Master in Advanced Architecture 2011/2012
The main goal of the process was to study the Milling process and use the 54mm Ballmill to explore the different layers of the Valchromat panel by subtraction method.
By creating a pattern of curves in Rhino3D we used the curves as toolpath in RhinoCAM to simulate the process. The entire milling process took 40min.
The concept behind the project was to exploit the 3 layer property of the valchromat panel, as well as to understand the tools being given and achieve an effect using the tool to our advantage. We wanted to do something which would take a lot of time to model in rhino but because of the rhinocam simulation would create a greater effect in a shorter time. We were inspired by the forms of layered rock and started analyzing how we could achieve a contoured layered effect whilst exposing the different coloured layers.
The modelling in rhino was done using the ‘heightfield from image command’. Some scaling and mirroring was required to fit in the model in the given constraints of 595 x 395 x 24 mm. The tool used was a 10mm diameter flat end tool. The stepover and offset controls were tweaked and played with in order for us to achieve the layered effect that we desired.
Considerations that we made for the material were that it might be fibrous and brittle inside so we were depending on the tool to be sharp and precise. This was not so and therefore our milled panel was a little hairy. We fixed this by finishing it with sandpaper. Read More
Inspired by Sand dunes formation and its patterns.
Performance
Horizontal Roughing was important to be done prior to the 3-axis Projection Pocketing in order to save time.
The whole process in total took 1 hour.
3D milling – Process consisted of two phases:
First phase:
horizontal roughing
Tool: BallMill 26mm in diameter
Dimensions of the board: 600 by 400mm
Boards of 8mm thickness
Time taken: 9 min.
Second phase:
Projection Pocketing following a rectangular path
Tool: Ballmill 12mm in diameter
Global parameters intol: 0 , outtol: 0.4,
% Tool Diameter: 25 %
Time taken: 48 minutes
Rhino file: steps of formation
Horizontal roughing
Students: Fernando Barba/ Jose Starsky Naya Lara / Ricardo Fernandez
In this project we wanted to emulate the idea of a topography based surface, our intentions were to simulate in RhinoCAM the capacity of the machine to build this gently shapes in order to obtain the result we wanted, Valchromat was picked and its intended to watch the depth of the material by trying to show all the three colors of the panel first doing a 26mm tool Horizontal Roughing to remove the most quantity of material and then pass to a 12mm Parallel finishing tool for a better smooth looking surface.
sii
The inspiration for this exercise came from the undulating scaled surface of fish skin. The geometry of the panel breaks from the repetitive nature of real fish scales by the introduction of a point of distortion. This point of distortion is further emphasized by using particular milling strategies.
In order to achieve the desired form, two milling finishings were used. The first strategy used was a parallel finishing. The tool diameter was 12mm ball mill with stepover control as 35% of the tool diameter. The spindle speed was set to 8077 and the cutting speed assigned was 15.24. The total time taken for this strategy was 70 minutes. The second finishing was a radial finish using the same 12mm dia ball mill tool with stepover control as 150% of the tool diameter. The cutting speed assigned was 15.24. The entire mat took 40 minutes to mill with this finishing.
