CNCMill: Difference between revisions

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[[Category:Hacking]]
[[Category:Hacking]]
= Links =
* Radial and Axial Depth of Cut
** [https://www.cnccookbook.com/2-tools-calculating-cut-depth-cut-widthstepover-milling/ Cut Depth and Stepover]
** https://www.harveyperformance.com/in-the-loupe/depth-of-cut/
*** Perimeter Milling
**** RDOC
***** Finishing: 3% - 5% of tool diameter
***** Roughing: 10% to 50% of tool diameter
**** ADOC
***** Shallower for roughing, deeper for finishing.
*** Slotting
**** ADOC
***** Roughing: 10% to 50% of tool diameter
***** Finishing (bottom): 3% - 5% of tool diameter
* Feeds & Speeds
** https://www.the-carbide-end-mill-store.com/Feeds-and-Speeds.html
** [[Feeds_and_Speeds]]


= G-Code =
= G-Code =


This may be specific to Acorn CNC at HSL.
This may be specific to Acorn CNC at HSL.
* https://en.wikipedia.org/wiki/G-code


== Comments ==
== Comments ==
Line 91: Line 112:


= Bearing Cup =
= Bearing Cup =
* [[BearingCupVersionOne]]
* [[BearingCupVersionTwo]]
* [[BearingCupVersionThree]]


== Face Material (001) ==
= Gear Cutting =
 
Lightest Possible Grazing Pass
 
Zero X to right end
 
Zero Y to middle of material, 25.4mm from edge
 
Zero Z with 3" five-tooth facing mill
 
Set spindle speed to 210 RPM.
 
<pre>
G21 (set units to millimeters)
G90 (set measurements to absolute, relative to machine zero)
F26 (set feed rate to 26mm per minute)
G0 Z20 (traverse to 20mm above part)
G0 X50 Y0 (traverse to outside part)
G0 Z5 (traverse to 5mm above part)
 
G1 Z1 (feed to 1mm above part)
 
G1 X-347 (feed to left end)
G0 Z20 (traverse to 20mm above part)
</pre>
 
* Update G1 Z1 to G1 Z0 and re-run.
* Update G1 Z1 to G1 Z-0.1 and re-run.
 
== Drill Center ==
 
Zero X to 13mm from short edge
 
Zero Y to 25.4mm from long edge (center of material)
 
Set spindle speed to 1200 RPM
 
=== Starter Center Drill (002) ===
 
Zero Tool Z Manually w/ 5/16 drill, zero Z to drill shoulder.
 
<pre>
G21 (set units to millimeters)
G90 (set measurements to absolute, relative to machine zero)
G0 Z20 (traverse to 20mm above part)
G0 X0 Y0 (traverse to origin XY)
F60 (set feed rate to 60mm per minute, 0.025 mm per tooth)
G0 Z5 (traverse to 5mm above part)
 
G1 Z-6 (feed to 6mm deep)
G0 Z5 (retract to 5mm above)
G0 Z0 (traverse to 0mm above)
G1 Z-12 (feed to 12mm deep)
G0 Z20 (traverse to 20mm above)
</pre>
 
=== Final Center Drill (003) ===


Zero Tool Z Manually w/ 1/2 drill, zero Z to drill shoulder.
== G-Code ==
<pre>
G21 (set units to millimeters)
G90 (set measurements to absolute, relative to machine zero)
G0 Z20 (traverse to 20mm above part)
G0 X0 Y0 (traverse to origin XY)
F60 (set feed rate to 60mm per minute, 0.035 mm per tooth)
G0 Z5 (traverse to 5mm above part)


G1 Z-6 (feed to 6mm deep)
[[GearCuttingVersionOne]]
G0 Z5 (retract to 5mm above)
G0 Z0 (traverse to 0mm above)
G1 Z-9 (feed to 9mm deep)
G0 Z20 (traverse to 20mm above)
</pre>


== Drill Screw Holes ==
== Notes ==


=== Drill Threaded Hole (004) ===
* On a 30mm radius gear, error from 1 degree involute curve approximation is on the order of thousandths of a millimeter.
* 20 degrees is the typical pressure angle.
* http://www.otvinta.com/gear.html
** http://www.otvinta.com/tutorial01.html
** Also: cnc-mill/involute_gear/calculator/Otvinta.com -- Involute Gear Calculator


Use bit that came with M4-0.7 tap.
== Not Profile-Shifted ==
 
Zero Z to drill bit shoulder.
 
