Difference between revisions of "ShopSabre"

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(Created page with "thumb|right|zPrinter 450 in the Idea Shop Prototyping Lab __TOC__ =About uPrint Plus= The uPrint Plus developed by Stratasys, Ltd. is a fused deposition mo...")
 
 
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[[File:UPrint.JPG|thumb|right|zPrinter 450 in the Idea Shop Prototyping Lab]]
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[[File:ShopSabrePro408.JPG|thumb|right|ShopSabre Pro 408 in the Idea Shop Prototyping Lab]]
 
__TOC__
 
__TOC__
=About uPrint Plus=
+
==About ShopSabre==
The uPrint Plus developed by Stratasys, Ltd. is a fused deposition modeling (FDM) machine also known as a 3D Printer, which is ideal for models of parts that need to mimic the strength and detail of plastic injection molding. The uPrint Plus extrudes layers of ABS thermoplastic about 0.010 inches thick that stack up to form a 3D model of the desired part. The uPrint Plus has at least 10 different colors of ABS to choose from.  
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The Shop Sabre is a 3-Axis CNC Router and is the machine of choice for cutting large parts quickly and accurately.
 +
 
 +
'''You must make a reservation to use the Shop Sabre.''' To make a reservation, your file must be tool pathed and checked by a qualified Idea Shop staff member. See the below calendar for toolpathing help availability.
 +
 
 
;General Stats<nowiki>:</nowiki>
 
;General Stats<nowiki>:</nowiki>
:'''Material :''' Acrylonitrile butadiene styrene (ABS)
+
:'''Material :''' MDF, Plywood, OSB, Wood, Foam, Acrylic.
:'''Maximum Part Size :''' 203mm x 203mm x 152mm (8in x 8in x 6in)
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:'''Maximum Part Size :''' 121 cm x 243 cm x 20 cm (48in x 96in x 8in)
:'''Layer Thickness :''' 0.254mm (.010in)
+
 
 +
 
 +
 
 +
<div class="col-md-12">
 +
<div class="col-md-6">
 +
<div class="panel panel-success">
 +
<div class="panel-heading">Strengths</div>
 +
<div class="panel-body">
 +
*Create large parts quickly and cheaply
 +
*Cuts a wide variety of materials
 +
*Can cut 3D shapes
 +
</div>
 +
</div>
 +
</div>
 +
<div class="col-md-6">
 +
<div class="panel panel-danger">
 +
<div class="panel-heading">Weaknesses</div>
 +
<div class="panel-body">
 +
*Cannot cut sharp interior corners (limited to bit diameter)
 +
*Toolpathing has a sharp learning curve and must be checked by a qualified staff member.
 +
</div>
 +
</div>
 +
</div>
 +
</div>
 +
<br clear=all>
 
----
 
----
  
=Processing=
+
==Processing==
:''Main Article : [[Processing UPrint Plus Files]]''
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:''Main Article : [[RhinoCAM]]''
[[File:Good Netfab Capture.PNG|thumb|right|Good STL in Netfabb]]
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[[File:Toolpath.JPG|thumb|right|ToolPath Simulation Running in RhinoCam]]
After you have designed the 3D model of your desired part, export the part in the STereoLithography (.stl) file format. The STL format describes only the surface geometry of the object instead of the object as a whole. Then open the file in the Autodesk Netfabb software to repair the file.
+
RhinoCam is the software used to create toolpaths for the ShopSabre, and is available on every computer in the IdeaShop. If you do not have much experience using Rhinoceros or RhinoCam, have a staff member help walk you through the process, since it can be tedious. Before creating a toolpath, feel free to use AutoCad to create the 2D geometry you wish to cut out since DWG files from AutoCad can be opened and used to create toolpaths in Rhinoceros. After creating and opening a file in Rhinoceros, double check the geometry and delete any duplicate lines or points. Join the remaining lines to create one solid geometry. Once you have your final geometry, you can begin creating your toolpath. If you are familiar with this process, go ahead and create the toolpath. If you are new to this process, have a staff member come and assist you. If you create the toolpath without a staff member, before you generate the G-Code, have a staff member double check all the settings and parameters you set for your toolpath.  
;We will only process STLs which have<nowiki>:</nowiki>
 
:1 shell per continuous part
 
:0 border edges
 
:0 invalid orientations
 
:0 holes.
 
;Due to the coarse resolution of the printer, it is advised that the geometry have a minimum wall thickness of 2mm in order to produce accurate models.
 
