Computer-Controlled Cutting-

Tasks for the week:-

-Learn to use vinyl cutter and use it for a purpose.

-Design a product developed along the lines of parametric design using 'press-fit' construction technique.

Vinyl Cutting

The vinyl cutter is a versatile machine that can cut thin sheets of vinyl, paper, or even copper sheets. It can be used to make anything from decals for laptops and cars to printed circuit boards for soft electronics.

What is machining :-

Machining is a removal of material from solid blocks or workpiece for manufacturing the objects. It has several processes cutting, drilling, forming, grinding, milling,etc

Machine Details-

In our lab,we have the Roland desktop vinyl cutter. It has a knife which is mounted on a CNC arrangement for linear motion.The knife can rotate on its axis and the bed has rollers for moving the sheet back and forth. The sheet is cut by moving knife over it. We can set the cutting velocity and cutting force depending on the material of the sheet we are cutting.

My Experiments-

This actually became bit critical for me since I had used cursive and exotic fonts for the design to be creative, yet with some help of the batchmates, we pulled off the sticker using the masking tape, Which looked like this.

I made logo for my college

In this machine I tried letter and logo sticker. I used corel draw for making college Name sticker. I downloaded one .png file from internet and edit the file in corel draw.

I added logo in coraldrow software

I am fast time using this software and I learned basic cammed and all the thing.

Cutting process in Vinyl cutting

Set the origin for the tool on the sheet and Send the image as a tool path to the cutter

Then once the cutting is done the step that remains is to peel it off perfectly,

Fab module settings for Vinyl cutting.

Diameter(mm) = 0.25 Overlap = 0.5 Offsets = 1 Error(pixels) = 1.1 Intensity = 0.5 Force = 90 Velocity = 5

My Fast attempt-

I measured the space on my laptop and fixed on a size of 12x4cm. Since this was a test cut, I cut the full image on a single sheet of blue vinyl.

The machine also generated offsets when it is started on a re-cut, which intern damages the design again. After the above process this was the final design I printed..

Note:

When sticking together different parts of the design, be sure to not let the tape touch the vinyl already stuck on the laptop, trim the edges properly.

After hours of cutting and careful peeling and sticking, this time I was successful.

Group Assignment-

For this task we had a group assignment where w had to study about the properties and kurf of the laser engravers, for that we splitted ourselves into two groups, each assigned with one machine,

The engraver has a very high amount of kurf lining, this was mostly seen due to constant loss of focus after a vertain use of the engraver

The kerf seen vertically is different than the kurf seen horizontally

After cutting check the dimension

The engraver has a very high amount of kurf lining, this was mostly seen due to constant loss of focus after a vertain use of the engraver

The kerf seen vertically is different than the kurf seen horizontally

The following were the results we received about the deflection in the kerf Out of which we concluded that 100% power and 50% speed was ideal for minimal kerf of 0.14mm

Acrylic 6mm: we made two patterns one with varying speed, another is different speed. The first pattern was having a constant power of 62% and speed ranging between 8 to 12. other has speed of 8 and the power ranging between 55% to 70% For this speed 8 and power at 68% is best result that was we found with the least kerf of 0.3mm

The machine has the ability to engrave on various layers in the 3rd axis of geometry and has very negligible kerf

{Press-fit Parametric design in solidwork:}

Creating a press fit kit in solidwork:-

I was amazed by the various designs for press fit kits. You can build anything you can imagine. I was lost for a while thinking about what to make, I loved the idea of bending wood. Then I decided I would start simple and progress to more complicated ones.

responsive

I decided to make a simple round modular element, which can be replicated many time, and combined to make unique designs. I used SolidWorks to draw the sketch and extruded it. The design is parametric and all the dimensions can be changed later to fit various materials of different thickness. I then exported the file as a .dxf file and opened it in Inkscape, I aligned the design and changed the color to match the cut line and cut out two test pieces.

They fit perfectly. In the next try I nested multiple copies so that I could batch print them.

And next step-:

responsive

I assembled them into a 3D shape.

Laser cutting-

I also use this machine and,I am really amazed by what this machine can do. It allows you to cut intricate parts for machines like gears, press fit assembly, pulleys, etc and can do it in a very short time. It is also very dangerous and should be treated with care.

