CAD/CAM

CNC Machining:

A manufacturing process that uses computer-controlled machines to precisely cut, shape, and drill materials like metal, plastic, and wood.It allows for complex designs that would be difficult or impossible to achieve manually.

HASS & Software:

We used the Haas Desktop Mill, which is a compact CNC machine for training and prototyping soft materials. The system is the same as all the larger HASS mills, so the skill set is fully transferable. Parts are held down using the 7" Desktop Mill Vise and parrelles if needed. We used a variety of endmills, ball mills, and drills.

Learning G-code has a steep learning curve, and we started by writing programs by hand before transitioning to using SolidWorks HSM. Writing code manually and checking it in FreshCut helped us grasp the fundamentals of G-code, making it easier to spot errors in the automatically generated code from the software. This hands-on experience gave us a deeper understanding of how the code drives the CNC machine and allowed us to troubleshoot more effectively.

When setting up parts in SolidWorks HSMWorks, defining the Work Coordinate System (WCS) is crucial for accurate machining. The WCS establishes the machine’s zero point, ensuring proper tool alignment and movement. It is typically set at the top-left corner of the stock to align with the CNC machine setup. Toolpaths are generated by selecting features on the 3D model, and all settings are verified through stock simulation to ensure the part is cut correctly before transferring it to the Haas Mill.

LAb examples

I specified the tools, speeds, feeds, cut depths, and tool paths in Solidwork's HSM. Using HSM to generate the G-code, I selected the pocket, hole, excursion, and facing. This G-code was then moved over to the HASS CNC machine, run in graphics, checked, and then milled out.

FlashCut CNC was used for real-time CNC visualization and G-code generating.

I learned how to make two parts fit tight using face offsets in HSM. First, I made the pocket too small, then measured the parts and adjusted the offset in HSM until they fit just right.

If you notice, the pocket is not a full square. This is because we used a round endmill, and you can't get 90-degree angles routing out the inside of this part.

G-Code is checked in FlashCut!

2D and 3-D milling using roughing passes facing and finishing spiral passes, all in SolidWorks HSM and the HASS desktop mill.

We had a time restraint of machining the part in under 10 minutes, so I had to balance the resolution of the spiral move with the time of machining.

In HSM I used stock-simulaiton to visualise the tool paths to check the G-Code before running on the real parts.

Drawing to G-Code

G-Code For Part Generated in Solidworks HSM

O00005

(Using high feed G1 F100. instead of G0.)

(Multiple tools allowed. Setting 15 must be enabled in the controller.)

(Machine)

( vendor: Haas Automation)

( model: Desktop Mill)

(T1 D=0.1875 CR=0. - ZMIN=-0.21 - flat end mill)

(T2 D=0.14 CR=0. TAPER=118deg - ZMIN=-0.2029 - drill)

N10 G90 G94 G17

N15 G20

N20 G53 G0 Z0.

(Face7)

N25 T1 M0

(MANUAL TOOL CHANGE TO T1)

N30 S2500 M3

N35 G17 G90 G94

N40 G54

N45 M8

N50 G1 X2.1219 Y-0.9251 F100.

N55 G0 G43 Z0.6 H1

N60 G0 Z0.2

N65 G1 Z-0.0312 F5.

N70 G18 G3 X2.1031 Z-0.05 I-0.0187 K0. F15.

N75 G1 X2.

N80 X0.

N85 G17 G2 Y-0.7583 I0. J0.0834

N90 G1 X2.

N95 G3 Y-0.5914 I0. J0.0834

N100 G1 X0.

N105 G2 Y-0.4246 I0. J0.0834

N110 G1 X2.

N115 G3 Y-0.2577 I0. J0.0834

N120 G1 X0.

N125 G2 Y-0.0908 I0. J0.0834

N130 G1 X2.

N135 G18 G2 X2.0187 Z-0.0312 I0. K0.0187

N140 G0 Z0.6

(2D Contour4)

N145 G17

N150 G1 X0.7636 Y-1.3565 F100.

N155 G0 Z0.6

N160 Z0.2

N165 G1 Z0.08 F5.

N170 Z-0.1113

N175 G19 G3 Y-1.3378 Z-0.13 J0.0187 K0. F15.

N180 G1 Y-1.319

N185 G17 G3 X0.7449 Y-1.3002 I-0.0188 J0.

