- This week i was finally able to get my feeds and speeds right to finally cut an entire sheet efficiently.
- This next week will be considered the first week of production for all the parts of the shredder.
- The feeds and speeds will be tuned further for the machine i am using to finish the full sheet without stopping (efficiency improvement)
- Hopefully the efficiency gets to a point that an entire shredders parts can be finished in a day (4 hours reservation on machine).
- Next week i will order more 3/4 inch drive shafts.
- I forgot to snap photos before i left the shop today so i will do so tomorrow.
- machining to begin again monday.
About this blog
dev blog for the reclaimer industrial grade mini shredder.
Entries in this blog
- Massive Update
- Yesterday i cut out a few shredder dials on the mill
- As you will see bellow they are perfect.
- I will be cutting more this coming week and hopefully have enough pieces by friday to make a whole shredder.
- The pieces are being cut on a tormach. the precision is great. parts are around .0025 in off. (that is about a hair strand)
- I will post alot of pictures bellow make sure to check them out.
- I finally got in 3 drive shafts. 3 3/4" square shafts of 1045 8" long
- i also got 2 sets of bearings in for testing
- a wider ID and a thinner ID one flange set and one non flange
- I have been investigating a multitude of manufacturing techniques since last update
- i think i have decided on milling it.(the thought i had since the beginning)
- i will be going to end mill retailer to get some tips and tricks to start.
- more coming very soon.
- After 1 week of being in shop let me show you guys how much i got done to get it online
- First i sourced a 6 foot 3 shelve industrial shelve
- a 8 foot x 30 inch table
- took everything from my parents place and stored it in the cage
- put ssd in old laptop and now it will be permanently used in the cage.
- also bought a lot of tools that will be used at tech shop rather than relying on tech shop to have the tools when i need them
check out the pictures bellow generally each picture represents a day of setting up the cage over a week period. so you will be able to see the progress.
also i will be starting a general blog called The Green Engineers Official Blog that will cover general stuff like this. check it out for periodic company updates.
- Today i secured The Green Engineers first work space
- It is the basement(lower floor) of tech shop san jose
- it is a 8'x12' "maker cage"
- So finally i can ge the stuff out of my parents place("storage") and into the place that i work on it
- No more lost tools and parts because someone moved them
- finally going to have one place to store everything
- this will speed up all work
- So now i will begin bringing everything that is involved with The Green Engineers into the "shop"
- and for the next little while every time that i go to tech shop i will be dropping stuff off and "furnishing it"
- super excited as this is a big move for The Green Engineers
- This should bring great efficiency to working on projects in a more timely manner
check bellow for images of the currently as of today empty maker cage. Now The Green Engineers HQ.
- Did some more cuts on the plasma
- i am struggling to get good cuts on it
- so i think im going to transition to using the water jet till i get the cutting right on the plasma
- so my expenses per shredder have just gone up drastically.
- each shredder should cost around 100$ to cut
- so once i get a prototype built the price for further units is going to jump drastically.
- im thinking somewhere along the $200 mark initially
- however it is going to decrease my time in post processing the steel to clean it up
- also this week i tried to heat treat the steel in a electric kiln at tech shop redwood city
- i found some issues with heat monitoring
- and decarbonization because of an oxygen deprived environment inside the kiln.
- but i bought some hardness testing files to test the rockwell C of the steel post heat treating and they are on there way from japan.
- also i will probably start designing my own kill to introduce carbon into the compartment to carbonize and prevent decarbonize.
check bellow for some awesome images. stay tuned for big update by end of week.
- Got some cutting in this week
- Got the calibration of the fusion 360 done to get the center square perfect
- going to finish up an entire shredder this coming weekend
- i am still shopping for bearing setup and a drive shaft supplier
- full product coming very soon
Check bellow for a lot of pictures.
- I have purchased and received the plate of steel.
- It is beautiful. 1055 1/4 inch steel 4' x 8'
- However now i need to figure out how to get it out of the back of my truck and into tech shop redwood city.
- as tech shop redwood city has no grade level door and no forklift from what i believe so it probably needs to be rolled in through front door on dolly.