<pre>
G21 (set units to millimeters)
G90 (set measurements to absolute, relative to machine zero)
G0 Z20 (traverse to 20mm above part)
G0 X9.5 Y9.5 (traverse to screw hole center XY)
F60 (set feed rate to 60mm per minute, 0.025 mm per tooth)
G0 Z5 (traverse to 5mm above)


G1 Z-5 (peck to 5mm deep)
* Bottom of Root to Pitch Radius = module
G0 Z6 (retract to 6mm above)
* Pitch Radius to Tip Radius = module
G0 Z0 (traverse to 0mm above)
* module = distance along pitch radian from pitch circle at 0 radians to base circle at standard pressure angle radians
G1 Z-10 (peck to 10mm deep)
** See: https://www.tec-science.com/mechanical-power-transmission/involute-gear/undercut/
G0 Z6 (retract to 6mm above)
** "Calculation of the minimum number of teeth"
G0 Z0 (traverse to 0mm above)
* 14 teeth minumum (17 hypothetical, 14 practical, some stretch to 12)
G1 Z-9 (peck to 9mm deep)
G0 Z20 (traverse to 20mm above)
</pre>


=== Drill Slip Hole ===
== Profile Shifted ==


Use .166" or 4.25mm bit.
* z=10, x=.4 pretty safe
* z=8, x=.4 probably works in practice
* https://khkgears.net/new/gear_knowledge/abcs_of_gears-b/gear_profile_shift.html
* http://www-mdp.eng.cam.ac.uk/web/library/enginfo/textbooks_dvd_only/DAN/gears/generation/generation.html


Zero Z to drill bit shoulder.
== Mesh Check ==


<pre>
Looks promising:
G21 (set units to millimeters)
G90 (set measurements to absolute, relative to machine zero)
G0 Z20 (traverse to 20mm above part)
G0 X-9.5 Y-9.5 (traverse to screw hole XY)
F60 (set feed rate to 60mm per minute, 0.025 mm per tooth)
G0 Z5 (traverse to 5mm above)


G1 Z-5 (peck to 5mm deep)
[[File:Mesh check.png|thumb]]
G0 Z6 (retract to 6mm above)
G0 Z0 (traverse to 0mm above)
G1 Z-10 (peck to 10mm deep)
G0 Z6 (retract to 6mm above)
G0 Z0 (traverse to 0mm above)
G1 Z-9 (peck to 9mm deep)
G0 Z20 (traverse to 20mm above)
</pre>


== Arc Bore Center ==
= Geometry =


Zero Tool Z w/ 6mm Square End Mill
== Circle from 3 Points ==


=== Bearing Retainer ===
https://stackoverflow.com/questions/4103405/what-is-the-algorithm-for-finding-the-center-of-a-circle-from-three-points#4103418


<pre>
<pre>
G21 (set units to millimeters)
  public static Circle circleFromPoints(final Point p1, final Point p2, final Point p3)
G90 (set measurements to absolute, relative to machine zero)
  {
G0 Z20 (traverse to 20mm above part)
    final double offset = Math.pow(p2.x,2) + Math.pow(p2.y,2);
G0 X0 Y0 (traverse to origin XY)
    final double bc =  ( Math.pow(p1.x,2) + Math.pow(p1.y,2) - offset )/2.0;
F120 (set feed rate to 120mm per minute)
    final double cd =   (offset - Math.pow(p3.x, 2) - Math.pow(p3.y, 2))/2.0;
G0 Z5 (traverse to 5mm above part)
    final double det =  (p1.x - p2.x) * (p2.y - p3.y) - (p2.x - p3.x)* (p1.y - p2.y);
 
   
G1 Z1 (feed to 1mm above part)
    if (Math.abs(det) < TOL) { throw new IllegalArgumentException("Yeah, lazy."); }
 
