Aluminum Machining Tutorial

From Lofaro Lab Wiki
Revision as of 03:39, 11 May 2016 by Agoldsto (Talk | contribs)

Jump to: navigation, search

Using CAM Tools

In order to machine parts first you must design your tool path using CAM (Computer Aided Manufacturing) Tools. In this tutorial we will show how to create toolpaths in Autodesk Fusion and export the Gcode for milling.

Setup

1. First, go to the file icon at the top menu and select 'New Design from File'. You must select a .stp format file. Once the file is selected on the left of the ribbon a tab should say 'sculpt'. Click the tab and scroll down to select 'CAM'. Just to the right of CAM is the 'setup' option. Click setup and a box should appear that says 'model orientation':


CAM setup.png


2. Click model orientation and select the axis you wish to adjust. Set the stock material within the file to match the way if will be placed on your milling machine. Then go to origin and choose selected point. This allows you to select a universal origin for your part. All tools and toolpaths will reference this origin.

3. Next, go select the drilling option. Drilling must always be performed first. Once the menu appears, near Tool click 'select' and choose the proper drill size. All parts for the ASL-Robot use three hole sizes, 2mm, 2.5mm, and 4mm diameter holes.


Tool selection.png


4. Once the tool has been selected click the geometry tab in the drilling menu and set the tool orientation to match that of your milling machine. Next click the 'heights' tab to the left of the geometry box and go to 'bottom height'. You will see small check box for 'drill through bottom'. Select the check box and the distance you wish to pierce through your material. This ensures that the drill goes all the way through your material. Then, BEFORE you close the drilling menu, make sure all boxes are unchecked and click the holes you wish to drill on your design. It will create a drilling path as shown below:


File:Drill Path.png


5. Once you've selected all the holes you with to drill click 'okay' and close the drill menu box. At the top where you selected drilling you can see an 'action' panel with three options. The left most option is the simulation. Simply click the simulation option and the play button at the bottom of the screen to see a simulation of the drilling operation. You should always simulate first to make sure the operation is as desired. Once you have confirmed the operation is as desired click the 'post process' option to the left of the simulation option. This will export the operation as a gcode file. NOTE: Make sure to choose the proper file extension for your milling machine. In our case we use generic linux (.ngc). Once the file is exported it can used on a milling machine.

6. For our parts there are two other required operations, boring and milling. Both operations use a mill. Clear the drilling operation from the file by deleting it under the setup folder. Then at the top there is a tab for '2D', from here you can now select a boring or milling operation. The milling operation we use is 2D Contour:


Contour bore.png


7. Both operations use the same tool, a milling bit. For our parts we used a 1/4 bit. Once the tool orientation has been set under the geometry tab, the tool path can be selected. For the Bore path simply choose a large hole you wish to bore out. For the 2D Contour CAREFULLY choose the perimeter you want to mill around. Make sure you are reaching to the bottom of your stock material if you wish to remove the piece completely. Below are examples of the Bore (top) and 2D Contour (bottom) Tool Paths:


Bore mill.png


8. Make sure to export each operation as a single gcode file. Once you have all three of your gcode files you are ready to begin milling.

Using Linux CNC