designer soap making a team project from concept to completion
TRANSCRIPT
Designer Soap Making
A Team Project
from
Concept to Completion
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A hyperlink page has been included to allow you to view parts of the slide show on an as-needed basis. This tutorial may be run simultaneously with the solid modeling software and the Cam package, allowing the user to move between them.
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Select the Item You Wish to View
Introduction
Activity Overview
Teamwork Guidelines
Printing Slide Notes
Mold Cavity Design
Mass Properties
Exporting From Inventor
Exporting From Mechanical Desktop
Verifying a Roughing Cycle
Verifying All Tool Paths
Creating the CNC Code
Milling the Mold Cavity
Suggestions for Pouring the Mold
Supplies on the Internet
The End
Creating All Tool Paths-----------------------------------
Assigning Tool Bits
Before viewing this presentation, you should print the slides in handout format to enable you to take detailed notes. Exit the
slide show and follow the directions below.
Pick File
Pick PrintBy activating printin this manner, you
are able to configurethe type of output as
in the dialog boxto the right.
PickBlack & White
Pick Handouts(2 or 3 slides per page)
then pick OK
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This activity uses:
The Team Design Approach Solid Modeling software: AutoDesk Inventor or Mechanical
Desktop 3.0 Cam Software: Surf Cam CNC mill control software for Prolite Machines Prolite 1000 Machining Center Machineable wax Clear glycerin soap, food coloring, fragrance oil, non-stick
cooking spray Microwave oven, plumber’s putty, clamps, candy thermometer
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First, we design the mold, using
AutoDesk Inventor
or
Mechanical Desktop 3.0
The following slides are from
a part replay sequence.
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Sketch this profile
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1” Extrusion
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Planar parallelwork plane with
offset of 1/2”
Profile of moldcavity
Draft angle is 8 degrees.[90 - 82 = 8]
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Extrusion 4” distance
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Sprue profile
Mold halves arecombined, later a
part split willcreate each half
Boat clip art hasbeen added and
extruded
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Sprue profile has beenextruded with a draft angle
of 20 degrees
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Fillet applied
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Part split completed
All corners filleted
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The volume of glycerin soap required can be determined by comparing the mass property of Volume for the solid block with that of the mold cavity block.
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Pick File, thenSave Copy As
Set the Save As file typeto SAT and pick Save
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Use the AMACISOUTcommand to translatethe model’s geometry
into a format that can beread by SurfCam
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This is the correct folderin which to place the
Amacisout file
Make sure the fileextension is sat
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Now we will convert the
solid model of the mold into
tool paths using a CAM package called
Surf Cam.
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Launch SurfCam andimport the SAT file usingthe sequence illustratedin the following slides
Pick 1
Pick 2
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Set up these dialog boxesas indicated by the arrows
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When the Sat filehas been successfullytranslated, pick Close
Sat file as it should appearin SurfCam. Note: theyellow arrows areobstructing the view ofsome details. In the next slide, we will turn them off.
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The next 2 slideswill illustrate how to eliminate the yellow
arrows that sometimesblock the user’s view of
wireframe elements
Pick 1
Pick 2
Pick 3
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The wire frame will be free of yellowarrows after shaft size
is set to zero, then pick OK
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Then double click here
To producethe Isometric viewPick View first
Now the viewing direction will be changed to Isometric
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It is very important to makesure the top surface on the
lower left corner of the modelis at the coordinates of 0, 0, 0
The following 4 slideswill illustrate how to
move the top surface of the lower leftcorner of the model to that location
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Move cursorto this point and left click
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Leave all values at zeroand pick OKPick
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Zoom Extents to center image
The move function shouldproduce the XYZ label
on the top of the part in thelower left corner
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Save your work after each major stepusing the following procedure
From the Main menupick Files
The first time the file issaved, use the Save Ascommand. This allowsyou to check for theproper destination folder.
This is the correctfolder, in the filename
box enter a name and pick Save
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We now must Maskout the wireframe
components which donot need to be machined
Pick the Mask icon
Pick 2
Third, pick here then pick OK
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We will now select the colorto apply to the non-machined
wireframes
From the Mainmenu, pick Edit
The next pick isColor
Select dark greenfrom the color palette.
