CNC

From ILabWiki

Table of contents
1 Mechanical System

1.1 Frame Body
1.2 Spindles
1.3 Table

1.3.1 Fixture plate
1.3.2 Clamping Kit
1.3.3 Vise
1.3.4 Double Side Tape
1.3.5 Vacuum Table
1.3.6 Cam Clamp Screw

1.4 Bits

1.4.1 For Non-ferrous Metal Cutting

1.4.1.1 PreciseBIT Stub End-mills (MN208)
1.4.1.2 American Carbide 2-flute Standard End-mills

1.4.2 For Plastic / Wood Cutting

1.4.2.1 MLCS Solid Carbide Spiral Upcut Router Bits
1.4.2.2 PreciseBIT Soft Media End-mills (MM208)
1.4.2.3 UltraBIT Soft Media End-mill (MM3I8)

1.4.3 For PCB Cutting

1.4.3.1 Chip-breaker Router Bits (RCC08)

1.4.4 Engraving Bits

1.4.4.1 PreciseBIT 2-flute Scoring / Engraving Bits (EM2E8)
1.4.4.2 PreciseBIT 4-flute Scoring / Engraving Countersinks

1.4.5 For 3D-Milling Ball-nose End-mill

1.4.5.1 American Carbide 2-flute Ball-nose End-mills
1.4.5.2 PreciseBIT 2-flute Ball-nose End-mills
1.4.5.3 PreciseCarve Tapered Ball-Nose Carving tools

1.4.6 Drill Bits

1.4.6.1 PreciseBIT Drill Bits (DC208)

1.4.7 Future Order List

1.4.7.1 Done
1.4.7.2 Sub
1.4.7.3 Plan

1.5 IGUS Chain
1.6 Dust Box

2 Electrical System

2.1 Power Supply
2.2 Stepper Motor
2.3 Inertial Dampers
2.4 Stepper Motor Drivers Board
2.5 Opto-Isolated Relay Board
2.6 Joystick

3 Other Tools

3.1 Measuring Tools

3.1.1 DRO
3.1.2 Stainless Steel Digital Caliberiper
3.1.3 Digital Indicator

4 Software

4.1 CNC Control Software

4.1.1 Mach3
4.1.2 KCam4
4.1.3 Linux EMC

4.2 CAM Software

4.2.1 Free Mill
4.2.2 CamBam (and CamBam Plus)
4.2.3 Vectric

4.2.3.1 Cut 2D
4.2.3.2 Cut 3D

4.2.4 LazyCAM
4.2.5 MeshCAM
4.2.6 MasterCamX
4.2.7 PowerMill
4.2.8 CAMWorks

4.3 CAD Software

4.3.1 SolidWorks 2008
4.3.2 Convert eps/pdf/ps file to DXF file

5 Cutting

5.1 Plexiglass
5.2 PCB board
5.3 MDF
5.4 Aluminium
5.5 Alumilite
5.6 Acetal / Delrin
5.7 Polycarbonate

5.7.1 Lexan
5.7.2 Hyzoid

5.8 UHMW
5.9 Garolite
5.10 Unit Convert

6 Dust Collection
7 Manufactory & Distributor

7.1 Material supplier
7.2 Enclosures
7.3 Machine tools Supply
7.4 Bits & Tools
7.5 Desktop CNC
7.6 Spindle
7.7 Motor Driver
7.8 Other CNC parts

8 Feature Plan
9 Extra Link

Mechanical System

Frame Body

Current we use Fireball CNC from probotix (http://www.probotix.com/) $599.00 each

Spindles

NIKOTA Multi-Purpose Rotary Cutting Tools(Router/Trimmer & Cut Off Tool)
120V/60Hz 5.0 Amps 600W (Must be connected to a 110-120V/15A time delay fuse or circuit breaker)
30000 RPM with 1/8"(3.175mm) or 1/4"(6.35mm)shank collect
Spindle Runout is 0.161mm(0.0063")


NIKOTA ROTARY TOOL KIT(fits Dremel tool holder)
120V/60Hz 1.0 Amps 120W
Variable Speed from 8,000 RPM to 30,000 RPM