Even if Netfabb reports no invalid orientations, if we see red triangles in repair mode there is a problem with your model. Print at your own risk.
 
 
----
 
----
  
==Fixing a File==
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==Prepping the ShopSabre==
:''Main Article : [[Fixing STLs]]''
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Before the ShopSabre is ready to run, there are a few steps that must be taken in order to safely operate it to the best of its abilities.
Students are welcome to use any of our computers for fixing their files in Netfabb or Rhino.
+
Make sure the compressor is on in order to supply air to the machine. It requires at least 100 psi to run, which can be checked by the gauge on the airline next to the machine.
;Here are some tips to get you started at home<nowiki>:</nowiki>
+
#'''Initial Setup:''' Ensure the compressor is on. Open the valve on the airline to the machine. Once the machine has enough air pressure, turn on power to the machine. Un-park the machine by removing the wooden block that sits behind the cutter head.
:Ideally in Rhino you want one closed polysurface before meshing.
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#'''Homing the machine:''' On the dedicated Shop Sabre desktop, open up WinCNC. Home the machine by pressing the HOME button. You can now use the computer to manually move the spindle to home in the X, Y, and Z directions.  
:NetFabb is better at meshing than Rhino. Consider opening the 3dm file in NetFabb to generate the STL instead.  
+
#'''Securing your material:''' Move the gantry out of the way and secure your stock to the spoil board. Line up the your material on the SW (SW being relative, but NE in terms of cardinal directions) corner of the spoil board, to get as close to the machine home as possible.  
:Default repair is decent at fixing holes, border edges, and invalid orientations. Then try using boolean join to reduce shells down to 1.
+
#'''Setting X, Y, and Z zero:''' Once your material is secured, establish the X and Y zero points. Be sure to set the Z zero to match your file. In instances where the Z zero is at the bottom of your stock box, you may have to set the Z zero before securing your material to the spoil board.
:If boolean join results in multiple shells then most likely the shells are not contiguous. Consider deleting extra shells in model.
+
#'''Measure tools:''' For jobs with tool changes, make sure to load tools in their appropriate spots, and pre-measure each tool using WinCNC.
:Extended repair wraps an existing STL in a new mesh. This can severely alter geometry and result in thin walled sections.
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#'''Warm Up:''' Once your material is secured, you may now turn on power to the spindle. With power now supplied to the spindle, select the warmup button on the computer. The spindle will move to the middle of the table and begin to spin.  
 +
#'''Running a job:''' After warming up, the machine is ready to run the generated G-Code. Download the posted file onto the desktop. DO NOT RUN FILES OFF OF THE Z DRIVE, AS NETWORK INTERRUPTIONS MAY CAUSE THE JOB TO FAIL. Have a qualified staff member double check that all of these steps have been done correctly before beginning to run the machine.
 
----
 
----
  
=Post Processing=
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==Running a Job==
:"Main Article : [[Preparing a File to Print]]"
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Once a staff member has confirmed the ShopSabre is ready to run, you may begin the job. You must be present at all times while the job is running to ensure the machine runs smoothly and without error. The user must be attentive and ready to abort the job if problems arise.
Once a file has been processed and is ready to be printed, find a shop supervisor to help add it to the queue. The length of the queue is highly variable, and the time it takes to print a model may range from a few days to being ready by the end of the day it is submitted. Keep in mind that the UPrint queue is very full during finals, midterms, and the time surrounding IPro Day. An estimate of queue length and a time to come pick up the part will be communicated to you once your part is added to the queue.
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 +
Once a job is complete, you may remove your material and parts from the spoil board, and clean up the work area.
 
----
 
----
 +
<div class="panel panel-default">
 +
<div class="panel-heading"><h3 style="margin: 0em; text-align:center; color:#A32929;">Tool Pathing Availability</h3></div>
 +
<div class="panel-body">
 +
{{#widget:Google Calendar
 +
|id=iit.edu_f5bhd78nlmf130tkd7iehmssag@group.calendar.google.com
 +
|color=A32929
 +
|height=500
 +
|showcals=false
 +
|showprint=false
 +
|showtitle=false
 +
|view=WEEK
 +
}}
 +
</div>
 +
</div>
  
=Printing a Part=
 
:"Main Article : [[Printing a Part]]"
 
Once a part is successfully in the queue, it is ready to be printed. The average part takes about 2 hours to print, while a very complex part could take full days to print. The webcam livestream on the IdeaShop wiki can be used to check the progress of your part.
 
