Using the Temporary Frame to Cut Parts

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We will now use the temporary frame and temporary sled to cut the parts for the larger final frame. In the process we will learn the basics of how to setup and operate the machine.

Step 1: Reconnect electronics.

If you unplugged your motors to install them on the frame, plug them in again now. Additionally, plug the USB back into your computer. Remember Port 3 is the left motor and Port 1 is the right motor when facing the machine.

Step 2: Open Ground Control.

Launch the Ground Control program

Step 3: Connect to the machine

In Ground Control, click Actions -> Ports. Select your machine then click Connect. The port will look different on different computer types. On Linux and Mac computers it will look different dev/tty/...

Step 4: Setup machine dimensions

Maslow needs to have an accurate understanding of it's dimensions for the internal calculations to be able to accurately relate the motion of the motors to the routers movements. To calibrate your machine's dimensions, click Actions -> Calibrate Machine Dimensions and then follow the on screen directions until your machine is calibrated.

A few notes about the calibration process

• the calibration process can easily take more than 30 minutes of your time.
• without the weight of the sled the motors will move in a rather jerky fashion during this process
• when using the buttons to rotate the sprocket to the 12 o-clock position, each 1 degree movement is very small, with all of the jerkiness of the motors it may seem like nothing is happening, but rest assured it is.
• in step 8, you will be instructed to make a few small test cuts. If you don't have an automatic z-axis or it isn't installed yet, Ground Control will ask you to manually move the z-axis. The height numbers it specifies are always absolute and negative numbers mean into the wood, while positive numbers mean away from the wood. You should end up with a series of 1 inch cuts.

As part of the calibration process, the machine will cut a test shape. This test shape can be cut either on a piece of scrap wood, or on the frame of the machine itself.

The machine's motions may be somewhat jerky when doing this process with the temporary sled. This is because the machine is expecting the weight of the finished sled (like picking up an empty soda can which you think is full).

Step 5: Load second sheet of plywood to cut

Attach the second sheet of plywood to the frame, ready to cut. This can be done with 'C' clamps or wood screws in the corners.

Step 6: Download the design files

Download the design files for the frame of the machine from (https://github.com/MaslowCNC/Mechanics/releases/tag/v1.3).

Step 7: Plan the layout

Before we start cutting parts, let's think for a second about where we want to cut each part to them to make them all fit.

You can plan to place your parts any way you would like, but I'm going to place mine like this:

Notes about cutting the parts

• The machine is more accurate and stable around the center of the work space.
• The temporary sled means the machine is less accurate than the final version.
• You might be well served to split the process up so that you can cut the most number of parts near the center
• The cutting process can take a long time potentially hours to do all the parts
• The engraving of the numbers isn't necessary, you can save a lot of time by skipping them
• It would be nice to suggest some feeds and speeds here:
• • I did okay with .25 step down, 30 inches per minute, and 12,000 rpm

Step 8: Generate g-code

Next, we need to generate g-code to let us cut the parts for the rest of the machine. We are going to generate gcode for our parts using the website www.MakerCAM.com and the .svg files available here. You can find a complete walk through for how to generate gcode for each part here

Step 9: Move to where you want to cut

Move the router to where you want to begin cutting the part. Notice that when the gcode file loads it is positioned above and to the right of the center of the sheet. Move the router to slightly below and to the left of where you would like to cut the part using the arrow buttons.

Step 10: Re-position the G-code

Re-position the gcode to the current position of the router by clicking the Define Home button in Ground Control. Note that the part will now be cut up and to the right of where the router is.

Step 11: Cut the part

You are now ready to cut your part. You can begin the cut when you are ready by pressing the Run button. You can re-position the design on your wood by moving the machine using the arrow buttons and then clicking the Define Home to move the design to the router's current location. It's a good idea to do a practice run before cutting the part with the router off to get a feel for the process, or cut a practice part from some scrap wood.

Step 12: Repeat

Repeat steps 8-12 for each of the parts of the frame. You can generate gcode for multiple parts at the same time, or even all the parts at once if you would like.

Notes on this process: When I was using the temporary sled and temporary frame to cut parts, the small size of the temporary sled was an ongoing issue that needed attention. When cutting a part close to where another part had been cut the temporary sled had a tendency to want to tilt into the opening, but could be guided by placing both hands on the router handles. I did this process without first attaching the z-axis which was somewhat tedious.

Using the temporary frame and sled, not all of my parts were of the best quality. I would recommend proceeding to constructing the final frame, then re-cutting any parts that you think could be improved. For example, one of the corners of the temporary sled caught while I was cutting this bracket resulting in a large gash (photo is of a part from a previous design version).

Now we are ready to proceed to assembling the final frame! Instructions can be found here.