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Brand New Build Foam CNC Lamborghini.

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  • #46
    If your cutting area is 40 cm X 40 cm and with vectric`s aspire you can layer the section that you want to cut to fit into the cutting area of your machine.I do agree it is going to take a long time to cut a full size car body but if you can build a cnc to cut it you can make a plan cutting the body enjoy your toy.Check your cutting speed also.

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    • #47
      ill be making my first test cut tommorow. This model is courtesy of arashb. i put it through aspire and made it so i can mill the whole thing without sectioning it off. This is why the lower bottoms are missing details on the model. i want to keep things simple for right now. Im still learning all the cad and cam stuff. Its gonna be 18" long model.



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      • #48
        good luck on the first run mate

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        • #49
          i started milling yesterday. Total program time is 10 hours. i will be upgrading and tweaking my machine some. i will upgrade to 8tpi acme screws instead of the current 16tpi threaded rod. this will make my machine move 2x faster. Also i will be upgrading the couplers to some real quality ones that will give little backlash. im going to take down the y axis tower a good 6-8 inches so that its more stable and i wont need that much z milling height anyway. Also i will be redooing the slides on the x axis, making them longer to be more stable and tighter than they were before. i believe with these upgrades and tweaks the machine will run as i wanted it to run and be able to mill harder solids.

          this is a video of the rough milling on the vigor RC model.

          CNC milling RC model car foam. - YouTube

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          • #50
            I was lucky to get some cash to buy some equipment and upgrade my CNC parts.

            http://i.imgur.com/cMkqm.jpg

            Acme screws are really essential in most CNC setups I have to say. The benefit over cost is really great!
            For my setup I paid 80 to 90 for the threaded acme rods, nuts (which should arrive at the store tomorrow) and large bearings. I will be really cutting costs by using plastic nuts to move the axises and I also made my own acme tap to make its holes.

            http://i.imgur.com/lmy0k.jpg
            http://i.imgur.com/NlSMa.jpg

            Youtube tap guide I found Homemade ACME Tap (final).wmv - YouTube


            In one of my first CNC builds, a metal nut I was using jammed while it was cutting (could have been from a lack of lube and bent rods), so I recommend plastic nuts for this reason also.
            Not mine http://www.thebackshed.com/cnc/images/Dscf1433.jpg

            Originally posted by SETHalpine View Post
            The most is important thing, it's the software and the tool that you can use.
            If your tool can't cut more than 4cm in proof (z), you'll need to proceed by step , many layers of 4cm, and depending of your software, make the same milling way many times.
            So i hope that your milling spindle can last during more thant one hour in continuous work

            In my case, using 4cm layers, i'm milling the lowest part in first, add a second after, milling it, add a third, milling it..etc
            But with freemill software, the tool make the same way at every step, and the tool width can touch the part already milled
            This is why, a 5 axes is so practical, the tool "never" touch during the travel.
            You really need to be aware of this fact, some parts will impossible to do, due to the width of the milling gantry !!!
            in this picture, the beginning of the second 4cm's layer

            http://img15.hostingpics.net/pics/163425cnc14.jpg

            BUT It's worth to build a bigger X ( at least 2 meter) or Y axe than a bigger Z ( for a car 20cm/30cm is quite enough to make the deal)
            If you have the time and some funds you really should build a larger CNC machine, specially if you're doing a whole car because it seems like that cut piece you have in the picture alone probably took over an hour where if your machine could hold a router and a large bit for the rough pass, it may do it in 10 minutes.
            What I hate about the cutting most is the noise it creates... I mean I can wear ear plugs or big headphones, but I wonder if the high pitch noise will reach my neighbours.

            Currently I plan to put my machine in a tiny storage room in the apartment where I have thick couch foam all around. Over the last 3 months I have also been collecting egg cartons and have a large stack of them which I want to surround the Z axis with so that the noise waves will bounce/deflect with in and reduce the sound. Over heating the router will be another problem.


            Originally posted by Hanlu View Post
            If your cutting area is 40 cm X 40 cm and with vectric`s aspire you can layer the section that you want to cut to fit into the cutting area of your machine.I do agree it is going to take a long time to cut a full size car body but if you can build a cnc to cut it you can make a plan cutting the body enjoy your toy.Check your cutting speed also.
            I kind of doubt Vectric software would slice it properly doing it the conventional way from top down... for example, the curved handles in this model may not come out perfect from top to bottom slices unless you do it like the following picture.




            Originally posted by ncrazyballa View Post
            ill be making my first test cut tommorow. This model is courtesy of arashb. i put it through aspire and made it so i can mill the whole thing without sectioning it off. This is why the lower bottoms are missing details on the model. i want to keep things simple for right now. Im still learning all the cad and cam stuff. Its gonna be 18" long model.
            Sorry about the holes in the model, nothing that a few pieces of gum can't patch right? Just kidding.
            There is a program called t-splines (for Rhino 3D software) that patches 3D sections and holes together, I just havent had time to install and learn it yet. It'll be interesting if the model comes together and soon enough I can start doing the same.

            What the model looks like and the car sources I used http://i.imgur.com/lJAMB.jpg
            ArashB
            Active Users
            Last edited by ArashB; 03-26-2012, 07:27 AM.
            Follow my designs on Facebook fan pages.:cool: [url]http://www.facebook.com/AutoArts[/url]

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            • #51
              Originally posted by ArashB View Post
              If you have the time and some funds you really should build a larger CNC machine, specially if you're doing a whole car because it seems like that cut piece you have in the picture alone probably took over an hour where if your machine could hold a router and a large bit for the rough pass, it may do it in 10 minutes.
              What I hate about the cutting most is the noise it creates... I mean I can wear ear plugs or big headphones, but I wonder if the high pitch noise will reach my neighbours.
              I've bought a water cooled spindle to avoid the noise (even if the milling of the foam make some noise) , which can run during many hours
              For the moment, i can't increase the size due to my job, i'm trying to find a bigger local for the car's build.

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              • #52
                Originally posted by ArashB View Post
                If you have the time and some funds you really should build a larger CNC machine, specially if you're doing a whole car because it seems like that cut piece you have in the picture alone probably took over an hour where if your machine could hold a router and a large bit for the rough pass, it may do it in 10 minutes.
                What I hate about the cutting most is the noise it creates... I mean I can wear ear plugs or big headphones, but I wonder if the high pitch noise will reach my neighbours.

                Currently I plan to put my machine in a tiny storage room in the apartment where I have thick couch foam all around. Over the last 3 months I have also been collecting egg cartons and have a large stack of them which I want to surround the Z axis with so that the noise waves will bounce/deflect with in and reduce the sound. Over heating the router will be another problem.

                i plan on using a grow tent to house my cnc machine, to keep the foam from going everwhere and to suppress the noise. Also i have a speed controller i got from harbor freight that controls the rpms on my router, i have it set close to minimum so the noise can only be heard 5 feet from outside the garage, you dont need that many rpms to cut foam anyway.

                i also plan on using a larger growtent as a paintbooth for coating molds.
                Attached Files

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                • #53
                  Great idea! I guess a homemade one of these could consist of thick blankets and tarp wrapped around a cage.

                  Some of my progress
                  http://img804.imageshack.us/img804/431/46446161.jpg
                  http://img835.imageshack.us/img835/2596/74649976.jpg
                  http://img190.imageshack.us/img190/7563/86835673.jpg
                  Follow my designs on Facebook fan pages.:cool: [url]http://www.facebook.com/AutoArts[/url]

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