- i was trying to go today but for whatever reason they were closed or something
- i am going to try to go tomorrow Sunday
- but i have a lot of summer class homework so i will see what is going on. As i am definitely going to talk to them to see what we can do.
- i also got a 3/4" solid square bar to check my holes to make sure they are correct.
- i will do the best i can to start cutting asap.
Pictures of plate down bellow
- I have finally tried the cut on the shopbot with a 3/32 square endmill 3/8 LOC and 1 1/2 overall
- long story short i picked wrong parameters and broke the endmill in about 5 seconds. within a cut of half a inch.
- so we have a few options either i can keep trying to figure out the parameters while paying for 15 dollar endmills every mistake.
- and supposibly even if you get the parameters right these endmills only last for less than 1 shredder each.
- or i up the endmill size but that would cause larger radius which would mean loss of detail and material. all of these cause alot of problems
- So i think i have come to the decision to make the cnc plasma my production machine.
- Then i will just spend the time to get rid of the taper problems. Most of the taper problems are just the inner square for shaft. so maybe a broach or a router bit
- i sent another inquiry to the steel company for the sheet. setup delivery locally for pickup.
- However the sheet for delivery is quite a bit more than i originally thought.
- I will be doing some summer work helping out starting monday so i will be able to get the sheet soon.
- Back home from vacation
- Going to try something new for first shredder.
- Tech shop is going to allow me to use the 4'x8' shopbot to try to cut with
- i have a 3/32" 2 flute end mill
- We are going to see what kind of quality i can get out of the shop bot as calculators say i can do 35.4 ipm so it wont be too bad on time even though first time im going to do a conservative depth of cut per pass
- i think the quality is going to be quite a bit better than the plasma and also the radius of the corners will also not be that bad as it would be 3/64th radius.
- endmill coming tomorrow
- going to be getting steel during week
- try first shredder this weekend.
- generating g-code now for shopbot.
- Finished school monday. Back on full time
- Went to redwood city techshop again and cut the gears.
- The gears were the first cuts using fusion 360 cam aka hsm works
- they had a weird twist in the gear i found out that that was because the arc in the plasma actually bends twords where the ground is and the twist was twords the ground clamp.
- the cam gcode was not plug and play. i had to modify it to work on torchmate. So i am going to go into more detail on what torchmate didn't like and make sure that that gcode is not outputted.
- However. fusion 360 still does not have nesting capabilities
- So i will try to use vcarve pro to do the gcode as it has nesting capabilities.
- I also had the chance to do varying speed lines on the plasma
- I did this to check to see ideal speeds to minimize dross which minimizes post cleanup.
- i started with 19 lines each with dropping speeds of 5 ipm with each line
- i found that 7 (70 - 40 ipm) of those lines had the least dross.
- i then put those into a array of 7 lines spread apart and cut them again to better see the dross more clearly and picked the best one i believe 65 ipm
- i plan on going back to tech shop redwood city tomorrow to cut out a full shredder to gauge the post cleanup. And also time the post cleanup
- i will be trying to use vcarve pro to do the nesting for the 4x12 plates of a36 to do an entire shredder. I will then try to assemble and see how it goes.
- However, i will be going on vacation with my family on Friday for 2 weeks. so i will only be working on the gcode from there. so if the a36 goes well i will pick up the 1045 plate from supplier and start cutting.
- I will also try to get the hardening option up on my store if anyone is interested in that.
check below for more pictures.
- Cut some test pieces this weekend at tech shop redwood city
- They came out pretty good. except a few problems that will need to be adjusted
- I now need to come up with a better way of knocking off the dross/slag
- The software that generates the gcode at redwood city's torchmate is ancient and garbage
- I will need to figure out how to leverage fusion to get better cuts. and use vcarve pro 8.5 to do nesting into whatever size of plate i have
- next i will be working on modifying the fusion files to adapt what i learned from the test cuts
- next weekend i plan on cutting out an entire shredder in A36 for first steel prototype.
check out bellow for all the pictures that i have taken from the cutting process. going to take some more close up shots of the parts i will add those when i take them
- I have taken the cnc plasma cutter class at tech shop redwood city.
