3.22 Finalize exact specifications of 3D printed parts.
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- Clarence Henderson
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1 3.22 Finalize exact specifications of 3D printed parts. This is the part that connect between the main tube and the phone holder, it needs to be able to - Fit into the main tube perfectly - This part need to be strong enough to hold both the cell phone and the holder. - The hole on the bar need to fit with the screw given, which has the diameter of 3mm, and it needs to connect with the holder part nice and tight.
2 - The bar needs to be thick enough so that it would not run out of shape when holding a phone This is the main body of the cell phone holder, it needs to - Strong enough to hold the phone - The hole at the bottom needs to be big enough for the cable to go through - Connect with the other part nicely - Gap in the middle need to fit with the small holder piece inside this piece
3 - The small piece on the middle needs to be able to slide from side to side This piece is the part that join with the phone holder, which is used for holding phones, it needs to - Strong enough and would not break as it is quite small - Be able to slide in the body part - Long enough to hold the phone
4 This is the piece that connect the main tube together, it needs to - Outside diameter need to be accurate, which is same size as the inner diameter of the tube - Strong enough so that it won't break - Hole in the middle needs to be big enough for the cables to go through
5 This piece will be putted on the top, which is designed for keeping the keys and coins in position. It needs to - The bottom part need to be fit into the main tube tight - Big enough to hold some keys and coins
6 AutoCAD Drawings Firstly, to make a start of my project, we need to open the AutoCAD, and create a new file. And then I draw the top view of the first piece, which is shown below. After that, i use the pulling tool to pull the piece into the correct length, and I used the Fillet Edge tool the make a smooth edge on my project, and the this piece becomes I kept the bottom of this part sharp because the straight angle would make it has a perfect fit with the cell phone holder part. To finish this part, I need to export this project into.stl file, to do so, I need to select the piece. After I have select the piece, I click the File button at the top left corner, and choose the Export button.
7 After that, a window will pop up, which shows the name the file would export to and the type of file you want it to be exported, in this case, I want to export this piece to.stl file. And finally, click the save button to save the exported file. For some part, it is a bit difficult when making the model in the AutoCAD, this is the piece that connect to the main tube. I need to make a hold on the middle of the head, so that I can put a screw across it to lock it tight with the phone holder. To make a hole, first I need to find out the center, so I drew 2 diagonal line and find the intersect, which is the center. Then I made a cylinder next to it with the diameter of 3mm and the length of 15mm (it just need to be longer than the diameter of the tube in the image. And I
8 shift the cylinder in to the tube just across the place where I want to remove. After that, I click and hold my mouse at the union tool, and 3 tools appears, they are the union tool, subtract tool and intersect tool. I click the subtract tool, and I select the piece that I want to save and press Enter, and select the part that I want to subtract, and press Enter again, the cylinder has disappeared and leave 2 holes and which is what I want. Before I using the Fillet Edge tool to get a smooth ending, I used the union tool to make my project into one piece so that I can use the Fillet tool correctly, (if I don t use the union tool, the pieces would be on its own, for example, in the image above,
9 the tube would be separate with the cube at the back, so when using the fillet tool, it would just get a round edge on the tube, but not the intersection. But after using the union tool, the two parts become one,) and now the Fillet tool can do the intersection.