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Use Intersect
Pick here anddrag across to
lower right
This will producea yellow selection
box. All surfaces under itwill be turned greenand masked fromcutter tool paths. 37
The green surfaces arenow masked from any
machining activity
Continue masking the outside vertical
surfaces as well as thetop surface
Mask both holesurfaces using theWithin selection
mode. The holes will be worked on
after the mold cavitytoolpaths are finished
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The mold cavity and spruesurface are now ready forcutter tool path application
Now would be a goodtime to save.
Always answer YESto both of the following
dialog boxes whilesaving
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First, pick NC from the Main menu
Pick 2
Pick 3
Pick 4
Set Maskingcolor to White
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First set maskto Yes
Pick 2Pick 3
Pick 4
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This is the tool bitselection dialog box.
Here we will select thecutter bit, set the speedand feed rate, depth of
cut and width of cut.
For this mold cavity, wewill use a 1/2” ball millfor the roughing cycle,a 1/4” ball mill for two
intermediate planar cycles,(on both the X and Y axes)
and a 1/8” ball millfor the Registration pin
Holes and the final cleanup of the mold
cavity.
Pick hereto select the
tool bit
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Pick this toolthen OK
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Adjust the parametersindicated by the
arrows then select the Cut Control
tab
The spindle speedand feed rates
used in this tutorialare for machinable
wax only.
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The actual tool number will depend on how you have set
up the tool library in the machining center software.
Adjust the parametersindicated by the
arrows, thenpick the Z Rough
Pocket Options tab
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Adjust the parametersindicated by the
arrows, thenpick OK
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Pick 1
Second, pickon this white
line
Third, pick on thiswhite line
After the third pick, youwill see a tool path simulation,
then pick Accept
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Pick theOperations Manager
Tool path description, eventuallyseveral more will be listed
The Operations Manager dialog boxkeeps track of the various tool paths
created, allows the graphical verificationof tool paths, and gives the user the ability
to change the order of machiningoperations by dragging and dropping
Pick Done to returnto Surf Cam
Press F8 to hide the toolpath in the Surf Cam screen.
This will keep the screenfrom being too cluttered asmore tool paths are added.
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We will now activate a graphicalverification of the previously applied
tool path - Pick theOperations Manager
First, pick NC Project
Next, pick Surf Cam Verify
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Pick here to addstock to the model
X, Y, Z valuesmust all be zero for
Corner 1
For Corner 2, the X + Y values must match the stock, with
the Z axis set to anegative thickness value
Pick Add after all valueshave been entered 50
Pick here to shadethe stock
Press the Playbutton to view
the cutting simulation
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Simulation progress bar
Press the Closebutton when done
viewing
Observe the result ofthe 1/2” ball mill.
The surface is rough,but material has been
removed quickly, keeping the cycle time shorter. We will now refine the cavity with
consecutively smallerbits.
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From the Main Menu:Pick NC, NC Mode, 3 Axis, Planer, Set mask color to white, Set Mask toYes, then pick Visible.
If you need assistance with the above, review slides 40 - 41.
Be aware of the fact that the contents of slide 42 (the tool selection dialogbox) will change with each tool path generated. These changes drivewhat tools, speeds, and feeds the milling machine uses. Be very carefulin supervising students, checking what they have changed, prior torunning their NC code. The most common problem I have experiencedwith student generated code is decimal point errors entered into thedialog boxes which can lead to disastrous results for the vise, etc.!
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Pick here first toproduce the dialog
box below.
Pick 1/4 HSSBall nose then OK
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Verify that you have selected a1/4” Ball nose
bit.
Change the toolnumber to 3
Turn Coolant Off
Spindle speed3000 Feed Rate
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Plunge Rate 3
Enter this comment
Pick Apply, thenpick the Cut Control
tab at the top ofthis dialog box
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Stock to leave:.03
Step Size:.002
Change only twoof the above
indicated settingsand pick OK
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Surf Cam isprompting for amachining start
point
Pick Keyboardto input the
values
This is the Keyboard input panel,accept the defaults by picking OK 57
Surf Cam is now promptingfor a point to establish the
direction of the cut
Pick Keyboard
Enter 5 and pick OK
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Surf Cam is now prompting for the direction to offset the
toolpaths as it generates them
Pick on this sideand watch the
tool paths beinggenerated
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X axis planar tool pathsbeing generatedWhen the tool path
is finished, pickthe Operations
Manager
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Observe the tool path description
First, selectNC Project
Second, selectSurf Cam Verify
If you need help with the toolpath Verification, return to the
index page and view theverification sequence.
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Successful verification of 1/4”X axis planar tool path. We will now
further refine the mold cavitywith a Y axis planar with a smaller
scallop rate. This will yield a smoothermold cavity surface.