N190 G1 X0.6131 Y-1.3001

N195 X0.4813 Y-1.2997

N200 X0.3495 Y-1.299

N205 G2 X-0.0063 Y-1.1265 I0.003 J0.4593

N210 X-0.0456 Y-1.0689 I0.3614 J0.289

N215 G1 X-0.2405 Y-0.7314

N220 G2 Y-0.2686 I0.4008 J0.2314

N225 G1 X-0.0456 Y0.0689

N230 G2 X0.3551 Y0.3002 I0.4008 J-0.2314

N235 G1 X0.4869 Y0.3001

N240 X0.6187 Y0.2997

N245 X0.7505 Y0.299

N250 G2 X1.1063 Y0.1265 I-0.003 J-0.4593

N255 X1.1456 Y0.0689 I-0.3614 J-0.289

N260 G1 X1.3405 Y-0.2686

N265 G2 Y-0.7314 I-0.4008 J-0.2314

N270 G1 X1.1456 Y-1.0689

N275 G2 X0.7449 Y-1.3002 I-0.4008 J0.2314

N280 X0.6143 Y-1.2132 I0. J0.1415

N285 G3 X0.4837 Y-1.1261 I-0.1306 J-0.0544

N290 G1 X0.3551

N295 G2 X0.1052 Y-0.9818 I0. J0.2886

N300 G1 X-0.0897 Y-0.6443

N305 G2 Y-0.3557 I0.25 J0.1443

N310 G1 X0.1052 Y-0.0182

N315 G2 X0.3551 Y0.1261 I0.25 J-0.1443

N320 G1 X0.7449

N325 G2 X0.9948 Y-0.0182 I0. J-0.2886

N330 G1 X1.1897 Y-0.3557

N335 G2 Y-0.6443 I-0.25 J-0.1443

N340 G1 X0.9948 Y-0.9818

N345 G2 X0.7449 Y-1.1261 I-0.25 J0.1443

N350 G1 X0.4837

N355 G2 X0.333 Y-1.0337 I0. J0.169

N360 G3 X0.2488 Y-0.8783 I-2.9363 J-1.4913

N365 G1 X0.0629 Y-0.5562

N370 G2 Y-0.4437 I0.0974 J0.0563

N375 G1 X0.2577 Y-0.1063

N380 G2 X0.3551 Y-0.05 I0.0974 J-0.0563

N385 G1 X0.7449

N390 G2 X0.8423 Y-0.1063 I0. J-0.1125

N395 G1 X1.0371 Y-0.4437

N400 G2 Y-0.5562 I-0.0974 J-0.0563

N405 G1 X0.8423 Y-0.8938

N410 G2 X0.7449 Y-0.95 I-0.0974 J0.0563

N415 G1 X0.3551

N420 G2 X0.2577 Y-0.8938 I0. J0.1125

N425 G1 X0.2488 Y-0.8783

N430 G2 X0.2499 Y-0.8614 I0.0132 J0.0076

N435 G3 X0.251 Y-0.8446 I-0.0121 J0.0092

N440 G1 X0.0791 Y-0.5469

N445 G2 Y-0.4531 I0.0812 J0.0469

N450 G1 X0.274 Y-0.1156

N455 G2 X0.3551 Y-0.0688 I0.0812 J-0.0469

N460 G1 X0.7449

N465 G2 X0.826 Y-0.1156 I0. J-0.0938

N470 G1 X1.0209 Y-0.4531

N475 G2 Y-0.5469 I-0.0812 J-0.0469

N480 G1 X0.826 Y-0.8844

N485 G2 X0.7449 Y-0.9312 I-0.0812 J0.0469

N490 G1 X0.3551

N495 G2 X0.274 Y-0.8844 I0. J0.0938

N500 G1 X0.251 Y-0.8446

N505 G3 X0.2254 Y-0.8377 I-0.0162 J-0.0094

N510 G1 X0.2091 Y-0.8471

N515 X0.2063 Y-0.8487 Z-0.1297

N520 X0.2036 Y-0.8503 Z-0.1289

N525 X0.201 Y-0.8518 Z-0.1275

N530 X0.1987 Y-0.8531 Z-0.1256

N535 X0.1967 Y-0.8542 Z-0.1233

N540 X0.1951 Y-0.8552 Z-0.1206

N545 X0.1939 Y-0.8559 Z-0.1177

N550 X0.1931 Y-0.8563 Z-0.1145

N555 X0.1929 Y-0.8564 Z-0.1113

N560 G0 Z0.6

(Face1)

N565 G1 X1.9251 Y0.1219 F100.

N570 G0 Z0.6

N575 Z0.2

N580 G1 Z-0.1113 F5.

N585 G19 G2 Y0.1031 Z-0.13 J-0.0187 K0. F15.

N590 G1 Y0.

N595 Y-1.

N600 G17 G2 X1.7583 I-0.0834 J0.

N605 G1 Y0.

N610 G3 X1.5914 I-0.0834 J0.

N615 G1 Y-1.

N620 G2 X1.4246 I-0.0834 J0.

N625 G1 Y0.

N630 G3 X1.2577 I-0.0834 J0.

N635 G1 Y-1.

N640 G2 X1.0908 I-0.0834 J0.

N645 G1 Y0.

N650 G19 G3 Y0.0187 Z-0.1113 J0. K0.0187

N655 G0 Z0.6

(2D Pocket4)

N660 G17

N665 G1 X1.4959 Y-0.4642 F100.

N670 G0 Z0.6

N675 Z0.2

N680 G1 Z0.1187 F5.