10 The final shape of this piece becomes And here are the other pieces that I made in AutoCAD.
11
12 CNC Machine CNC Machining is a process used in the manufacturing sector that involves the use of computers to control machine tools. Tools that can be controlled in this manner include lathes, mills, routers and grinders. The CNC in CNC Machining stands for Computer Numerical Control. In modern CNC systems, end-to-end component design is highly automated using computer-aided design (CAD) and computer-aided manufacturing (CAM) programs. The programs produce a computer file that is interpreted to extract the commands needed to operate a particular machine via a post processor, and then loaded into the CNC machines for production. Since any particular component might require the use of a number of different tools drills, saws, etc., modern machines often combine multiple tools into a single "cell". In other installations, a number of different machines are used with an external controller and human or robotic operators that move the component from machine to machine. In either case, the series of steps needed to produce any part is highly automated and produces a part that closely matches the original CAD design. Here are some example of CNC machines CNC router is a computer controlled cutting machine, it can be used to cut many hard materials that hand held router can not cut, such as aluminum, steel and plastic. A CNC router typically produces consistent and high-quality work and improves factory productivity. Unlike a jig router, the CNC router can produce a oneoff as effectively as repeated identical production. Automation and precision are the key benefits of CNC router tables. By comparison, the hand held router is a tool used to rout out (hollow out) an area in the face of a relatively hard workpiece, typically of wood or plastic. The main application of routers is in woodworking, especially cabinetry. And it is not easy to do the very accurate work by using the hand held router, while using CNC router to the the fine work is easy, you just need to make the model on a computer, and transfer the
13 code to the CNC machine, then the machine would do the work for you. And here are some of the code that the CNC machine use to make the project. Code Description G00 G01 G02 Rapid positioning Linear interpolation Circular interpolation, clockwise Milling ( M ) M M M Turning ( T ) T T T Corollary info On 2- or 3-axis moves, G00 (unlike G01) traditionally does not necessarily move in a single straight line between start point and end point. It moves each axis at its max speed until its vector is achieved. Shorter vector usually finishes first (given similar axis speeds). This matters because it may yield a dog-leg or hockey-stick motion, which the programmer needs to consider depending on what obstacles are nearby, to avoid a crash. Some machines offer interpolated rapids as a feature for ease of programming (safe to assume a straight line). The most common workhorse code for feeding during a cut. The program specs the start and end points, and the control automatically calculates (interpolates) the intermediate points to pass through that will yield a straight line (hence "linear"). The control then calculates the angular velocities at which to turn the axis leadscrews via their servomotors or stepper motors. The computer performs thousands of calculations per second, and the motors react quickly to each input. Thus the actual toolpath of the machining takes place with the given feedrate on a path that is accurately linear to within very small limits. Very similar in concept to G01. Again, the control interpolates intermediate points and commands the servo- or stepper motors to rotate the amount needed for the leadscrew to translate the motion to the correct tool tip positioning. This process repeated thousands of times per minute generates the desired toolpath. In the case of G02, the interpolation generates a circle rather than a line. As
14 with G01, the actual toolpath of the machining takes place with the given feedrate on a path that accurately matches the ideal (in G02's case, a circle) to within very small limits. In fact, the interpolation is so precise (when all conditions are correct) that milling an interpolated circle can obviate operations such as drilling, and often even fine boring. Addresses for radius or arc center: G02 and G03 take either an R address (for the radius desired on the part) or IJK addresses (for the component vectors that define the vector from the arc start point to the arc center point). Cutter comp: On most controls you cannot start G41 or G42 in G02 or G03 modes. You must already have compensated in an earlier G01 block. Often a short linear lead-in movement will be programmed, merely to allow cutter compensation before the main event, the circle-cutting, begins. Full circles: When the arc start point and the arc end point are identical, a 360 arc, a full circle, will be cut. (Some older controls cannot support this because arcs cannot cross between quadrants of the cartesian system. Instead, four quarter-circle arcs are programmed back-to-back.) Corollary info M00 M01 M02 Compulsory stop Optional stop End of program M T M T Non-optional machine will always stop upon reaching M00 in the program execution. Machine will only stop at M01 if operator has pushed the optional stop button. Program ends; execution may or may not return to program top (depending on the control); may or may not reset register values. M02 was the original M T program-end code, now considered obsolete, but still supported for backward compatibility.[7] Many modern controls treat M02 as equivalent to M30.[7] See M30 for additional
15 discussion of control status upon executing M02 or M30. 3D printer is one of the CNC machine, 3D printing is any of various processes used to make a three-dimensional object. In 3D printing, additive processes are used, in which successive layers of material are laid down under computer control. These objects can be of almost any shape or geometry, and are produced from a 3D model or other electronic data source. A 3D printer is a type of industrial robot. After you plug the 3D printer to the computer, a software appears, which is called Up and you can use this software to control the 3D printer and sending the project. The project need to be export to the.stl file, and if you open the.stl file with notebook, there appears some code which the machine can read it
