NOVA LABS CNC 101: SHOPSABRE OPERATION AND SAFETY

What is unique about our ShopSabre RC4 CNC?

Creates large projects

Computer operated from digital model or drawing

Dimensions are accurate to +/- 0.002in

Able to cut foam, plastic, wood, MDF, aluminum, and composites

Can not cut very hard materials like Steel or Ti

Can not undercut in a single operation

Takes a long time to get complex smooth surfaces, can yield great results

Requires some understanding and training

Requires attention or it can misbehave badly

Safety

Wear proper PPE (personal protection equipment)Safety glasses, closed toe shoes ,roll up long sleeves, don’t wear gloves,

Know where the emergency stop is located

Know which materials are allowed to be cutKnow the proper feeds and speeds for the material you are working on

If the bit seems broken or is misbehaving, hit “STOP” in the software, and if

necessary hit the emergency stop button

Do not put your hand or any other body part in the area of head travel while the

machine is running.

Do not use the machine table as a workbench or leave items on it even if you

are using it. (power drills, backpacks, etc)

ShopSabre Stats

Machine Specs:

Footprint 63” x 70”

Cut Area 55” x 48”

Z Clearance 8"

Z Travel 9"

Collet Sizes

Min/Max RPM 2000/18000

Max Speed 400 in/min

2D vs 3D

2.5D Machining

Cuts profiles and pockets

Hole drilling

Engraving

3D Machining

Complex curvature

Smooth surfaces

Also can be used for 2.5D machining

3D cutting foam

3D cutting MDF

Tool Chain

1. Create a 2D or 3D model, or download one off the interneta. OnShape, Solidworks, Sketchup, Open S Cad, Inventor …

b. File types are .DXF for 2D or .STL for 3D

2. Convert the file to GCode with a CAM software like V-Carvea. V-Carve, plugins for OnShape or Solidworks, Master Cam

b. V-Carve has a special export setting for the ShopSabre to run the automatic spindle speed

c. File type is .gcode

3. Set up the CNC machine with the vacuum and mount your part

4. Install the end mill

5. Set the X,Y,Z zero locations

6. Run the GCode on the ShopSabrea. WinCNC

Toolchain CAD

First Step of the CNC toolchain

At Nova Labs, You have Access to

Onshape and Fusion 360 in the computer

lab

Toolchain CAM

Fusion 360 CAM

Toolchain CAM

Vcarve

End Mills

There are many basic end mill types, each optimized for different materials, finish quality, precision, and

cutting speed.

3-4 D cutting depth to prevent cutter bending

End Mill, Continued

There are many basic end mill types, each optimized for different materials, finish quality, precision, and

cutting speed.

Larger diameter end mills cut faster but leave a rougher surface finish. Smaller end mill diameters can

make smaller geometry.

Standard end mills have a flat bottom, ball nose end mills are rounded and are better for complex surface

machining.

Flute count is the number of cutting blades. It can range from 1 to 8 or more. 2, 3, and 4 are the most

common. More flutes gives a cleaner cut but requires you to go slower.

Steeper flute angles are better for harder materials, but leave leave a rougher surface and require you to

cut slower.

Up cut and down cut: The cutting surface of the flute allows you to pull or push material. Down cut are

better for fragile materials like plywood or foam.

Stepovers

.75D Stepover .5D Stepover

Bigger stepovers make rougher surfacesThese are good for soft materials like foam that can be easily sanded later

Smaller stepovers make smoother surfacesThese are good for hard materials where big stepovers would cause too much heat buildup. Smaller stepovers allow for faster speed as well which compensates for the small amount of cutting on each pass.

End Mill Installation

The collets go in the head of the CNC machine

The collet must match the diameter of the end mill

Make sure at least ½ inch of the end mill is in the collet (more is better)

Tighten the collet with the pair of wrenches

Hand spin the collet to make sure the end mill is centered

Mounting the workpiece

Every part needs to be securely mounted to the spoilboard

The spoilboard is designed to be disposable, so don’t worry about damaging it

with screws

Light parts like foam can be adhered with double sided tape or spray glue

Heavier parts should use screws or clamps

Be sure not to cut through a screw with the cnc machine!

G-Wizard

Under the feed and speed tab, choose the following:

Material to cut

Bit type, size, and material (Carbide or High Speed Steel)

Be sure it’s using the ShopSabre RC4 profile

Select your type of cut with the finish slider

Write down the numbers provided including:

Depth of cut

Spindle RPM

Feed Speed

Step-over

SETUP

1. Remove items from the surface table

2. Find the vacuum cart and connect it to the CNC machine

3. If there is excess material left on the surface table use the shop vac

4. Open the WinCNC program on the CPU

5. Release the emergency stop button

Software

WinCNC is the designated program to operate the CNC machine.

Start

Pause

Tech manual: http://www.wincnc.net/webfiles/CNC%20Windows/Manuals/WinManual_2.2.pdf

Software

Portable Hand Jogger

The portable hand jogger allows the user to control the the CNC machine remotely

in the X,Y, Z axis.

Speed and Feeds

Note: http://www.destinytool.com/speeds--feeds.html

Typical data for ShopSabre using ¼ end mill with ⅛ depth of pass

Material Feed (in/min) Speed (RPM)

Foam 120 8000

MDF 80 16000

ABS Plastic 141 10000

Hard Plastic 40 14000

Plywood 25 12000

Hardwood 15 6000

Links

Great source of CNC information and terminology http://www.hsmworks.com/docs/cncbook/en/

Feeds and SpeedsWe are getting GWizard For the PC:

http://www.cnccookbook.com/FeedSpeedsCalculator/CCGWizard.html

Cad and CAMFusion 360 by Autodesk: http://www.autodesk.com/products/fusion-360/overview

Onshape: https://www.onshape.com

Vcarve: http://www.vectric.com/products/vcarve.htm

Project Ideashttps://www.opendesk.cc

Other Info

CAD/Drawing softwareOnshape, Sketchup, Turbo CAD, AutoCAD, Inventor, Open S Cad, Inkscape, SolidWorks

CAM SoftwareArtCam, MasterCam, MeshCAM, FreeMill, CamBam, PyCam