Pick the Close buttonafter inspecting the
verification. In the eventthe tool path is unacceptable,follow the procedure in the
next slide to delete it.
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Pick theOperations Manager
To delete a badtool path, pick the
path name andpress the Delete
key
Confirm your intention to delete the tool path by
picking Yes
Pick Done toproceed 63
We will now mask the moldsprue from further machining
by changing its color togreen. Remember, earlierwe set up green surfaces
to be masked from selection.
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We will now select the colorto apply to the non-machined
wireframes
From the Mainmenu, pick Edit
The next pick isColor
Select dark greenfrom the color palate.
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Pick 1
Pick 2
Pick 3
Pick 4
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Place the Withinselection box
around the sprue
This should change the color of the sprue
to green thuspreventing another toolpath from being created
on this surface.
The next slide willillustrate how toapply the Y axistool path using a
1/4” ball mill.67
From the Main Menu:Pick NC, NC Mode, 3 Axis, Planer, Set mask color to white,Set Mask to Yes, then pick Visible.
If need assistance with the above, review slides 40 - 41.
Be aware of the fact that the contents of slide 42 (the toolselection dialog box) will change with each tool pathgenerated. These changes drive what tools, speeds, andfeeds the milling machine uses. Be very careful insupervising students, checking what they have changed,prior to running their NC code. The most common problemI have experienced with student generated code is decimalpoint errors entered into the dialog boxes which can lead todisastrous results for the vise, etc.!
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Pick 1/4” Ball nosethen pick OK
Change the entries in the dialog boxes as shown below by the arrows
Pick Apply, thenpick the Cut
Control tab ontop of page
Pick OK when finishedin the Cut control box
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Select point to begin using the
Keyboard option Accept the current XYZvalues by picking OK
Select point in directionof cut using the Keyboard option
Enter 3 and pick OK
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Select side to offsetby picking about here.
You will now see a toolpath generated.
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Tool path being generated
When tool pathis completely
generated, pickAccept
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Run the Surf Cam Verify cycle on all the tool paths.
If you need a review ofthe Verify function, return
to the index.
We will now completethe tool paths by using
a 1/8 Ball nose bitin just the boat cavity.
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Now we will changethe viewing directionand the color of the
mold cavity.
First, pick View
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Double clickTop View
Top View is nowdisplayedNow we will
change the colorof all entities to green, start by picking Edit.
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Pick 1
Pick 2
Pick 3Then, pick about here and drag to the
lower right corner surrounding all the white surfaces with the yellow box
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All mold surfaces arenow green. Set the
Editing color to white byfirst picking Edit, Color then the white block.
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Pick Within, then pick about here and drag to the lower right corner, surrounding all the boat surfaces with the yellow box. This will produce a white boat
image that can be selected for a tool path.
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Pick this icon and setthe dialog box Mask
colors as they are on theright. This will allow tool paths
to be assigned only to the white surfaces.
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In the following slides, we will
assign a 1/8 Ball nose cutter to
both X and Y axis planar tool
paths. These two cutter paths will
further refine the outline of the boat.
From the Main Menu, pick NC, NC Planar, 3 Axis, Planar, set Mask to Yes, then pick Visible
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Pick 2 then OK
Pick 1
Now, adjust the 3 axisPlanar dialog box to
have the values indicatedby the arrows.
When finished, pick Apply, thenpick the Cut Control tab.
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Adjust the contentsof this dialog box as
indicated by the arrows
Pick Applywhen finishedwith changes.Then pick OK
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Pick 1
Pick 2Accept the zero values
Pick 3
Pick 4Change value to 5
and pick OK
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Pick about here for direction of offset for tool path
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X axis planar tool pathhas been generated
Pick Accept tokeep the tool path
After picking Accept,SAVE your work
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Switch to the Isometric view, then follow instructions to
add the Y axis tool path to the boat cavity.
Pick View
Double Click
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Set Mask toWhite
Pick 1
Pick 2
Pick 3
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Set maskingstatus to YES
Pick 4
Pick 5
Pick 6then select 1/8Ball nose cutterand press OK
After step 61/8 Ball nose
should be present
Set values indicatedby arrows, pick Apply
then pick the CutControl tab
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Set values as indicatedby arrows, then pick OK
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Use Keyboard optionto enter coordinates
of point to begin. Accept the currentvalues by picking
OK
Use Keyboard option toestablish the direction of cut
Enter this valuethen pick OK
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Pick about hereto establish side of part to offset the
tool paths
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When tool path iscomplete pick Accept
Now would be a good time to Save
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We will now create the tool paths for the registration pins
Adjust the color mask properties of both holes to white.
