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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