- The cuts it does are quick but pretty rough and will need finishing by hand filing and buffing.
- However, i learned that tech shop redwood city also has a small heat treating oven for knives that looks like it would be big enough for at least one shredder at a time to heat treat then temper.
- I will be doing some testing on that with a gear that i cut and some hardness testing files to see what type of hardness i can put out.
- So i will work on a price and make that available for you guys as well. When i am done testing.
- I am going to be in contact with my supplier to tell them that i am going to be purchasing a 1/4 inch 1045 about 4"x4" sheet
- Also i am going to head out there this weekend with some A36 and do some test cuts as that should be pretty similar to the 1045.
- Also i will try to harden a piece of A36 and it probably wont work.
- we are really close to getting a prototype cut and finalized to run into production and possibly some heat treating of a few if you guys desire.
Check out pictures bellow.
- CNC Plasma Cutter Redwood City appointment coming up soon
- About time to purchase the plate of 1045 steel
- I machined the jig for the A36 for cutting out of the tormach
- It was machined out of HDPE Starboard.
- It is a jig to mount 2 4" x 12" x 1/4" A36 Plate to be cut and held down in the tormach. so when i swap in the next pair of A36 plate in i dont have to rehome the tormach
- plate purchase coming up. Bearings as well, as well as drive square bar. Stay tuned
- First cuts coming very soon.
Check out pictures below.
- TechShop is still closed. They failed one of their inspections so the re-open date has been pushed back to 4/5/2017 instead of 4/1/2017
- I have signed up for the cnc plasma class. issue is that the closest class i was able to sign up for is 4/28/2017
- I have been calling in for every class from now to 4/28/2017 if a seat come available that i could fill in between now and then.
- When TechShop San Jose reopens i will be moving forward with the template for the A36 shredders to be able to mill out. even though that process will take like 6-7 hours to make 1 shredder
- In the mean time i have been looking to buy some heavy duty flange bearings so i can adapt my model to accommodate them.
- Then buy the square drive shafts for machining. Or source hexagon shafts
- Techshop San Jose is now closed for move to the new twice as large location
- I was preparing to machine a template for machining the 4" x 12" inch A36 plates. However something new came up
- Tech Shop Mid Peninsula in Redwood City just got the permits for their cnc plasma cutter to be used again
- This is a great development. This will decrease the time for cutting the shredder by about 11 times. which drastically increases my speed for production
- However one thing that I will have to deal with is the quality of cut. the quality of cut is not going to be as good as a water jet or the mill. As technically the plasma cnc cutter is the worst quality of cut all cnc machines. as plasma cnc machines are built for speed not quality of cut.
- The plasma cnc machine will leave dross. and more taper than the other cnc machines. so I'm predicting a lot more cleanup than the mill.
- qThe Bad is that the class to learn the machine is full until the 20th of next month. I am working to getting into a class or checked off on the machine asap.
- So I will be just buying the 1045 steel 4' x 8' x .25" plate (does 8.5 shredders). and start cutting. if everything checks out we are ready to rock and roll
- Again thanks for your guys patience. it is coming
check out pictures bellow for some pictures of example cuts from the cnc plasma cutter.
- 1st. Techshop has pushed back there close date AGAIN from March 2nd to March 23rd.
- this has 2 effects. 1 positive 1 negative
- Got more time to work on setup on cam.
- However, the negative is that i will not have access to the water jet till the 23rd plus 10 days for them to close and move everything.
- After pricing out the steel i have found out that buying the pre cut plates of steel is extremely expensive
- The best option is to buy 4' x 10' giant sheets and cutting out the plates from the sheets on the water jet. that is what i am going to be using in production. and also it is cheaper for prototype
- Im still contemplating taking some A36 out of my garage and welding the smaller plates into bigger plate and grind the welds flat
- however i dont think that that will make a very good functional prototype. Im still probably going to do so because i need to get rid of that 1/4 inch steel
- Now i have a chance to make the template or jig out of plastic so i can instantly home every sheet i put in in order to swap them out quickly. As each machine takes 3.5 sheets
- I have gotten an estimate for machine time. It came in at 5.5 hours minimum per shredder. my estimate was 2.5 hours. so the price of the shredder if not pre-ordered before first prototype will see a more drastic price increase than originally expected.