(repeatable cut)
G1 X6 Y0 (feed to bore size)
G2 X6 Y0 I-6 J0 (bore circle to same location around machine zero)
G1 X0 Y0 (feed to origin)
(repeatable cut)
 
G1 Z-2 (feed to 2mm below surface)
 
(repeatable cut)
G1 X6 Y0 (feed to bore size)
G2 X6 Y0 I-6 J0 (bore circle to same location around machine zero)
G1 X0 Y0 (feed to origin)
(repeatable cut)
 
G1 Z-4 (feed to 4mm below surface)
 
(repeatable cut)
G1 X6 Y0 (feed to bore size)
G2 X6 Y0 I-6 J0 (bore circle to same location around machine zero)
G1 X0 Y0 (feed to origin)
(repeatable cut)
 
G1 Z-6 (feed to 6mm below surface)
 
(repeatable cut)
G1 X6 Y0 (feed to bore size)
G2 X6 Y0 I-6 J0 (bore circle to same location around machine zero)
G1 X0 Y0 (feed to origin)
(repeatable cut)
 
G1 Z-8 (feed to 8mm below surface)
 
(repeatable cut)
G1 X6 Y0 (feed to bore size)
G2 X6 Y0 I-6 J0 (bore circle to same location around machine zero)
G1 X0 Y0 (feed to origin)
(repeatable cut)
 
G1 Z-9 (feed to 10mm below surface)
 
(repeatable cut)
G1 X6 Y0 (feed to bore size)
G2 X6 Y0 I-6 J0 (bore circle to same location around machine zero)
G1 X0 Y0 (feed to origin)
(repeatable cut)
 
G0 Z20 (traverse to 20mm above part)
</pre>
 
=== Bearing Cup ===
 
<pre>
G21 (set units to millimeters)
G90 (set measurements to absolute, relative to machine zero)
G0 Z20 (traverse to 20mm above part)
G0 X0 Y0 (traverse to origin XY)
F120 (set feed rate to 120mm per minute)
G0 Z5 (traverse to 5mm above part)
 
G1 Z1 (feed to 1mm above part)
 
(repeatable cut)
G1 X8.03 Y0 (feed to bore size)
G2 X8.03 Y0 I-8.03 J0 (bore circle to same location around machine zero)
G1 X0 Y0 (feed to origin)
(end repeatable cut)
 
G1 Z-2 (feed to 2mm below surface)
 
(repeatable cut)
G1 X8.03 Y0 (feed to bore size)
G2 X8.03 Y0 I-8.03 J0 (bore circle to same location around machine zero)
G1 X0 Y0 (feed to origin)
(end repeatable cut)
 
G1 Z-4 (feed to 4mm below surface)
 
(repeatable cut)
G1 X8.03 Y0 (feed to bore size)
G2 X8.03 Y0 I-8.03 J0 (bore circle to same location around machine zero)
G1 X0 Y0 (feed to origin)
(end repeatable cut)
 
G1 Z-6 (feed to 6mm below surface)
 
(repeatable cut)
G1 X8.03 Y0 (feed to bore size)
G2 X8.03 Y0 I-8.03 J0 (bore circle to same location around machine zero)
G1 X0 Y0 (feed to origin)
(end repeatable cut)
 
G1 Z-7 (feed to 7mm below surface)
 
(repeatable cut)
G1 X8.03 Y0 (feed to bore size)
G2 X8.03 Y0 I-8.03 J0 (bore circle to same location around machine zero)
G1 X0 Y0 (feed to origin)
(end repeatable cut)
 
G0 Z20 (traverse to 20mm above part)
</pre>
 
== Arc Cut Perimeter ==
 
Zero Tool Z w/ 3/8 Square End Mill
 
Check for Z-9 Clearance above Vise
 
<pre>
G21 (set units to millimeters)
G90 (set measurements to absolute, relative to machine zero)
F120 (set feed rate to 120mm per minute)
G0 Z20 (traverse to 20mm above part)
G0 X25 Y5.93 (traverse to cut start XY)
G0 Z5 (traverse to 5mm above part)
 
