The Trinket Box by Bernie Solo. Lid – Part 1 of 2
This two-part blog post discusses the programming of “The Trinket Box” designed by Bernie Solo of Solo Studio Works (www.solostudioworks.com) (Ortonville MI) using RhinoCAM.
For new users, this 2-part post can be very instructional on how to approach the machining of parts requiring both 2½ Axis and 3 Axis toolpaths from one and two sides (i.e., flip machining) made of reclaimed cherry wood.
In Part 1 we will see how Bernie programs the lid of The Trinket Box. As you can see from the RhinoCAM screen image below, it contains an intricate embossed design that will require some fine 3 Axis finishing toolpaths. In Part 2, we discuss machining the base.
Bernie has modeled the stock in Rhino along with the part and utilizes the Stock from Selection option in RhinoCAM. You will also see from the Machining Job tree on the left that the lid requires machining from both the top and the bottom. The Setup Bottom performs Hole Pocketing for the 4 Stock alignment holes as well as some basic 2½ Axis Facing, Pocketing and Profiling.
After machining the bottom, the stock is flipped on the router using the 4 holes for alignment.
Setup Top is where it gets interesting. Bernie uses 3 Axis Horizontal Roughing with a ¼” Flat Mill and Re-Roughing with a ⅛” Flat Mill. For finishing the intricate emboss design, Bernie selects the 3 Axis 3D Offset Pocketing strategy using a 1/16” Dia. Tapered or “V” Mill. This toolpath strategy (shown inset in the image below) creates a nice consistent toolpath with a constant 3D stepover set to 20% of the tool diameter. This gets down into the embossed areas and cleans them up very nicely.
The sequence of images below shows the procedure Bernie uses to machine the top of the lid. Note the 3 Axis Re-Roughing (D) and the nice Along Path 3D ramp approach motion on his 2½ Axis Profiling operations (F) and (G).
A. The part is modeled in Rhino 5. Note the reference lines Bernie has drawn on the XY plane. These are used as modeling aids and for toolpath containment purposes.
B. The Stock is displayed. It was created from geometry that Bernie modeled in Rhino and used in the Stock from Selection option in RhinoCAM.
C. 3 Axis Horizontal Roughing with a ¼” Flat Mill is performed using the Offset cut pattern, 50% Stepover and 0.062” Stepdown. Note the curve on the XY plane (shown highlighted in yellow) that Bernie uses as Control Geometry to contain the toolpath.
D. 3 Axis Horizontal Re-Roughing using a smaller ⅛” End Mill is used to remove additional material. Note that no air is being cut in this operation! RhinoCAM uses the cat material simulation from the previous roughing operation to determine the areas where additional material can be removed.
E. 3 Axis 3D Offset Pocketing is the finishing operation used to remove the remaining stock from the top of the lid including the intricate embossed area using a 1/16” Dia. Tapered or “V” Mill. This creates a nice finishing toolpath with a constant 3D stepover set to 20% of the tool dia.
F. This is the first of two 2½ Axis Profiling It is used as a roughing operation to remove material around the sides of the lid. Notice the 3D Ramping approach motions (shown in magenta) Bernie uses at each cut level. Each is 0.25” long at a 10-degree ramp angle. Also, notice the four triangular Bridges & Tabs created on the sides of the Profiling cut. These can be added automatically to allow the part to remain stationary with the stock during machining.
G. The second 2½ Axis Profiling operation is used as a finishing operation. It includes one finishing cut level around the lids perimeter with a 3D Ramping approach motion, this time set to 1.25” inches long at a 20-degree angle. Notice how the approach ramp wraps completely around the front end of the lid!
RhinoCAM is the GO TO choice of Makers world-wide for its accuracy, affordability, ease of use and wide range of configurations from Express to Premium, encompassing 2 through 5 Axis milling as well as turning modules. All completely integrated into Rhino 5. Don’t have Rhino? No problem, download VisualCAD/CAM, the stand-alone version with all of the same features as RhinoCAM! For more information about Bernie Solo, we invite you to visit his YouTube channel WorksbySolo as well as on Facebook and Instagram.