 
----
 
----
 +
==Machine Proficiency==
 +
----
 +
<div class="alert alert-warning" role="alert" style="font-weight:bold; text-align:center">Under Construction</div>
 +
In order for an individual to advance in machine proficiency they must demonstrate ability to perform certain actions or tasks. All levels include abilities and concepts from lower levels.
 +
 +
This section is primarily for student workers.
 +
 +
===<span style="background-color:#C0C0C0">Level 0</span>===
 +
<div class="col-md-6">
 +
Individual has demonstrated they are capable of:
 +
*Turning on the appropriate switches and valves to be able to move the machine.
 +
*Setting XYZ zero according to appointment description.
 +
*Properly fixing material to spoil boards.
 +
</div>
 +
<div class="col-md-6">
 +
Individual understands the concepts:
 +
*The limit switches on the machine.
 +
*How the machine is powered and how it moves.
 +
</div>
 +
<br clear=all>
 +
 +
===<span style="background-color:red">Level 1</span>===
 +
<div class="col-md-6">
 +
Individual has demonstrated they are capable of:
 +
*Safely parking the machine.
 +
*Attaching a tool using appropriate collet.
 +
*Posting a created tool path for the appropriate machine.
 +
*Creating the tool path for a 2-½ axis job with profiling, slotting, pocketing or drilling features.
 +
</div>
 +
<div class="col-md-6">
 +
Individual understands the concepts:
 +
*Differences between Climb and Conventional milling.
 +
*What tool to use and when to use it.
 +
*Understanding how different materials react when cut
 +
*Basics of G-Code.
 +
*Basic RhinoCAM knowledge.
 +
</div>
 +
<br clear=all>
 +
===<span style="background-color:yellow">Level 2</span>===
 +
<div class="col-md-6">
 +
Individual has demonstrated they are capable of:
 +
*Picking appropriate feeds and speeds based on tool and material.
 +
*Creating a 3-axis toolpath including roughing and finishing.
 +
</div>
 +
<div class="col-md-6">
 +
Individual understands the concepts:
 +
*Understand the math behind determining feed rates and speeds.
 +
*Balance between Speed vs Surface Finish, and when to apply them.
 +
*Excellent RhinoCAM knowledge.
 +
</div>
 +
<br clear=all>
  
==Cleaning Parts==
+
===<span style="background-color:green">Level 3</span>===
:"Main Article : [[Removing and Cleaning a Part]]"
+
<div class="col-md-6">
[[File:ChemicalBath.JPG|thumb|right|The chemical bath used to clean support material off of printed models.]]
+
Individual has demonstrated they are capable of:
Once the model has been successfully created, it is removed from the printer and separated from the printing tray base. From here, it is placed in a chemical bath in order to remover the support material in a way that does not affect the model. Please allow 1-3 hours for the model to sit in the bath, depending on the complexity of the model, in order to successfully remove all support material. Once this process is complete, the part is ready to be picked up by the creator.
+
*Creating a toolpath for a double sided job.  
 +
</div>
 +
<div class="col-md-6">
 +
Individual understands the concepts:
 +
*Spatial awareness between RhinoCAM, the machine, material, and fastening the material.
 +
*Maintaining accuracy when moving the material.
 +
</div>
 +
<br clear=all>

Latest revision as of 15:57, 4 May 2021

ShopSabre Pro 408 in the Idea Shop Prototyping Lab

About ShopSabre

The Shop Sabre is a 3-Axis CNC Router and is the machine of choice for cutting large parts quickly and accurately.

You must make a reservation to use the Shop Sabre. To make a reservation, your file must be tool pathed and checked by a qualified Idea Shop staff member. See the below calendar for toolpathing help availability.

General Stats:
Material : MDF, Plywood, OSB, Wood, Foam, Acrylic.
Maximum Part Size : 121 cm x 243 cm x 20 cm (48in x 96in x 8in)


Strengths
  • Create large parts quickly and cheaply
  • Cuts a wide variety of materials
  • Can cut 3D shapes
Weaknesses
  • Cannot cut sharp interior corners (limited to bit diameter)
  • Toolpathing has a sharp learning curve and must be checked by a qualified staff member.



