cnc hot wire foam cutter cnc styrocut 3 cnc loader. 2.1 click - ‘reset’ 2.2 use jog tower to...

Design Fabrication Workshop / DOA / NUS IV. CNC Hot Wire Foam Cutting / CNC Styrocut

Copyright © 2009-2012 NUS

Model: CNC StyrocutSize: W1200 x D1200 X H900Material: EPS & XPS FoamsInterface: Desk CNC, Mach 3 Input: .dxf, .dnc

CNC HOT WIRE FOAM CUTTER CNC Styrocut


Copyright © 2009-2012 NUS 2

Sample Output

Save Geometry as ‘.dxf’While importing from rhino export in ‘.dxf format as version R12 Lines and Arcs’

The cutting margin in EPS is between 1 to 2 mm depending on the material density, the wire property (resistance) and current passing through. Pre-test a sample and prepare files accordingly for percision cutting.

INTRODUCTION

CNC Styrocut - 2D



MACHINE OPERATION AND PROCESS

CNC Styrocut - 2D

1. Switch On the CNC multitool.

2. Make sure the wire is horizontally and vertically aligned using Mach 3 CNC loader.2.1 Click - ‘Reset’2.2 Use Jog tower to move both towers together. UPW moves the CNC in upward direction and DWN moves it downward. Use directional arrows to move towers individually.




CNC Styrocut - 2D

3. Place the material on the base board with its vertical surface aligned parallel to the cutting wire.

Desk CNC Interface

4.0 File > Open DXF

4.1 View > View All




CNC Styrocut - 2D

5. Select > Select All.The color of the cutting profile should change to blue color.

6. Edit DXF > Scale, Move, Rotate Selected




CNC Styrocut - 2D

6.1 Click - ‘Move to Origin’(The drawing sample is moved to origin)The values for Bottom Left X & Y change to ‘0’.

6.2 Input ‘Scale Factor’ and Click - ‘Scale’.Scale up or down the dxf file to required sample output.The values for Top Right X & Y change to final output size.




CNC Styrocut - 2D

6.3. Input cutting in depth for material ‘Bottom Left X & Y’ and Click - ‘Move’.The wire will move into the material in both X & Y directions before cutting the actual profile.The size of the output also changes accordingly.

6.4 Click - ‘Cancel’




CNC Styrocut - 2D

7.0 View > Zoom All

7.1Select > Select All

7.2 File > Save Geometry as DXFSave as a new file ‘XYZ’

8. File > Foam Cutter > Open Top Left/Larger DXF Contour

Load dxf file ‘XYZ’ from saved location.




CNC Styrocut - 2D

9. Toolpath > 4 Axis Foam Cut

Click - ‘Create’

Input Feed rate ‘450’(Feed rate can vary between 300 to 500 depending on the material density)

Click - ‘Cancel’

10. Toolpath > Run Machine.

Save file in ‘.dnc’ format for cutting in ‘Mach 3 Loader’




CNC Styrocut - 2D

11. Click - ‘Load’

Load saved ‘XYZ.dnc’ file in Mach 3 Loader.

12. Set Origin (0,0)Click ‘Zero’ tab for ‘X Horizontal and Y Vertical’ both on ‘Left Tower and Right Tower.’

The (0,0) point corresponds to the bottom ‘Left Edge of the Material’




CNC Styrocut - 2D

13. Switch ‘ON’ the power supply to heat the wire.

13.1 Manually adjust the current in the range of 20 - 25 depending on material density.

13. Click - ‘Start’

The toolpath of the CNC Hotwire can be checked on screen, displayed in the middle.



Sample Output

The cutting margin in EPS is between 1 to 2 mm depending on the material density, the wire property (resistance) and current passing through. Pre-test a sample and prepare files accordingly for percision cutting.

INTRODUCTION

CNC Styrocut - 3D (Conical)





1. Switch On the CNC multitool.

2. Make sure the wire is horizontally and vertically aligned using Mach 3 CNC loader.2.1 Click - ‘Reset’2.2 Use Jog tower to move both towers together. UPW moves the CNC in upward direction and DWN moves it downward. Use directional arrows to move towers individually.



3. Calculating Distancesa. dist.1 – should be as small as possibleb. dist.2 – your materialc. dist.3 – should be as small as possible, move the towers togetherd. total wire distance between the two bolts (spring included)total wire = dist.1 + dist.2 + dist.3

3.1 Calculate Cutting Cycles (Projections)sideB = 44mmsideA = 75mmdist.1 = 140mmdist.2 = 300mmdist.3 = 370mmtotal wire = 810mmProjection A = 90mmProjection B = 5mmIf the cutting wire is toolong, the cutting cycle of the left tower can become negative.

INTRODUCTION






3.2 Calculate the ‘Scale Factor’ for Input files

Scale factor for Side A = 90/75 = 1.2

Scale Factor for Side B = 5/44 = 0.1136

3.3 Save two separate .dxf files

SideA.dxf (Larger Side)

SideB.dxf (Smaller Side)





3.4 Place the material according to the calculations done above.

You may choose the right tower with the fixed end for the shorter cycle. The spring is on the left tower.

Desk CNC Interface

4.0 File > Foam Cutter > open Top/Left/larger DXF contour (SideA.dxf )

4.1 View > View All

4.2 Select > Select All.The color of the cutting profile should change to blue color.





5.0 Edit DXF > Scale, Move, Rotate Selected

5.1 Click - ‘Move to Origin’

5.2 Input Scale Factor for Side A = 1.2Click - ‘Scale’

5.3 Input Cutting Distance in materialX = 10, Y = 10Click - ‘Move’Click - ‘Cancel’

6.0 View > Zoom All

6.1Select > Select All

6.2 File > Save Geometry as DXFSave as a new file ‘Projection_SideA.dxf’





7. Repeat Steps 4 to 6(CNC Styrocut - 3D Conical) and save dxf file‘Projection_B.dxf’

(Use Scale Factor 0.1136 for Side B Projection)

8.1 File > Foam Cutter > Open Top/Left/Larger DXF ContourLoad file ‘Projection_SideA.dxf’

8.2 File > Foam Cutter > Open Top/ Right/Bottom DXF ContourLoad file ‘Projection_SideB.dxf’





9. Toolpath > 4 Axis Foam Cut

Click - ‘Create’

Input Feed rate ‘450’(Feed rate can vary between 300 to 500 depending on the material density)

Click - ‘Cancel’

10. Toolpath > Run Machine.

Save file in ‘.dnc’ format as ‘Conic.dnc’ for cutting in ‘Mach 3 Loader’




CNC Styrocut - 2D

11. Click - ‘Load’

Load saved ‘Conic.dnc’ file in Mach 3 Loader.

12. Set Origin (0,0)Click ‘Zero’ tab for ‘X Horizontal and Y Vertical’ both on ‘Left Tower and Right Tower.’

The (0,0) point corresponds to the Bottom ‘Left Edge of the Material’




CNC Styrocut - 2D

13. Switch ‘ON’ the power supply to heat the wire.

13.1 Manually adjust the current in the range of 20 - 25 depending on material density.

13. Click - ‘Start’

The toolpath of the CNC Hotwire can be checked on screen, displayed in the middle.

cnc hot wire foam cutter cnc styrocut 3 cnc loader. 2.1 click - ‘reset’ 2.2 use jog tower to...

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