G1 Z1 (feed to 1mm above part)
 
(repeatable cut)
G1 X14.32 Y5.93 (feed to first arc start)
G2 X-5.93 Y-14.32 I-14.32 J-5.93 (arc cut to second arc start)
G2 X-14.32 Y-5.93 I-3.57 J4.82 (arc cut to third arc start)
G2 X5.93 Y14.32 I14.32 J5.93 (arc cut to fourth arc start)
G2 X14.32 Y5.93 I3.57 J-4.82 (arc cut to first arc start)
G1 X25 (cut to outside part)
(end repeatable cut)
 
G1 Z-2 (feed to 2mm below part)
 
(repeatable cut)
G1 X14.32 Y5.93 (feed to first arc start)
G2 X-5.93 Y-14.32 I-14.32 J-5.93 (arc cut to second arc start)
G2 X-14.32 Y-5.93 I-3.57 J4.82 (arc cut to third arc start)
G2 X5.93 Y14.32 I14.32 J5.93 (arc cut to fourth arc start)
G2 X14.32 Y5.93 I3.57 J-4.82 (arc cut to first arc start)
G1 X25 (cut to outside part)
(end repeatable cut)
 
G1 Z-4 (feed to 4mm below part)
 
(repeatable cut)
G1 X14.32 Y5.93 (feed to first arc start)
G2 X-5.93 Y-14.32 I-14.32 J-5.93 (arc cut to second arc start)
G2 X-14.32 Y-5.93 I-3.57 J4.82 (arc cut to third arc start)
G2 X5.93 Y14.32 I14.32 J5.93 (arc cut to fourth arc start)
G2 X14.32 Y5.93 I3.57 J-4.82 (arc cut to first arc start)
G1 X25 (cut to outside part)
(end repeatable cut)
 
G1 Z-6 (feed to 6mm below part)
 
(repeatable cut)
G1 X14.32 Y5.93 (feed to first arc start)
G2 X-5.93 Y-14.32 I-14.32 J-5.93 (arc cut to second arc start)
G2 X-14.32 Y-5.93 I-3.57 J4.82 (arc cut to third arc start)
G2 X5.93 Y14.32 I14.32 J5.93 (arc cut to fourth arc start)
G2 X14.32 Y5.93 I3.57 J-4.82 (arc cut to first arc start)
G1 X25 (cut to outside part)
(end repeatable cut)
 
G1 Z-8 (feed to 8mm below part)
 
(repeatable cut)
G1 X14.32 Y5.93 (feed to first arc start)
G2 X-5.93 Y-14.32 I-14.32 J-5.93 (arc cut to second arc start)
G2 X-14.32 Y-5.93 I-3.57 J4.82 (arc cut to third arc start)
G2 X5.93 Y14.32 I14.32 J5.93 (arc cut to fourth arc start)
G2 X14.32 Y5.93 I3.57 J-4.82 (arc cut to first arc start)
G1 X25 (cut to outside part)
(end repeatable cut)
 
G1 Z-9 (feed to 9mm below part)
 
(repeatable cut)
G1 X14.32 Y5.93 (feed to first arc start)
G2 X-5.93 Y-14.32 I-14.32 J-5.93 (arc cut to second arc start)
G2 X-14.32 Y-5.93 I-3.57 J4.82 (arc cut to third arc start)
G2 X5.93 Y14.32 I14.32 J5.93 (arc cut to fourth arc start)
G2 X14.32 Y5.93 I3.57 J-4.82 (arc cut to first arc start)
G1 X25 (cut to outside part)
(end repeatable cut)


G0 Z20 (traverse to 20mm above part)
    final double idet = 1/det;
   
    final double centerx =  (bc * (p2.y - p3.y) - cd * (p1.y - p2.y)) * idet;
    final double centery =  (cd * (p1.x - p2.x) - bc * (p2.x - p3.x)) * idet;
    final double radius =
      Math.sqrt( Math.pow(p2.x - centerx,2) + Math.pow(p2.y-centery,2));
   
    return new Circle(new Point(centerx,centery),radius);
  }
</pre>
</pre>

Latest revision as of 06:11, 4 August 2022


Links

G-Code

This may be specific to Acorn CNC at HSL.