16 Setting up and using 3D printer Zeroing Zeroing is also called initializing, to do so, we can press the button at the front for about 3 second or if the 3D printer is connect to the computer, and we can use the software called UP to initialize it. And what it does is move the plate in XYZ axis to check the maximum distance it can go, it would just simply moves up and down, left and right, and front and back. It is a good idea to do the auto leveling if you haven't use the 3D printer for a long time or you drop the machine accidentally. To do the auto leveling, we need to plug in the black calibration cable into the auto leveling sensor and mount under the print head. So we can using the UP software to do the auto level, there is a button that you can click in computer that called auto leveling, if you click it, the plate would move up, and the nozzle would click 9 times on the plate to see if the plate is flat or not. After you do so, the computer would give you the information about it whether it is leveled or not. Also, you can check the nozzle height before printing your project, just simply click the nozzle height detect in the computer, the table will rise up and the nozzle will touch the silver switch in order to automatically set the height. Preheating table Before you start to print your project, you have to make sure that the table is heated up, the reason for it is that the plastic would stick to the table so it would not snap or lift up by accident. Heating the table would help making a more accurate model. Placing your model To place your model, first you need to connect the 3D printer to a computer, in the UP software, you click file, and then click open to open the project that you have done, the file must be in the form of.stl. After you place the model into the software, you can click auto placement, this would automatically put your project on the center, the best place that computer calculated. Also, there is a menu on the right that you can use to move, rotate or scale your project in the XYZ direction. You need to pay attention to how you want to put your project, because 3D printer is printing layer by layer, so this would affect the strength of your project, also, sometimes it might creates some supports which waste some material. Setting Sometimes you also need to change a few settings to get a better object, firstly, Z Resolution, this is the thickness of the layers, if you want a fine product, you may need to change this to as small as possible. The Fill option is about the objects internal fill, for example, if you want your object to be hard, you might need to change the fill to solid, which means there is no holes in the object. Support angle is another thing that you might opened to change, the greater the angle, the more support it will print, so the object you are printing would not go out of shape so easily. Sometimes you might need to change the
17 printing speed, to do so, change the settings in the print quality, normal means average quality, fine means good quality but takes longer to print, while fast mode would give you a draft quality but it takes less time. After you have done all these, you can click OK and start printing. Problems and issues I have had some problems when I did the prototype, when I print the phone holder part for the first time, I printed it at the wrong way, and this makes the tube very weak, and it does break right after I take the object out. Safety For safety, you need to wear gloves when you take the hot plate out, and when you want to take the rafts and support material out, you need to wear safety glasses to avoid the flying pieces.
18 Evaluate and record process After I print out all my pieces the first time, I found out some problems. For the small piece that been put into the cell phone holder, the part that will stuck into the holder is too wide, which it is designed to fit tightly inside, but the problem is I can t put it in, if I force it in to the phone holder, the phone holder would just snap. So I redesign the piece again and make it narrower, and this time, it works better, even though I need to put some force to put it in, it would not break the phone holder. For the phone holder part, same problem as above, I have made the wall thicker to increase the strength and also, I have make the gap larger for the small part to fit in. When printing, I have to lie the piece down to get a better strength on the tube as 3D printer would print stuff layer by layer. Also, I need to change the settings in the 3D printing software, make the support angle to 50 degrees to help keeping it in shape. When I Print this part for the first time, the weather was too cold, and the piece just warped as the table cools down too fast. So later on the teacher made a box to cover the whole 3D printer to keep it warm, and this makes the project been printed much better.
19 For the part that connect to the main tube, the cube was too big and it does not fit in the hole on the main tube, so I redesign the project again to make it smaller, and also make the wall on the back thicker to get a better strength so it would not break so easily ( the original one broke). I have to make the support angle to 50 degree for this part because if I don t do that, the part would go out of shape. For the part that sit on the top, it was too big, and it is too hard to get the support off after cooled down. So I redesign a smaller one, and have 4 small tubes that sticks out to hold the keys.
20 These are the final product that been printed out.
21 So far, I have meet most of the specifications of my design. But for the cell phone holder part, the charger does not go through, and we can charge our phone on the phone holder, so for farther improvement, I will redesign the cell phone part again, I would change the way that it connect to the tube, I might split it in to two branches and a hole on the middle for the cable to go through.
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