Improving CNC milling user experiences

(R&D cohesive CNC milling user experiences by providing an operation brochure)

_{This is intended for simple milling operations that you will use in 90% of the cases

-> Horizontal Roughing and Parallel Finishing}

Rhino

_{Check UNITS and SIZE}

_{Units are set to mm}

_{Model has the correct size}

_{Maximum Model Size for}_{ISEL milling: 1350x950x300mm(Tool length)
PRECIX milling: 2000x1000x200mm(Tool length)}

^{Units are set to mm}

^{Model has the correct size}

_{Create 3 LAYERS}

_{STOCK MATERIAL(i.e. full foam block)}
_{GEOMETRY(final outcome)}
_{MACHINING REGION(where to mill?)}

_{Assign to STOCK MATERIAL layer}

_{Volume of the material piece to mill form}

_{Assign to GEOMETRY layer}

_{Surface(s) that define your final model. Mustn’t have any holes/openings from top view}

_{Assign to MACHINING REGION layer}

_{Closed polyline(s) that define the area to mill (Can be different for each operation)}

^{Assign to
STOCK MATERIAL layer}

^{Check holes and openings of GEOMETRY layer from top view}

^{Assign to MACHINING REGION layer}

PLACEMENT

_{Place stock material (together with all other geometry) at world zero 0,0,0

(Make sure you’re not working with a custom CPlane!)}

_{In top view world zero has to be at the lower left corner of the material}

_{In front view world zero is at the top left corner of the material}

Rhino CAM

_{PROGRAM(Setting up the machine operation)}

_{1. Define Stock Material(Right click on stock)}

_{Box stock(manually define 0-point and box dimensions)}
_{Stock from selection(Select objects in stock materials layer->Stock from selection)}
_{Turn off Stock Material layer}

_{2. Horizontal Roughing(HR)-Removing material as quickly as possible
(Machining Operations - 3 Axis Adv - Horizontal Roughing)}

_{Control Geometry: Select closed curves from Machining Region that you want to use for HR}
_{Tool: Choose a large tool(ca. 8 - 12mm) that can still access the smaller pockets of your geometry}
_{Feeds&Speeds: Use settings from excel file according to the material}

_{Clearance Plane: Stock Max + Dist = 6mm}
_{Advanced Cut Parameters: Uncheck Arc fitting !}
_{Engage/Retract -> nothing to change}

_{Cut Levels (step size for roughing):}
_{Stepdown Control: Distance (i.e. 6mm for Foam with 12mm Tool)}
_{Cut Levels: Bottom (No milling deeper than this Value) 1-2mm above lowest material level}

_{Cut Parameters:
Stepover Distance (Offset btw. paths): less than 1/2 of tool diameter! (i.e. 5mm for 12mm)}

3. Parallel Finishing (PF)

_{Control Geometry: Select closed curves from Machining Region that you want to use for PF}

_{Tool: Choose a small tool (ca. 3 - 8mm) that captures most of the detail of your geometry (i.e. courtyards) and doesn’t collide with material in deep valleys!}

_{Feeds &Speeds: Use Settings from excel file according to your material}

_{Clearance Plane: Stock Max + Dist = 6mm}

_{Advanced Cut Parameters: uncheck “Arc fiting” !}

_{Entry/Exit -> nothing to change}

_{Z Containment-> nothing to change}
_{Cut Parameters:}
_{Stepover Distance (Offset btw. paths): 1mm}

_{SIMULATE(Simulating the Milling Process and checking for Collision)}

_{Always simulate before posting the file!}
_{Play - Pause - To End -> For skipping the Visuals}
_{Collisions will show as RED parts in the simulation geometry}
_{Right click on Setup -> Information -> To view how long will it take?}
_{If there are no collisions, proceed to:}

_{POST(Transfer milling path to machine language)}

_{If you post for the first time, you have to change following preferences:

Double click on post -> Post processor should be ISEL or PRECIX -> Edit -> Units must be metric!}

_{Post each operation separately by right click on i.e. “Horizontal Rouging”-> Post}
_{Naming Convention:

HR_12Fmm (Horizontal Roughing with 12mm Flat Tool)

PF_4Bmm (Parallel Finishing 4mm Ball Tool)}
_{Names cannot be longer than 8 characters!}
_{Output will be .txt File, check if exported completely by scrolling to end-> last line should be “PROGEND”}