Laser cutting machine

I am using SIL Indian made laser cutting machine with has flowing characteristics Laser Power

60/80/100/130/150 Watt Wave Length 10.6 um Supply Voltage AC 220 V + 10% Reposition Accuracy + 0.05 mm Cutting Speed 0~30000 mm / min

Generally we are using SIL laser or CO2 laser cutter which having 600*900mm bed area and can cut material up to 6mm.

The laser cutter works by focusing a high energy beam of light in a small area to vaporize the material there. In our lab, we use the SIL Laser , it uses a Carbon dioxide(CO2 ) laser for generating the high energy beam.

The laser beam is generated at the back of the machine, which is then diverted by a system of prisms. The beam is then focused and moved using a CNC arrangement that allows for rapid 2D motion.

Setting up the machines-

Power	Material	Speed
62	6mm Acrylic	15
62	12mm Acrylic	6
62	3mm Acrylic	15
62	3mm Mdf	20
65	6mm cardboard	60

Power	Material	Speed
30/20	6mm Acrylic	250

Downloaded file or recent file is on the top. Select your file press the file and then enter.

In this machine we can cut MDF ,acrylic up to 6mm and paper as well .

Set the origin, check the frame(Total area of your object) and give "START" command for cutting.

The laser cutter head:

responsive

I use 3mm MDF sheet for my fest trial on SIL Laser. on very fest I used foiling setting

responsive

{ Next 1 Pressfit}

The core task was to develop a kit of 3D jigsaws that can be randomly arranged to generate various shapes

responsive

{ Next 2 Pressfit}

responsive

The best way to go for the designs like these was using the method of parametric design, since the size of the slot and the thickness of the material has to be changing relatively with the availability of the material(files at the end of the data) For the following,

{ Next 3 Pressfit}

responsive

{ Next 4 Pressfit}

responsive

Note:

The acrelic and MDF I was cutting on averaged a thickness of 3mm. Hence accounting for the kerf I put the hole width as 3mm. This gave a good fit.

{Pressfit Mobile Stand}

Initially learned how to draw the concept of y press fit mobile stand, of which I made a sketch in solid works, and assembled it to see how it works(represented by the image below)

responsive

**Then after I simulated them to and saved them individually s different part files, that could be converted to *.dxf easily, adnd be fed to the laser.**

responsive

File loaded in SIL Laser cutting machine

responsive

{Next use the cardboard laser cutting }

responsive

{Final cut acrylic sheet 3mm successful}

Mobile stand

responsive

mobile stand

Learning Outcomes-

In this assignment I learned about parametric design which is really best for experiment the same design with varying dimension. Good experience in group work.

To download my files click -:here

kamleshBisht

Passionately innovating

Computer-Controlled Cutting-

Tasks for the week:-

-Learn to use vinyl cutter and use it for a purpose.

-Design a product developed along the lines of parametric design using 'press-fit' construction technique.

Vinyl Cutting

The vinyl cutter is a versatile machine that can cut thin sheets of vinyl, paper, or even copper sheets. It can be used to make anything from decals for laptops and cars to printed circuit boards for soft electronics.

What is machining :-

Machining is a removal of material from solid blocks or workpiece for manufacturing the objects. It has several processes cutting, drilling, forming, grinding, milling,etc

Machine Details-

My Experiments-

This actually became bit critical for me since I had used cursive and exotic fonts for the design to be creative, yet with some help of the batchmates, we pulled off the sticker using the masking tape, Which looked like this.

I made logo for my college

In this machine I tried letter and logo sticker. I used corel draw for making college Name sticker. I downloaded one .png file from internet and edit the file in corel draw.

I added logo in coraldrow software

I am fast time using this software and I learned basic cammed and all the thing.

Cutting process in Vinyl cutting

Set the origin for the tool on the sheet and Send the image as a tool path to the cutter

Then once the cutting is done the step that remains is to peel it off perfectly,

Fab module settings for Vinyl cutting.

Diameter(mm) = 0.25 Overlap = 0.5 Offsets = 1 Error(pixels) = 1.1 Intensity = 0.5 Force = 90 Velocity = 5

My Fast attempt-

I measured the space on my laptop and fixed on a size of 12x4cm. Since this was a test cut, I cut the full image on a single sheet of blue vinyl.