N685 X1.4948 Y-0.465 Z0.1117

N690 X1.4918 Y-0.4675 Z0.1057

N695 X1.4875 Y-0.4715 Z0.1016

N700 X1.4827 Y-0.4765 Z0.1

N705 G3 X1.488 Y-0.4709 Z0.0807 I0.0673 J-0.0583

N710 X1.4938 Y-0.4657 Z0.0615 I0.062 J-0.064

N715 X1.5001 Y-0.4611 Z0.0422 I0.0562 J-0.0691

N720 X1.5067 Y-0.457 Z0.0229 I0.0499 J-0.0738

N725 X1.5137 Y-0.4536 Z0.0036 I0.0433 J-0.0778

N730 X1.5209 Y-0.4507 Z-0.0156 I0.0363 J-0.0813

N735 X1.5283 Y-0.4485 Z-0.0349 I0.0291 J-0.0842

N740 X1.5359 Y-0.4469 Z-0.0542 I0.0217 J-0.0864

N745 X1.5437 Y-0.446 Z-0.0734 I0.0141 J-0.0879

N750 X1.5514 Y-0.4458 Z-0.0927 I0.0063 J-0.0888

N755 X1.5592 Y-0.4463 Z-0.112 I-0.0014 J-0.0891

N760 X1.5669 Y-0.4474 Z-0.1312 I-0.0092 J-0.0886

N765 X1.5744 Y-0.4492 Z-0.1505 I-0.0169 J-0.0875

N770 X1.5818 Y-0.4517 Z-0.1698 I-0.0244 J-0.0856

N775 X1.5889 Y-0.4548 Z-0.1891 I-0.0318 J-0.0832

N780 X1.53 Y-0.6217 Z-0.1995 I-0.0389 J-0.0801

N785 X1.55 Y-0.4458 Z-0.21 I0.02 J0.0868

N790 G1 X1.4216 F15.

N795 G3 X1.4152 Y-0.4569 I0. J-0.0074

N800 G1 X1.4632 Y-0.5401

N805 G3 X1.4876 Y-0.5542 I0.0244 J0.0141

N810 G1 X1.5914

N815 G3 X1.6042 Y-0.5414 I0. J0.0128

N820 G1 Y-0.4586

N825 G3 X1.5914 Y-0.4458 I-0.0128 J0.

N830 G1 X1.55

N835 G2 X1.45 Y-0.3792 I0. J0.1083

N840 G3 X1.35 Y-0.3125 I-0.1 J-0.0417

N845 G1 X1.2775

N850 G3 X1.2277 Y-0.3988 I0. J-0.0575

N855 G1 X1.3778 Y-0.6588

N860 G3 X1.4276 Y-0.6875 I0.0498 J0.0287

N865 G1 X1.68

N870 G3 X1.7375 Y-0.63 I0. J0.0575

N875 G1 Y-0.37

N880 G3 X1.68 Y-0.3125 I-0.0575 J0.

N885 G1 X1.35

N890 G2 X1.336 Y-0.3031 I0. J0.0152

N895 G3 X1.3219 Y-0.2937 I-0.0141 J-0.0059

N900 G1 X1.2775

N905 G3 X1.2114 Y-0.4081 I0. J-0.0762

N910 G1 X1.3615 Y-0.6681

N915 G3 X1.4276 Y-0.7062 I0.066 J0.0381

N920 G1 X1.68

N925 G3 X1.7562 Y-0.63 I0. J0.0762

N930 G1 Y-0.37

N935 G3 X1.68 Y-0.2937 I-0.0762 J0.

N940 G1 X1.3219

N945 X1.3195 Y-0.2939 Z-0.2095

N950 X1.3172 Y-0.2944 Z-0.209

N955 X1.3149 Y-0.2951 Z-0.2086

N960 X1.3122 Y-0.2965 Z-0.2065

N965 X1.3097 Y-0.2982 Z-0.2045

N970 X1.3083 Y-0.2996 Z-0.2015

N975 X1.3069 Y-0.3012 Z-0.1984

N980 X1.3061 Y-0.3024 Z-0.1913

N985 G0 Z0.6

N990 M9

N995 M5

N1000 G53 G0 Z0.

M02

(0.14063in Drill)

N1005 T2 M0

(MANUAL TOOL CHANGE TO T2)

N1010 S2500 M3

N1015 G17 G90 G94

N1020 G54

N1025 M8

N1030 G1 X0.55 Y-0.5 F100.

N1035 G0 G43 Z0.6 H2

N1040 G0 Z0.2

N1045 G98 G81 X0.55 Y-0.5 Z-0.2029 R0.15 F5.

N1050 G80

N1055 G0 Z0.6

N1060 M5

N1065 M9

N1070 G53 G0 Z0.

N1075 G53 G0 X0. Y0.

N1080 M30

Simple Milling Operations

Facing, 2D Pocket, and Drilling

Gabe's Portfolio