Dremel 395 Rotary Tool $54.99 each
120V/60Hz 1.15 Amps 138W 1/5HP
Variable Speed from 5,000 to 35,000 RPM
Spindle Runout is 0.159mm(0.0062")


Bosch PR20EVSK Colt Palm Grip Fixed Base Variable Speed Router $103.25 each
120V/60Hz 5.7 Amps 684W 1HP(746W)
Variable Speed from 16,000 to 35,000 RPM
with 1/4"(6.35mm)shank collect

Table

Fixture plate


Dimension 26.375" x 15.75" x 3/4 T6061 Aluminum

50 mm Grid 3/8-16 UNC 91 Tap hole

Weight: 30.37 lb (13.8 Kg)

Clamping Kit

Image:ClampingSet.gif

Harbor Freight 58 Piece Combination Step Block and Clamp Set

3/8"-16 NC Studs, 1/2" Clamps $34.99 + Tax + Shipping

Vise

Image:6inVise.gif


Harbor Freight 6" Jaw Capacity Drill Press Vise $17.99 + Tax + Shipping

Double Side Tape

Vacuum Table

DIY Vacuum Table (http://www.cncdudez.co.uk/vactable.htm)

Cam Clamp Screw

Cam Screw (http://www.industrydepot.com/FixtureClamps.htm)

Bits

For Non-ferrous Metal Cutting

PreciseBIT Stub End-mills (MN208)

  • Fish tail point eliminates backside breakout and splintering
  • High flute volume supports high feed rates / chip loads
  • Cutting edge geometry virtually eliminates chatter at high feed rates
  • Flute geometry enhances rigidity for more accurate, single pass cutting at high chip loads

____________________Specifications_________________

  • Runout (TIR) - ±0.0002 in.
  • Material - solid submicrograin carbide
  • Operating RPM - 20k RPM to 100k RPM

____________________Applications_______________

  • Machining non-ferrous fabrication
  • Engraving plaques, signs and awards
  • Cutting and shaping mild steels
Item# Dia(mm) Dia(in) Max Doc OAL Price
MN208-0313-005F 0.8mm 1/32" 0.050"(1.27mm) 1.42" $8.28
MN208-0394-008FC 1.0mm 0.0394" 0.075"(1.90mm) 1.42" ZrN coated $11.59
MN208-0787-020F 2.0mm 0.0787" 0.200"(5.08mm) 1.42" $8.28
MN208-1250-020F 3.18mm 1/8" 0.200"(5.08mm) 1.42" $8.66

American Carbide 2-flute Standard End-mills

Item# Dia(mm) Dia(in) Max Doc OAL Price
#2001250 3.175mm 1/8" 0.5"(12.7mm) 1.5" $5.71

For Plastic / Wood Cutting

MLCS Solid Carbide Spiral Upcut Router Bits

Image:MLCSbits4.jpg

Recommend cutting depths of 1/2 the bit dia per pass(1/16" or 1.5875mm).

Item# Dia max Doc Shank Size OAL Price
#0541 1/8"(3.175mm) 1/2"(12.7mm) 1/4" 2" $11.00
#5146 1/4"(6.35mm) 1"(25.4mm) 1/4" 2.5" $15.00

PreciseBIT Soft Media End-mills (MM208)


  • Fish tail point eliminates backside breakout and splintering
  • High flute volume supports high feed rates / chip loads
  • Cutting edge geometry virtually eliminates chatter at high feed rates
  • Flute geometry enhances rigidity for more accurate, single pass cutting at high chip loads
  • Compatible with ebony, rosewood and all other hardwoods

_______________ Specifications- _______________

  • Geometry - 2 flute, 1/8" shank, fish tail point
  • Length - 1.5 in. ±0.010 in.
  • Helix angle - 28°
  • Runout (TIR) - ±0.0002 in.
  • Material - solid submicrograin carbide
  • Operating RPM - 20k RPM to 100k RPM