The machine also generated offsets when it is started on a re-cut, which intern damages the design again. After the above process this was the final design I printed..

Note:

When sticking together different parts of the design, be sure to not let the tape touch the vinyl already stuck on the laptop, trim the edges properly.

After hours of cutting and careful peeling and sticking, this time I was successful.

Group Assignment-

For this task we had a group assignment where w had to study about the properties and kurf of the laser engravers, for that we splitted ourselves into two groups, each assigned with one machine,

The engraver has a very high amount of kurf lining, this was mostly seen due to constant loss of focus after a vertain use of the engraver

The kerf seen vertically is different than the kurf seen horizontally

After cutting check the dimension

The engraver has a very high amount of kurf lining, this was mostly seen due to constant loss of focus after a vertain use of the engraver

The kerf seen vertically is different than the kurf seen horizontally

The following were the results we received about the deflection in the kerf Out of which we concluded that 100% power and 50% speed was ideal for minimal kerf of 0.14mm

The machine has the ability to engrave on various layers in the 3rd axis of geometry and has very negligible kerf

{Press-fit Parametric design in solidwork:}

Creating a press fit kit in solidwork:-

I was amazed by the various designs for press fit kits. You can build anything you can imagine. I was lost for a while thinking about what to make, I loved the idea of bending wood. Then I decided I would start simple and progress to more complicated ones.

They fit perfectly. In the next try I nested multiple copies so that I could batch print them.

And next step-:

I assembled them into a 3D shape.

Laser cutting-

I also use this machine and,I am really amazed by what this machine can do. It allows you to cut intricate parts for machines like gears, press fit assembly, pulleys, etc and can do it in a very short time. It is also very dangerous and should be treated with care.

Laser cutting machine

I am using SIL Indian made laser cutting machine with has flowing characteristics Laser Power

60/80/100/130/150 Watt Wave Length 10.6 um Supply Voltage AC 220 V + 10% Reposition Accuracy + 0.05 mm Cutting Speed 0~30000 mm / min

Generally we are using SIL laser or CO2 laser cutter which having 600*900mm bed area and can cut material up to 6mm.

The laser cutter works by focusing a high energy beam of light in a small area to vaporize the material there. In our lab, we use the SIL Laser , it uses a Carbon dioxide(CO2 ) laser for generating the high energy beam.

The laser beam is generated at the back of the machine, which is then diverted by a system of prisms. The beam is then focused and moved using a CNC arrangement that allows for rapid 2D motion.

Setting up the machines-

Downloaded file or recent file is on the top. Select your file press the file and then enter.

In this machine we can cut MDF ,acrylic up to 6mm and paper as well .

Set the origin, check the frame(Total area of your object) and give "START" command for cutting.

The laser cutter head:

I use 3mm MDF sheet for my fest trial on SIL Laser. on very fest I used foiling setting

{ Next 1 Pressfit}

The core task was to develop a kit of 3D jigsaws that can be randomly arranged to generate various shapes

{ Next 2 Pressfit}

The best way to go for the designs like these was using the method of parametric design, since the size of the slot and the thickness of the material has to be changing relatively with the availability of the material(files at the end of the data) For the following,

{ Next 3 Pressfit}

{ Next 4 Pressfit}

Note:

The acrelic and MDF I was cutting on averaged a thickness of 3mm. Hence accounting for the kerf I put the hole width as 3mm. This gave a good fit.

{Pressfit Mobile Stand}

Initially learned how to draw the concept of y press fit mobile stand, of which I made a sketch in solid works, and assembled it to see how it works(represented by the image below)

Then after I simulated them to and saved them individually s different part files, that could be converted to *.dxf easily, adnd be fed to the laser.

File loaded in SIL Laser cutting machine

{Next use the cardboard laser cutting }

{Final cut acrylic sheet 3mm successful}

Mobile stand

mobile stand

Learning Outcomes-

In this assignment I learned about parametric design which is really best for experiment the same design with varying dimension. Good experience in group work.

To download my files click -:here

**Then after I simulated them to and saved them individually s different part files, that could be converted to *.dxf easily, adnd be fed to the laser.**