- so in the mean time shopbot out the jig and check the fit on the tormach. and double check the cad file and save the cam for the tormach. and maybe try some A36
- I have taken all the preq steps to get me to the place when i am ready to machine a prototype
- I have sat in on the classes i need for the Tormach at tech shop and my current (temporary) cam software VCarvePro 8.5
- I currently have the prototype shredder nested out in VCarvePro 8.5. ready for 2D routing cam
- i need to call up my supplier to get some A36 in a 10.5" x 19" x 1/4" plates. and maybe my first 1045 steel 10.5" x 19" x 1/4" plate for first shredder
- I found out that i will need 3.5 plates of 9.5" x 18" x 1/4" plates per shredder and my estimated time is to be about 130 minutes minimum for machining not including changing plates
- Because i will find extra expenses in the manufacturing after i manufacture my first prototype i will realize some of these extra expenses and i will increase sale price to reflect that
- Also when i begin manufacturing the 3 shredders i will also discover the manufacturing the final production of machining and those expenses will also reflect that.
- So if you have not yet purchased a shredder yet now is the time to do it as this will be the cheapest you will ever find it. after these other 2 points price will increase in according to increase in costs and plugging it into a equation i made so increase cost will not be known tell it is calculated.
- stay tuned as next update will probably be pictures from the prototype machining process.
- Techshop has pushed back their hard close date twice since last update.
- the new hard close date is now March 2nd
- Techshop is now only going to close for one week in after march 2nd
- that being said I have begun to continue forward on the metal prototype.
- I have setup a vcarve 8.5 pro file at tech shop that has been setup for the max travel for the tormach
- now I just need to generate the routing toolpath for the tormach.
- and I have to take the tormach class to get associated with the machine
- then machine a prototype. make improvements from prototype then we are good to go into production.
- I am back to school now and will talk to my instructor about possible housing of a kiln to heat treat the shredder and then price that out.
- then I will begin work on the funnel/shroud and motor attachment.
- I checked the static stress of the shredder dials. I changed a few things and I have found that my original design is yielding the best performance. So I will not need to modify my original design.
- Because I am going to be going with my original design I will not be able to get the shredder to withstand any additional stress without hardening.
- MAIN POINT!!!!: TechShop informed me a few days ago that they lost their lease extension. The lease extension was going to allow them to not shut down the shop and slowly move all the machinery to the new location. If you need to use the equipment at new location you go to new location, if the equipment is at the current location use that equipment. However now that it is lost they need to do a hard close and move everything. So they are hard closing at the end of the month 1/26/2017. Also they will need to stay closed for an entire MONTH in order to finish construction on new location to be up to code and to finish moving all the equipment to the new location. so I will not be able to do production on the project tell around 2/26/2017. But the new location is going to be nice with a lot of storage so I should be able to get storage on site. They are also going to be putting together a 2nd Tormach.
- Thanks for your interest everyone that came from kickstarter or a forum
- The Reclaimer is currently on sale on this websites store http://www.thegreenengineers.com/store/
- the starting price is $125 dollars because i was able to drop the price. i was able to drop the price because now i am milling out the shredders instead of water jetting (very expensive)
- The basic unit is now equipped with 1045 steel instead of A36. This was a stretch goal but now comes included as the base model. this is because of decrease of price for steel with my new supplier so I will just include it now without extra cost
- This is also a base for a lot of expansions one of which is the shroud. another is a motor, and finally a stand. The motor will need to be installed on the shroud to function so the motor will not be able to function without the shroud (for liability issues).
- Where do we go from here
- I now begin to optimize the blade shapes so you can cut the most hardest material possible without hardening.
- I will also generate the CAM using Fusion 360 CAM for a Tormach
- order the 1045 steel plates and buy the flange bearing
- Production should start February and ship out late February
- After shipping in February work on shroud, motor, and stand.
The $125 dollar for base unit and price increase when I start building in February and increase again after shipment in late February. so now is the best time to pick one up.
Stay in the loop by checking back into this blog often.