This week’s focus is on mastering large-format machining techniques to create designs on a meter scale. Below are the tasks and details for this week.
Custom Microcontroller BoardReal-Time Data Reading
During our group work, we began by testing the runout and noticed that the path width was narrower than anticipated, likely due to wood expansion. We also cut a square block to check alignment. The measurements showed slight discrepancies: our design was 3 inches by 3 inches, but the actual cut was 3.024 inches by 3.015 inches. Additionally, we observed variations in the thickness of our plywood material. While we initially assumed a thickness of 0.5 inches, the actual sheet measured around 0.463 inches. This means that using 0.5 inches for joint holes could result in a loose fit. To ensure precision, we adjusted our approach to account for these variations. We also set the spindle speed to 10,000 rpm and the feed rate to 150 inches per minute.
Individual Assignment
For my individual assignment, I focused on machining two wooden boards that form the outer structure of the boat body for my final project, the e-tow. Additionally, I cut wooden lids to encase the electronics boxes and marked out foam shapes to ensure the boxes fit snugly.
Overview of all parts to be cut
After preparing the parts, I used Fusion 360 to create a CAM (Computer-Aided Manufacturing) toolpath for machining.
Fusion 360 Toolpath
The machining process began with setting up the ShopBot and preparing the materials.
Preparing to cut
After cutting, I was left with excess foam and marked out the cable outlines using the ShopBot.
Leftover foam after cuttingMarking cable outlines with the ShopBot
Finally, I manually shaped the boxes to achieve a tight fit and sanded the sharp edges of the wood pieces. Initially, I attempted to use a 1/8-inch endmill, but it broke during the process, so I switched back to a 1/2-inch endmill.
Manually shaping the boxes for a precise fit
Assignments
Group Assignment:
Complete your lab's safety training ✓
Test runout, alignment, fixturing, speeds, feeds, materials, and toolpaths for your machine ✓
Individual Assignment:
Design, mill, and assemble a large-scale project (approximately one meter in size) ✓
