Anna Vasileiou

Computer-controlled machining

For this week's assignment we had to test the runout, alignment, speeds, feeds, and toolpaths for our CNC
machine (group assignment) and make (design - mill- assemble) something big (individual assignment).

Deb, Elina, Kii, and I joined our forces to run the first tests while Chris Dewart was there helping us with
setting up the mastercam file and C.R. Onsrud aka the CNC milling machine.

Before developing our design in rhino, we measured the thickness of the OSB stock we were provided with for the
assignments' requirements. The thickness we got was approximately 0.45".

We then decided to treat the individual assignment as an assembly of transformable components that would form
a big group project but when disassembled they would give each of us our own individual "something big" project. The
overall structure would begeometrically based on hexagons that would be connected to each other by three different
types of 3d printed joints: 60-degree rotational ones, 120-degree fixed joints, and 60-degree fixed joints.

For the group testing we therefore designed generic geometries like a triangular and circular surface to test the
behavior of OSB.

Chris helped us place the OSB test board on the machine's bed and removed any air left between the board and the bed by
pushing the two press buttons below the bed.

Next, Chris set up the z coordinate of the machine's endmill to define how deep the cut would be adn did a simulation before milling started.

Here is the first outcome of the milling.

Here is the second outcome of the milling.

We then moved back to rhino to start designing the joints we would eventually 3d print. We came up with a rotational
two-parts system forming a 60-degrees angle when not rotated and a 120-degrees angle when rotated.

We redesigned both the 60 and 120-degrees joints to add slots and "buttons" that would let the joints' components interlock
with each other and stay in place. Here is the design as developed in rhino.

After doing our first print tests, we found some points of failure and had to re-adjsut our design by increasing the
thickness of the hoints' "legs" and chamfering their interior profile at the point where they connect to the joint's base.

In the meantime we milled our OSB plates by following the exact same process we followed for our original group milling tests.