_______________ Applications _______________

  • Cutting inlay pockets and shaping components
  • Shaping / routing hardwoods and softwoods
  • General purpose soft media machining
Item# Dia max Doc Price
MM208-0313-013F 0.8mm(1/32") 0.13"(3.3mm) Soft Media End-mill $9.24
MM208-0625-020F 1.59mm(1/16") 0.2"(5.08mm) inlay pocket roughing cutter $9.82
MM208-0625-050F 1.59mm(1/16") 0.5"(12.7mm) DeepReach Fish-tail End-mill $10.54
MM208-0938-053F 2.38mm(3/32") 0.53"(13.462mm) Soft Media End-mill $11.06
MM208-1250-050F 3.175mm(1/8") 0.50"(12.7mm) 2-flute fish-tail End-mill $9.82
D(Dia x Length) E(Dia x Length)
0.3" x 0.18" 1/8" x 0.7"
7.62mm x 4.572mm 3.175mm x 17.78mm
____________ __________ __________ ____________ ____________
Name A (Dia x Length) B (Length) C (Length)
1/32" Bits 1/32" x 0.13" 0.29" 0.2"
0.79375mm x 3.302mm 7.366mm 5.08mm
1/16" Bits 1/16" x 0.2" 0.22" 0.2"
1.5875mm x 5.08mm 5.588mm 5.08mm
1/16" Bits Deep 1/16" x 0.5" 0.02" 0.1"
1.5875mm x 12.7mm 0.508mm 2.54mm
3/32" Bits 3/32" x 0.5" 0.3" 0.7"
2.38mm x 12.7mm 7.62mm 17.78mm
1/8" Bits 1/8" x 0.5" 0.3" 0.7"
2.38mm x 12.7mm 7.62mm 17.78mm

UltraBIT Soft Media End-mill (MM3I8)

  • Fish tail point eliminates backside breakout and splintering
  • High flute volume supports high feed rates / chip loads
  • 3-Flute design eliminates chatter at high feed rates
  • 3-Flute design brings the rigidity and precision of a stub mill to a high-aspect ratio milling cutter.
  • Cutting edge geometry tuned to all aspects of inlay pocket cutting and component shaping


_______________ Specifications- _______________

  • Geometry - 3 flute, 1/8" shank, fish tail point
  • Length - 1.5 in. ±0.010 in.
  • Helix angle - 28°
  • Runout (TIR) - ±0.0002 in.
  • Material - solid submicrograin carbide
  • Operating RPM - 20k RPM to 100k RPM

_______________ Applications _______________

  • Compatible with most materials used in inlay and entarsia
Item# Dia max Doc Price
MM3I8-0625-031F 1.59mm(1/16") 0.31"(7.874mm) UltraBIT Soft Media End-mill $12.65
MM3I8-1250-050F 3.18mm(1/8") 0.5"(12.7mm) UltraBIT Soft Media End-mill $12.65

For PCB Cutting

Chip-breaker Router Bits (RCC08)


  • Fish tail point eliminates backside breakout and splintering
  • Chip-breaker grind combines aggressive cutting action with high flute volume for enhanced swarf removal.

Item# Dia max Doc Price
RCC08-0315-026F 0.8mm(1/32") 0.256" $4.76
RCC08-0394-020F 1.0mm 0.197 " $4.77
RCC08-0787-032F 2.0mm 0.315" $4.77
RCC08-1250-047F 3.175mm 0.472" $4.77

Engraving Bits

  • spiral geometry insures efficient debris removal
  • Cutting edge geometry virtually eliminates chatter at high feed rates
  • 30° tip designed for scrimshaw engraving in ivory, horn, phenolics, and all hardwoods. Not optimized for metal engraving, or PCB trace isolation
  • 60° & 90° tips optimized for engraving non-ferrous metals, hardwoods, phenolics, stabilized woods and composite minerals.
  • Proprietary ZrN coating extends bit life and improves cut quality

PreciseBIT 2-flute Scoring / Engraving Bits (EM2E8)

Item# Deg Tip Web Price
EM2E8-1250-30V 30° V point 0.005" PreciseBIT 2-flute Scoring / Engraving bit $8.43
EM2E8-0625-60V 60° V point 0.005" PreciseBIT 2-flute Scoring / Engraving bit $9.15

PreciseBIT 4-flute Scoring / Engraving Countersinks

Item# Deg Dia Price
EM4E8-2500-060V 60° V point 1/4"(6.35mm) Scoring / Engraving 4-flute Countersink $27.25

