NOVA LABS CNC 101: SHOPSABRE OPERATION AND SAFETY

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1 NOVA LABS CNC 101: SHOPSABRE OPERATION AND SAFETY

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3 What is unique about our ShopSabre RC4 CNC? Creates large projects Computer operated from digital model or drawing Dimensions are accurate to +/ in Able to cut foam, plastic, wood, MDF, aluminum, and composites Can not cut very hard materials like Steel or Ti Can not undercut in a single operation Takes a long time to get complex smooth surfaces, can yield great results Requires some understanding and training Requires attention or it can misbehave badly

4 Safety Wear proper PPE (personal protection equipment) Safety glasses, closed toe shoes,roll up long sleeves, don t wear gloves, Know where the emergency stop is located Know which materials are allowed to be cut Know the proper feeds and speeds for the material you are working on If the bit seems broken or is misbehaving, hit STOP in the software, and if necessary hit the emergency stop button Do not put your hand or any other body part in the area of head travel while the machine is running. Do not use the machine table as a workbench or leave items on it even if you are using it. (power drills, backpacks, etc)

5 ShopSabre Stats Machine Specs: Footprint 63 x 70 Cut Area 55 x 48 Z Clearance 8" Z Travel 9" Collet Sizes ⅛, ¼, ⅜, ½ inch Min/Max RPM 2000/18000 Max Speed 400 in/min

6 2D vs 3D 2.5D Machining Cuts profiles and pockets Hole drilling Engraving 3D Machining Complex curvature Smooth surfaces Also can be used for 2.5D machining

7 3D cutting foam

8 3D cutting MDF

9 Tool Chain 1. Create a 2D or 3D model, or download one off the internet a. OnShape, Solidworks, Sketchup, Open S Cad, Inventor b. File types are.dxf for 2D or.stl for 3D 2. Convert the file to GCode with a CAM software like V-Carve a. V-Carve, plugins for OnShape or Solidworks, Master Cam b. V-Carve has a special export setting for the ShopSabre to run the automatic spindle speed c. File type is.gcode 3. Set up the CNC machine with the vacuum and mount your part 4. Install the end mill 5. Set the X,Y,Z zero locations 6. Run the GCode on the ShopSabre a. WinCNC

10 Toolchain CAD First Step of the CNC toolchain At Nova Labs, You have Access to Onshape and Fusion 360 in the computer lab

11 Toolchain CAM Fusion 360 CAM

12 Toolchain CAM Vcarve

13 End Mills There are many basic end mill types, each optimized for different materials, finish quality, precision, and cutting speed. 3-4 D cutting depth to prevent cutter bending

14 End Mill, Continued There are many basic end mill types, each optimized for different materials, finish quality, precision, and cutting speed. Larger diameter end mills cut faster but leave a rougher surface finish. Smaller end mill diameters can make smaller geometry. Standard end mills have a flat bottom, ball nose end mills are rounded and are better for complex surface machining. Flute count is the number of cutting blades. It can range from 1 to 8 or more. 2, 3, and 4 are the most common. More flutes gives a cleaner cut but requires you to go slower. Steeper flute angles are better for harder materials, but leave leave a rougher surface and require you to cut slower. Up cut and down cut: The cutting surface of the flute allows you to pull or push material. Down cut are better for fragile materials like plywood or foam.

15 Stepovers Bigger stepovers make rougher surfaces Smaller stepovers make smoother surfaces These are good for soft materials like foam that can be easily sanded later These are good for hard materials where big stepovers would cause too much heat buildup. Smaller stepovers allow for faster speed as well which compensates for the small amount of cutting on each pass..75d Stepover.5D Stepover

16 End Mill Installation The collets go in the head of the CNC machine The collet must match the diameter of the end mill Make sure at least ½ inch of the end mill is in the collet (more is better) Tighten the collet with the pair of wrenches Hand spin the collet to make sure the end mill is centered

17 Mounting the workpiece Every part needs to be securely mounted to the spoilboard The spoilboard is designed to be disposable, so don t worry about damaging it with screws Light parts like foam can be adhered with double sided tape or spray glue Heavier parts should use screws or clamps Be sure not to cut through a screw with the cnc machine!

18 G-Wizard Under the feed and speed tab, choose the following: Material to cut Bit type, size, and material (Carbide or High Speed Steel) Be sure it s using the ShopSabre RC4 profile Select your type of cut with the finish slider Write down the numbers provided including: Depth of cut Spindle RPM Feed Speed Step-over

19 SETUP 1. Remove items from the surface table 2. Find the vacuum cart and connect it to the CNC machine 3. If there is excess material left on the surface table use the shop vac 4. Open the WinCNC program on the CPU 5. Release the emergency stop button

20 Software WinCNC is the designated program to operate the CNC machine. Pause Start Tech manual:

21 Software

22 Portable Hand Jogger The portable hand jogger allows the user to control the the CNC machine remotely in the X,Y, Z axis.

23 Speed and Feeds Note: Typical data for ShopSabre using ¼ end mill with ⅛ depth of pass Material Feed (in/min) Speed (RPM) Foam MDF ABS Plastic Hard Plastic Plywood Hardwood

24 Links Great source of CNC information and terminology Feeds and Speeds We are getting GWizard For the PC: Cad and CAM Fusion 360 by Autodesk: Onshape: Vcarve:

25 Other Links CAD/Drawing software Onshape, Sketchup, Turbo CAD, AutoCAD, Inventor, Open S Cad, Inkscape, SolidWorks CAM Software ArtCam, MasterCam, MeshCAM, FreeMill, CamBam, PyCam End Mills and materials