First Cuts

With the router mounted yesterday, I was ready to make my first actual cuts with the CNC. I designed the new router clamp in AutoCAD and used VCarve to generate the toolpaths and g-code.

AutoCAD drawing.

I flipped the y-axis direction in stepconf to fix the problem from yesterday and opened up the g-code in LinuxCNC. It looked good and the router clamp felt fairly tight so I felt ready to begin cutting. I used the smallest router bit (not exactly a "true" end mill) I had to cut this part out, which was 5/8 of an inch. With all my safety equipment on, I hit run.

Woops.

I immediately hit several problems and stopped the machine. The clamp was actually slightly loose and router could wobble back and forth. The router also flexed and jerked in the clamp quite significantly in all directions under the load. To make the clamp tighter, I just used several layers of duct tape to fill in the gap between the router and the clamp. It worked like a charm and held the router very tightly.

Duct tape solves everything.

In VCarve, I recalculated the tools paths so they only took out one hundred thousands (1/10") of an inch and slowed down the feed rate to about forty-five inches per minute.

This resulted in a successful cut. It isn't the most accurate cutout (there are visible defects on the edges) but it's pretty nice for a first attempt.

In the middle of cutting.	LinuxCNC running the machine.
Done cutting!	Not bad.

This machine makes a mess when cutting. I'll definitely need a vacuum.

Here's a list of tasks I need to do to make the CNC better:

• Make a second router clamp and replace the old clamp
• Buy a shopvac (or other dust collector) and make an attachment for it so it sucks up the dust right at the router
• Soundproof the shed (sorry to the neighbors that I might have annoyed at night)
• Add in the limit switches and the e-stop
• Build a clear barrier around the entire table (to catch residual dust and stop any flying chips)
• Buy smaller end mills (including ball mills, v-bits, etc.)
• Buy a variable speed router/spindle with less runout
• Buy a solid state relay to control the spindle
• Make the whole machine more rigid