For 3D-Milling Ball-nose End-mill

American Carbide 2-flute Ball-nose End-mills

Item# Dia Max Doc OAL Shank Price
#4000156 1/64" 1/32" 1.5" 1/8" $12.83
#4000312 1/32" 1/8" 1.5" 1/8" $8.21
#4000625 1/16" 1/4" 1.5" 1/8" $7.61
#4002500 1/4"(6.35mm) 3/4" 2.5" 1/4" $13.11

PreciseBIT 2-flute Ball-nose End-mills

Item# Dia Max Doc OAL Price
MM208-1250-050B 1/8"(3.18mm) 0.5"(12.7mm) 1.5" PreciseBit 2-flute Ball-nose End-mill $20.26

PreciseCarve Tapered Ball-Nose Carving tools

Item# Dia Max Doc OAL Price
CM404-0625-100B 1/16"(1.59mm) 1"(25.4mm) 2" 1/4" Shank $29.95

Drill Bits

PreciseBIT Drill Bits (DC208)

  • Shallow point angle minimizes backside breakout and splintering
  • Tip geometry produces shallow glue pockets for anchoring inlaid components
  • Point geometry and back tapered flutes virtually eliminate top surface splintering
  • Four facet drill point minimizes grabbing and lifting of work-piece

____________________Specifications_________________

  • Runout (TIR) - ±0.0002 in.
  • Material - solid submicrograin carbide
  • Operating RPM - 20k RPM to 100k RPM
  • Anticipated Life - anticipated life: 3,000 holes min. (FR4)

____________________Applications_______________

  • Drilling hardwoods, composites, non-ferrous metals
  • Inlay pockets for mother-of-pearl dots
  • Drilling printed circuit substrates


DC208-M035-023D .35mm (0.014) metric drill bit 5.842mm (0.23") max DOC $2.82

DC208-M050-031D .50mm (0.020) metric drill bit 7.874mm (0.31") max DOC $2.82

DC208-M060-034D .60mm (0.024) metric drill bit 8.636mm (0.34") max DOC $2.82

DC208-M070-040D .70mm (0.028) metric drill bit 10mm (0.40") max DOC $2.82

DC208-M080-040D .80mm (1/32") metric drill bit 10mm (0.40") max DOC $2.48

DC208-M090-040D .90mm (0.035) metric drill bit 10mm (0.40") max DOC $2.48

DC208-M100-040D 1.00mm (.039) metric drill bit 10mm (0.40") max DOC $2.48

DC208-M125-040D 1.25mm (.049) metric drill bit 10mm (0.40") max DOC $2.48

DC208-M150-040D 1.50mm (.059) metric drill bit 10mm (0.40") max DOC $2.48

DC208-M160-040D 1.60mm (.063 sub 1/16") metric drill bit 10mm (0.40") max DOC $2.48 

2-256 Tap Drill #50 (0.0700")1.778mm

DC208-M175-040D 1.75mm (.069) metric drill bit 10mm (0.40") max DOC $2.48 x2

DC208-M200-040D 2.00mm (.079) metric drill bit 10mm (0.40") max DOC $2.76 

4-40 Tap Drill #43 (0.089")2.2606mm

DC208-M225-040D 2.25mm (.089) metric drill bit 10mm (0.40") max DOC $2.76

DC208-M240-040D 2.40mm (.095 sub 3/32") metric drill bit 10mm (0.40") max DOC $2.76

DC208-M250-040D 2.50mm (.098) metric drill bit 10mm (0.40") max DOC $2.76 x2

DC208-M260-040D 2.60mm (.102) metric drill bit 10mm (0.40") max DOC $2.76 

6-32 Tap Drill #36 (0.106")2.6924mm

DC208-M275-040D 2.75mm (.108) metric drill bit 10mm (0.40") max DOC $2.76

DC208-M300-040D 3.00mm (.118 sub 7/64") metric drill bit 10mm (0.40") max DOC $2.76 x2

