workflow speed since clamping of the material being cut is not necessary. There are also machines utilizing up to six axes.

Laser Cutting Workflow

Loading and unloading can take up valuable production time but the speed of cutting with a laser can make up for this. Not having to clamp down the materials to be cut in some instances also saves time. Another consideration is if the laser cutter can be left on. Workers may have to turn turn off the power to take materials out of the machine and interrupt the flow of cutting.

Lighting is another consideration in a manufacturing environment. Light emitting diode (LED) lighting is becoming more popular for saving energy. More green ways of lighting manufacturing environments are becoming available such as using motion sensors so lights are not used when no one is working.

Laser Cutting Equipment and Maintenance

With the money spent on laser cutting machines, sufficient upkeep can ensure that they keep running in a safe and reliable way. If the machine is not running optimally, bad cuts can be made. Process control such as checking cutting nozzles, lenses and other optics should be conducted regularly. Conducting frequent inspections on alignment can prevent many future problems. Air sources can affect focal lenses of the laser cutter. Lens clarity is extremely important. Operators can look at a focal lens and tell if it is dirty as well as by checking it with a polarizer. A lens can then be cleaned with alcohol and fine tissue or replaced. Laser optical components are considered consumables. Chiller units need to be maintained as well. They should be started prior to cutting. A laser cutter that has not been maintained will also run slower. Replaceable parts should also be kept available if they are needed. Keep exhaust systems up to par as well.

Laser Cutting and Training

Training of use of a laser cutting machine should include hands-on training as well as additional training in a classroom environment. It should involve basic operation of the laser cutter such as how to start and shut down the machine, operation and programming of the machine, upkeep and maintenance as well as safety. Oftentimes the purchaser of the machine will receive training from the supplier of the machine. Other training could include the creation and loading of drawings, scaling, and rotation. Other things to be learned are file usage, code, databases, laser tables and metrics. CAD and computers need to be comprehended to use a laser cutter. One should understand how to measure materials’ thicknesses in relation to whether the laser cutters can cut them effectively. Blueprint reading should also be a skill held by a laser cutter user. Users need to be educated in quality control and geometric tolerance to know the range of precision of a laser cutter. Material Requirements Planning (MRP) involves planning everything needed for a job as well as inventory taking. Software is used for these tasks. Proper training on these systems is key as the common problem with them is the data often is erroneous. Some of these errors can be taken care of through proper teaching.

One should be able to use measuring tools such as calipers or a vernier caliper which can offer more accurate measurements. Other basic tools someone should be skilled in the use of are a ruler, protractor, compass and basic mathematical tools.

Quality Control

In order to keep improving workflow processes, Corrective Action Requests (CARs) and Corrective Action Notifications (CANs) can be done. This involves problem reporting, the cause of the problem, and future problem preventions. Software can take care of these issues and is called workflow quality management software. For instance, if one event occurs, a notification in a certain form such as an email will go out to a person who handles that problem. The action will then be taken to correct the problem.

Much knowledge and skill is required in operating a laser cutter. Having the wherewithal to operate the machine properly in a proper environment will keep a machine working efficiently on many projects for a long time to come.

Here is a new video of our great little table top machine cutting aluminum once again with a larger 2HP Craftsman Spindle. We are cutting with a 1/4″ carbide cutter at 12000 rpm and going .025″ deep per pass. Nothing too heavy but it ia hadling it easily.