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The following narration will assist you in creating tool paths for the registration pin holes.
•From the Surf Cam main menu pick: NC, NC Mode, 3 Axis, Z Rough
•Select using the Visible option with Masking turned ON
•Pick OK at the Surf Cam Material Information dialog box
•Pick Done from the Selection menu, this will reveal the Surf Cam 3 Axis Z Rough dialog box. The first group of settings will be done in the Tool Information Tab.
•Pick the Tool bit button and set the bit size to a 1/8” diameter cutter
•Set tool number to (2), Coolant off, Spindle speed = 3056, Feed Rate=15, Plunge Rate=3
•Enter this statement for the comment: 1/8” cutter for Registration pins and pick Apply. Do not pick OK just yet.
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Next, pick the Cut Control Tab and make the following changes.
•Stock to leave = 0
•Z step size = .125
•XY step size = .0625
•Pick Apply but not OK.
Now pick the Z Rough Pocket Options Tab and make these changes.
•Side roughing step size = .0625
•Depth roughing step size = .125
•Material cut mode and Pocket cut mode = spiral
•Pick Apply and then OK. You should observe at tool path being created for the holes. Pick Accept, then save your work.
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We will now use Surf Cam Verify to check the entire set
of tool paths.
As the verification cycle proceeds, make sure the cutter paths don’t endanger the vise and produce the smoothness of cut
adequate for a mold cavity.
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Pick the Operations Managerto get the dialog box below.
Next, pick NC Project.Selecting this will enablethe verification of all the
generated tool paths below
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For a review of the verification process,
pick this icon to returnto the hyperlink page.
Verification progress
Pick the Close buttonwhen finished and
Save the file.
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Now that the tool paths have been verified, our next operation is to create numeric code
by picking the Post button from the Operations Manager.
Pick NC Project to insureall tool paths are used
to generate numeric code
Pick Post to create NC code
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Completed codemust now be saved,pick File, Save As
Pick here to find the correctfolder to save code. Thiswill allow you to browseto the desired folder.
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Double-Click this folderwhich was created
earlier in the Mechanical folder
Double-Click this folderwhich was created
earlier in the SurfCam files folder
Make sure to change the filetype extension to .nc
This is the only extensionrecognized by the Prolite
machining center.
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Close thisapplication
Pick Done, save theSurf Cam file and
exit Surf Cam
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We are now ready to launch the ProLite machining center software and open the NC code just created.
Pick Open
Select NC fileand pick Open
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The NC code has been opened. In the next slide group, we will apply
line numbers to allow the runningof segments of the code as needed.
Pick Edit
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Pick here,This will allow
changes in the code
Unlocked codehas a whitebackground
Pick Edit, then Renumber
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Pick here toapply line numbers
Line numbers applied
Now would bea good time to save
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Before you begin the milling process, consult the Prolite Machining Center’s operation manual for the details of setting up the tool library, tool length offsets and general operating procedures. Below are the
tool library settings for cutting mold cavities in machinable wax.
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Using the CNC code you have just created,you now machine the mold.
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Mold Release
MachinableWax Mold
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Excessive shrinkage caused by over heating of glycerin soap.
Microwave ovens vary in power. You should try heating a four oz. bar for 1 min. to gauge the results. The
soap should be 150-160 degrees Fahrenheit, to avoid excessive shrinkage.
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Temperature Measurement
Use a candy thermometer,available at grocery stores.
The temperature prior to pouring should be in the range of 150 - 160 degrees Fahrenheit. It may be necessary to let the melted
soap cool down for a few minutes. If poured too hot, excessive shrinkage and bubbles may appear.
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Do not put Thermometer inThe microwave
oven.
Soap should becut into 1/2” thick pieces for quicker
melting
Microwave for1 minute onfull power for
each 4 oz. bar
Use eyeprotection when
pouring
Clear glycerinsoap is available
in the supermarket or via the Internet Soap can be
scented as well ascolored
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Use plumber’s putty toexpand the sprue volume.
As the soap cools, shrinkage will occur in the
sprue.
Always use safety glasses
The use of an air nozzle can assist in removing soap from the mold.
Use quick adjust mini clamps orspring clamps
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