DC208-M315-040D 3.15mm (.124) metric drill bit 10mm (0.40") max DOC $2.76

DC208-1250-040D 1/8" (3.175mm) fractional drill bit 10mm (0.40") max DOC $2.76 

8-32 Tap Drill #29 (0.1360")3.4544mm

DC208-M350-050D 3.50mm (.138) metric drill bit 12.7mm (0.50") max DOC $5.24 

10-32 Tap Drill #21 (0.1590")4.0386mm

DC208-M400-050D 4.00mm (.158 sub 5/32") metric drill bit 12.7mm (0.50") max DOC $7.19 

12-24  Tap Drill #16 (0.1770")4.4958mm

DC208-M450-050D 4.50mm (.177) metric drill bit 12.7mm (0.50") max DOC $7.92 

1/4 Tap Drill #7 (0.201")5.1054mm

DC208-M500-050D 5.00mm (.197 sub 3/16") metric drill bit 12.7mm (0.50") max DOC $9.24

DC208-M550-050D 5.50mm (.217 sub 7/32") metric drill bit 12.7mm (0.50") max DOC $9.91

DC208-M635-050D 6.35mm (.25 1/4") metric drill bit 12.7mm (0.50") max DOC $11.92

Future Order List

Fractional drill bit

Done 

DC208-M160-040D   	 1.60mm (.063" 1/16")  metric drill bit, 0.40 in. max DOC $2.48
DC208-M240-040D   	 2.40mm (.095" 3/32")  metric drill bit, 0.40 in. max DOC $2.76 
DC208-M635-050D   	 6.35mm (.25"  1/4")   metric drill bit, 0.50 in. max DOC $11.92

Sub 

DC208-M395-050D   	 3.95mm (.156" 5/32")  metric drill bit, 0.50 in. max DOC $7.19 
DC208-M555-050D   	 5.55mm (.219" 7/32")  metric drill bit, 0.50 in. max DOC $9.91
8-32 Tap Drill 3.454mm
DC208-1360-050D   	 #29 (0.1360")3.4544mm number drill bit, 0.50 in. max DOC       $5.25 
6-32 Tap Drill
DC208-1065-040D   	 #36 (0.106")2.6924mm number drill bit, 0.40 in. max DOC        $2.76 
4-40 Tap Drill
DC208-0890-040D   	 #43 (0.089")2.2606mm number drill bit, 0.40 in. max DOC    	$2.76 
12-24  Tap Drill
DC208-1770-050D   	 #16 (0.1770")4.4958mm number drill bit, 0.50 in. max DOC    	$7.91 

1/4 Tap Drill
DC208-2010-035D   	 #7 (0.201")5.1054mm number drill bit, 0.50 in. max DOC    	$9.24 
10-32 Tap Drill
DC208-1590-050D   	 #21 (0.1590")4.0386mm number drill bit, 0.50 in. max DOC    	$7.15
2-256 Tap Drill
DC208-0700-040D   	 #50 (0.0700")1.778mm number drill bit, 0.40 in. max DOC    	$2.48

Plan 

DC208-M480-050D   	 4.80mm (.189" 3/16")  metric drill bit, 0.50 in. max DOC $7.92 
DC208-M520-050D   	 5.20mm (.205" 13/64") metric drill bit, 0.50 in. max DOC $9.24 

MM208-0625-020B   	 1/16" (1.59 mm) Ball-nose End-mill, 0.2" max DOC, 1.5" OAL    	$28.88

End Mill: 1/8" Shank & Dia for Aluminum Cutting (http://www.use-enco.com/CGI/INSRIT?PMAKA=317-5287&PMPXNO=19498687&PARTPG=INLMK32)

PreciseBits (http://www.precisebits.com)

IGUS Chain

The chain keeps all cable in a good shape.

Image:IgesChain.jpg

Dust Box

Made by L-Bracket and 1/8" plexiglass

Bottom Size

Width x Depth x Height = 80cm x 90cm x 70cm


Top Size

Width x Depth x Height = 80cm x 60cm x 70cm


Door Size

W x L = 80cm x 74.5cm


Electrical System

Power Supply

24V 4.5A Switching Power Supply 100-240VAC 50-60Hz

Stepper Motor

Current we have three set of motors,each set have three motors. We recommended the motor from Keling Inc. which has sturdy power and economical price.