Processing

Main Article : RhinoCAM
ToolPath Simulation Running in RhinoCam

RhinoCam is the software used to create toolpaths for the ShopSabre, and is available on every computer in the IdeaShop. If you do not have much experience using Rhinoceros or RhinoCam, have a staff member help walk you through the process, since it can be tedious. Before creating a toolpath, feel free to use AutoCad to create the 2D geometry you wish to cut out since DWG files from AutoCad can be opened and used to create toolpaths in Rhinoceros. After creating and opening a file in Rhinoceros, double check the geometry and delete any duplicate lines or points. Join the remaining lines to create one solid geometry. Once you have your final geometry, you can begin creating your toolpath. If you are familiar with this process, go ahead and create the toolpath. If you are new to this process, have a staff member come and assist you. If you create the toolpath without a staff member, before you generate the G-Code, have a staff member double check all the settings and parameters you set for your toolpath.


Prepping the ShopSabre

Before the ShopSabre is ready to run, there are a few steps that must be taken in order to safely operate it to the best of its abilities. Make sure the compressor is on in order to supply air to the machine. It requires at least 100 psi to run, which can be checked by the gauge on the airline next to the machine.

  1. Initial Setup: Ensure the compressor is on. Open the valve on the airline to the machine. Once the machine has enough air pressure, turn on power to the machine. Un-park the machine by removing the wooden block that sits behind the cutter head.
  2. Homing the machine: On the dedicated Shop Sabre desktop, open up WinCNC. Home the machine by pressing the HOME button. You can now use the computer to manually move the spindle to home in the X, Y, and Z directions.
  3. Securing your material: Move the gantry out of the way and secure your stock to the spoil board. Line up the your material on the SW (SW being relative, but NE in terms of cardinal directions) corner of the spoil board, to get as close to the machine home as possible.
  4. Setting X, Y, and Z zero: Once your material is secured, establish the X and Y zero points. Be sure to set the Z zero to match your file. In instances where the Z zero is at the bottom of your stock box, you may have to set the Z zero before securing your material to the spoil board.
  5. Measure tools: For jobs with tool changes, make sure to load tools in their appropriate spots, and pre-measure each tool using WinCNC.
  6. Warm Up: Once your material is secured, you may now turn on power to the spindle. With power now supplied to the spindle, select the warmup button on the computer. The spindle will move to the middle of the table and begin to spin.
  7. Running a job: After warming up, the machine is ready to run the generated G-Code. Download the posted file onto the desktop. DO NOT RUN FILES OFF OF THE Z DRIVE, AS NETWORK INTERRUPTIONS MAY CAUSE THE JOB TO FAIL. Have a qualified staff member double check that all of these steps have been done correctly before beginning to run the machine.

Running a Job

Once a staff member has confirmed the ShopSabre is ready to run, you may begin the job. You must be present at all times while the job is running to ensure the machine runs smoothly and without error. The user must be attentive and ready to abort the job if problems arise.

Once a job is complete, you may remove your material and parts from the spoil board, and clean up the work area.


Tool Pathing Availability


Machine Proficiency


In order for an individual to advance in machine proficiency they must demonstrate ability to perform certain actions or tasks. All levels include abilities and concepts from lower levels.

This section is primarily for student workers.

Level 0

Individual has demonstrated they are capable of:

  • Turning on the appropriate switches and valves to be able to move the machine.
  • Setting XYZ zero according to appointment description.
  • Properly fixing material to spoil boards.

Individual understands the concepts:

  • The limit switches on the machine.
  • How the machine is powered and how it moves.


Level 1

Individual has demonstrated they are capable of:

  • Safely parking the machine.
  • Attaching a tool using appropriate collet.
  • Posting a created tool path for the appropriate machine.
  • Creating the tool path for a 2-½ axis job with profiling, slotting, pocketing or drilling features.

Individual understands the concepts:

  • Differences between Climb and Conventional milling.
  • What tool to use and when to use it.
  • Understanding how different materials react when cut
  • Basics of G-Code.
  • Basic RhinoCAM knowledge.


Level 2

Individual has demonstrated they are capable of:

  • Picking appropriate feeds and speeds based on tool and material.
  • Creating a 3-axis toolpath including roughing and finishing.

Individual understands the concepts:

  • Understand the math behind determining feed rates and speeds.
  • Balance between Speed vs Surface Finish, and when to apply them.
  • Excellent RhinoCAM knowledge.


Level 3

Individual has demonstrated they are capable of:

  • Creating a toolpath for a double sided job.

Individual understands the concepts:

  • Spatial awareness between RhinoCAM, the machine, material, and fastening the material.
  • Maintaining accuracy when moving the material.