Comments

Comments are in parentheses.

G0X0Y0 (rapid traverse to origin - the traverse will be executed, but this parenthetical comment is ignored)

Active Units

G20 (set active units to inches)
G21 (set active units to millimeters)

Absolute v. Incremental

G90 (absolute measurements, relative to machine zero)
G91 (incremental measurements, relative to previous ending position)

Feeds

F sets the feed rate in the active units.

G20 (inches)
F15 (15 inches per minute)
G1 X0 Y0 (traverse to origin at 15 IPM) (spaces are optional)
G21 (millimeters)
F375 (375 mm per minute)
G1X0Y0 (traverse to origin at 375mmPM)

Straight Line Traversal

G0 is fast traversal. Careful not to run the tool into the part. Each axis is run at full speed until reaching its destination (ie: the tool follows multiple line segments, not an interpolated straight line).

G21 (set millimeters)
G90 (set absolute coordinates)
G0X3 (fast traverse the X axis to origin + 3 millimeters)
G0X1Y-2.6Z3 (fast traverse to { 1, -2.6, 3 } millimeters)
G0X0Y0Z0 (fast traverse to origin)
G0 X1 Y-2.6 Z3 (fast traverse to { 1, -2.6, 3} mm with spaces for readability)

Straight Line Cuts

G1 is an interpolated straight line from current position to the new position, moving at feed rate.

G21 (set millimeters)
G90 (set absolute coordinates)
F350 (set feed speed to 350mm per minute)
G0X0Y0Z0 (move to origin)
G1X10Y20Z-5 (move in a straight line from {0,0,0} to {10,20,-5} at 350mm per minute)

Plane Selection

G17, G18, G19 select XY, ZX, or YZ as the active plane.

Arc Cuts

G2 is a clockwise cut from the current position { X1, Y1, Z1 } to the destination at { X2, Y2, Z2 } about the center { X1 + I, Y1 + J, Z1 + K }.

G3 is counterclockwise.

If the active plane is XY, all three Z's must be the same and do not need to be specified. The same applies for ZX and Y, and for YZ and X.

Note: I, J, and K are always incremental measurements from X1, Y1, Z1

G17 (set plane to XY)
G90 (set absolute coordinates)
G1 X-1 Y0 Z0 (cut line to {-1, 0, 0 } at feed rate)
G2 X1 Y0 I1 J0 (cut arc to { 1, 0, 0 } about center at { -1 + 1, 0 + 0, 0 } )

Drill Array Pecking

TBD

Bearing Cup

Gear Cutting

G-Code

GearCuttingVersionOne

Notes

Not Profile-Shifted

Profile Shifted

Mesh Check

Looks promising:

Mesh check.png

Geometry

Circle from 3 Points

https://stackoverflow.com/questions/4103405/what-is-the-algorithm-for-finding-the-center-of-a-circle-from-three-points#4103418

  public static Circle circleFromPoints(final Point p1, final Point p2, final Point p3)
  {
    final double offset = Math.pow(p2.x,2) + Math.pow(p2.y,2);
    final double bc =   ( Math.pow(p1.x,2) + Math.pow(p1.y,2) - offset )/2.0;
    final double cd =   (offset - Math.pow(p3.x, 2) - Math.pow(p3.y, 2))/2.0;
    final double det =  (p1.x - p2.x) * (p2.y - p3.y) - (p2.x - p3.x)* (p1.y - p2.y); 
    
    if (Math.abs(det) < TOL) { throw new IllegalArgumentException("Yeah, lazy."); }

    final double idet = 1/det;
     
    final double centerx =  (bc * (p2.y - p3.y) - cd * (p1.y - p2.y)) * idet;
    final double centery =  (cd * (p1.x - p2.x) - bc * (p2.x - p3.x)) * idet;
    final double radius = 
       Math.sqrt( Math.pow(p2.x - centerx,2) + Math.pow(p2.y-centery,2));
    
    return new Circle(new Point(centerx,centery),radius);
  }