Size Type Step Torque (oz-in) Torque (N-cm) Shaft Diameter Shaft Type Model Price Link
NEMA 23 4Wire Bipolar 1.8° 270 oz-in, 191 N-cm ¼" w/ flat key Dual Shaft 9A_KL23H276-28-4B $39.99 Keling (http://www.kelinginc.net/SMotorstock.html)
NEMA 23 6Wire Unipolar 1.8° 113 oz-in, 80 N-cm ¼" Single Shaft 57BYG007-R $37.69 Jameco (http://www.jameco.com/webapp/wcs/stores/servlet/ProductDisplay?jameco_page=42&langId=-1&productId=237623&catalogId=10001&freeText=237622&storeId=10001&search_type=mfgr&ddkey=http:StoreCatalogDrillDownView)
NEMA 17 4Wire Bipolar 1.8° 33 oz-in, 23 N-cm 5mm Single Shaft 17HS4002-56M $14.95 SparkFun (http://www.sparkfun.com/commerce/product_info.php?products_id=8420)
---------------- ------------- ---------------- ---------------- ------------------------ ------------------- --------------------------------- ------------ ---------------

The Torque Conversion Page (http://www.alwayslearn.com/conversion/torque.html)

Inertial Dampers

CNCzone Damper thread (http://www.cnczone.com/forums/showthread.php?t=32284)

How to make a damper (http://solsylva.com/cnc/dampers.shtml)

Damper for sale (http://www.microkinetics.com/stepper_motors/mtaccess.htm)

Stepper Motor Drivers Board

Easy-CNC (http://www.easy-cnc.com/3axisdriver.html) bio-polar motor driver board

I/O Name Pins
Output X Step 2
Output X Dir 3
Output Y Step 4
Output Y Dir 5
Output Z step 6
Output Z Dir 7
Input E-Stop 10
Input X-Home Limit 11
Input Y-Home Limit 12
Input Z-Home Limit 13
Input Others 15
Output Others 1,8,9,14,17
LPT GND 18-25
_________ _________ _________

Opto-Isolated Relay Board

Image:ET-OPTO-RELAY4.jpg

4 channels relay for Spindle control from Futurlec (http://www.futurlec.com/Opto_Relay_4.shtml) $14.90 each

Joystick

Other Tools

Measuring Tools

DRO

Read Signal From Digital Scale (http://www.shumatech.com/support/chinese_scales.htm#Chinese%20Scale%20Protocol)

DRO to RS232 (http://www.compendiumarcana.com/caliper/)

DRO to LCD (http://rchobby.gmxhome.de/elektro/pic/caliper/calip_eng.htm)

Stainless Steel Digital Caliberiper

Image:Digital_Caliper.jpg

Neiko Tools 12" Digital Caliper Measuring Tool $24.51 each

RESOLUTION: 0.01mm/0.0005"

ACCURATE to 0.02mm/0.001"

Digital Indicator

Range: ±0.01"/0.2mm

Resolution: 0.00005" / 1.0um (0.001mm)

Software

CNC Control Software

Mach3

Free with First 500 Line G-Code, US$175.00 for Full Version

ArtSoft (http://www.machsupport.com/) Mach3 runs under Windows XP

Mach3 setup tutorial

KCam4

An inexpensive machine control program.

Linux EMC

Full Free Version: LinuxCNC (http://www.linuxcnc.org) EMC(Enhanced Machine Controller) runs under Ubuntu 8.04LTS


CAM Software

Free Mill

Free 3D CAM FreeMill (http://www.mecsoft.com/Mec/Products/FreeMill.shtml)

CamBam (and CamBam Plus)

There are the free CamBam (http://www.cambam.co.uk/) version or the advanced version (tutorial). We received a sponsorship from CamBam HexRay Ltd. (FIXXX: need website) Thanks for their support!

Vectric

http://www.vectric.com

Great CAM software for hobbyist. Not functional trial version available.

Cut 2D

Cut 3D

LazyCAM

Come with Mach3 CNC control software. Video Tutorial (http://www.machsupport.com/videos/)

MeshCAM

MeshCAM (http://www.grzsoftware.com/std.php)

MasterCamX

MasterCamX (http://www.mastercam.com/)

Cam Instructor (http://caminstructor.com/index.php?p=index)

LA reseller (http://www.patongroup.com)

PowerMill

Delcam PowerMill (http://www.powermill.com/)

CAMWorks

Teksoft CAMWorks (http://www.teksoft.com/camworks/camworks.htm)

CAD Software

SolidWorks 2008

Convert eps/pdf/ps file to DXF file

1.Download and install Ghostscipt (gs863w32.exe) (http://mirror.cs.wisc.edu/pub/mirrors/ghost/gnu/current/), GS View (gsv49w32.exe) (http://mirror.cs.wisc.edu/pub/mirrors/ghost/ghostgum/), pstoedit (http://www.pstoedit.net/pstoedit)

2.Open eps file in the GS View and clicking on the edit menu and "convert to vector".

Cutting

Plexiglass

up-cut spiral solid carbide bit

plexiglas using a standard 1/4" 2 flute router bit is

9500 RPM

Feedrate: 8 mm/s (19 IPM)

Depth of cut: 2mm (5/64")


For a 1/8" 2 flute router

9500 RPM

Feedrate: 20 mm/s (47 IPM)

Depth of cut: 1.5mm (around 1/16")

If you are using a 1/16" dia cutter, make the cut in 2 passes, 1/16" deep each. With a speed of 15,000RPM, a cutting feed rate of about 30 IPM should be about right (if a little bit slow).

PCB board

Think & Tinker Engraving Bits from PreciseBits (http://www.precisebits.com)

MDF

Aluminium

Alumilite

Acetal / Delrin

Operation___________ Depth of Cut______ Speed(sfpm)______ Feed(in/rev)______
End Milling - Rough 0.250" 250 - 450 0.002 - 0.010
End Milling - Finish 0.050" 350 - 550 0.001 - 0.005


operation__________ Dia of Bits________ Spindle Speed(rpm)______ Feed Rate(in/min)______
End Milling - Rough 1/16"(0.0625") 15000 - 27000
End Milling - Rough 1/8"(0.125") 7640 - 13750
End Milling - Rough 1/4"(0.25") 3820 - 6875

Feed Rate Speed = RPM * Feed(in/rev) = in/min

Polycarbonate

This is where the router bit spinning clockwise and follows the pattern in a counterclockwise path. This allows the bit to scoop out the material and deposit it on the drop side of the mother sheet

Using xylene to remove the glue layer if the cover paper get too old and very hard to peel off.

50IPM

1/8" 4 flute end mill bit from enco.

Lexan

Proxxon spindle run at full RPM

1/16" two flute upcut carbide end mill(PreciseBits MM208-0625-050F)

Dry Run at 7 IPM at DOC .03" w/ internal cuts made clockwise and outside cuts CCW.

5 - 7mm ( 20RPM ) 1.27mm up-cutter from Think n Tink.

Hyzoid

UHMW

Ultra High Molecular Weight Polyethylene

Garolite

Garolite Phenolics (GAROLITE)

It machines like butter but yet is vary strong. Its 10x nicer to machine than plastic

Unit Convert

Surface Feet Per Minute (SFPM) = (Pi * Diameter * RPM) / 12

Cutter Chip Load (CL) = Feed Rate (Inches Per Minute) / RPM / Number of Teeth

Feed Rate Speed = RPM * Feed Rate(in/rev) = in/min 

Machining Terms & Formulas
Terms 	Formulas
IPM=Inches Per Minute 	IPR x RPM = IPM
IPR=Inches Per Revolution 	IPM / RPM = IPR
RPM=Revolutions Per Minute 	SFM x 3.82 / D = RPM
SFM=Surface Feet Per Minute 	D x RPM x .26 = SFM
D=Drill Diameter

Tool calculator (http://www.monstertool.com/monster_tool_calculators.html)

Dust Collection

The Dust Deputy DIY (http://store.oneida-air.com/dust-deputy.aspx)

Manufactory & Distributor

McMaster-Carr (http://www.mcmaster.com/)

Material supplier

Hastings Plastics,Santa Monica CA  (http://www.hastingsplastics.com/)

Speedy Metals (http://www.speedymetals.com)

Advanced Industrial (http://www.cncplastics.com)

Enclosures

PacTec  (http://www.pactecenclosures.com/)

Polycase  (http://www.polycase.com/shop-by/application/desktop-instrument.html)

Machine tools Supply

Harbor Freight Tools (http://www.harborfreight.com/) Tools Store

Grizzly Industrial (http://www.grizzly.com/) Tools Store

Micro-Mark Tool (http://www.micromark.com/) Small Tools

Enco (http://www.use-enco.com) Tools Store

Bits & Tools

Amana Tool (http://www.amanatool.com/) CNC Router Bits

PreciseBits (http://www.precisebits.com)

Drill City (http://drillcity.stores.yahoo.net/routerbits1.html)

MLCS (http://www.mlcswoodworking.com/shopsite_sc/store/html/smarthtml/pages/bt_solid.html#flush_bevel_anchor) Spiral Upcut Router Bits

Ekstrom Cutter (http://www.ekstromcutter.com) Bits and Spindles

Mill & Router Bits (http://www.onsrud.com)

American Carbide (http://www.american-carbide.com)

Desktop CNC

Fireball CNC (http://www.probotix.com/)

Home Shop CNC (http://homeshopcnc.com/)

K2 CNC (http://www.k2cnc.com/) Orange County,CA

Dumpster CNC (http://dumpstercnc.com/) CNC Anti-backlash Parts

Float Head Design (http://www.robio.be/cnc/final/index.htm)

Romaxx CNC (http://www.romaxxcnc.com/)

Low Cost Modular CNC (http://www.modularcnc.com/)

Micro Kinetics (http://www.microkinetics.com/)


Spindle

Mini Mill Head Assembly R8 Spindle (http://www.littlemachineshop.com/products/product_view.php?ProductID=1663)

Wolfgang TB-350S  (http://stores.ebay.com/Wolfgang-Engineering)

Sherline spindles (http://www.sherlineipd.com/spindles.htm)

CNC On A Budget (http://www.cnconabudget.com/index.html)

Colombo spindles (http://www.pdscolombo.com) $3000+ more!

Laser CNC (http://www.nilno.com/laser_intro/index.html)

Motor Driver

Gecko Drive (http://www.geckodrive.com)

Other CNC parts

Very Cheap Knobs + $4 Shipping (http://futurlec.com/Switches/KNOB22.shtml)

4th axis rotary 4th axis  (http://www.deepgroove1.com/options.htm)

Feature Plan

  1. Dust Box
  2. Clamping Plate w/ clamping set
  3. USB Hub in control box
  4. Spindle Relay Control
  5. Upgrade Spindle $249.69
    1. Bosch Colt PR20EVSK $103.25 (http://www.amazon.com/Bosch-PR20EVSK-1-Horsepower-Variable-Router/dp/B000ANQHTA/ref=pd_bbs_sr_1?ie=UTF8&s=hi&qid=1237521438&sr=8-1)
    2. Precision Collets $69.95 + $12.59 (http://www.precisebits.com/gateways/ColletsNutsHome.htm)
    3. Spindle mount $49.95 + $13.95 (http://www.probotix.com/index.php?view=product&path=32&product_id=72)
  6. Motor Encoder feedback system
  7. Air/Vacuum system
  8. 4Axis Support
  9. ModIO/ModBus support
  10. Engraving Bits
  11. DRO w/ Mach3

Extra Link

Speed & Feed Calculator (http://www.whitney-tool.com/html/calculatorSpeedFeed.html)

Drilling Calculator  (http://www.mapal.us/calculators/drilling/CalculatorDrilling.htm)

Cutting Sheet Aluminum on a CNC Router (http://www.woodweb.com/knowledge_base/Cutting_Sheet_Aluminum.html)

How to make Clamping Devices (http://www.majosoft.com/engraving/html/how_to_make_clamping_devices.html)

Proxxon MF70 conversion to CNC (http://www.majosoft.com/engraving/html/proxxon_mf70_conversion_to_cnc.html)

Hexapod Robot CNC Router - Cutting 3D face (http://www.youtube.com/watch?v=quN37YskoaM)

A lot of CNC project (http://www.cad2gcode.com)

CNC router parts for 8020 (http://www.cncrouterparts.com)

DIY Vacuum Attachment for CNC (http://www.cerebralmeltdown.com/cncstuff/page2/router/index.htm)

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