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.
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.
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.
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
Techshop went bankrupt yesterday and all locations are now permanently closed
Thus i have lost my office location for storage close to my machines
Also my access to heavy duty tools is now lost
Now i have next to 0 tools available to me
That put a major strain on this project. As the only way i was able to economically fabricate the shredder was on techshops redwood city plasma cnc which is now have no access
So i am not sure if i will be able to complete the project. i have maybe 4-5 shredders cut however one of the integral pieces were not cut due to needing to be finalized.
so i can try to source getting those last few parts cut
then my only option to get the project done quickly is to source a cheap place to cut the parts and just take the loss or build my own machine
but building my own machine would take forever
I will keep you guys posted on the finishing of the parts for my machines.
above link has pdf talking about closure.
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.
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 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.
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.
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.
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.
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.
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.
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.
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.
At this point now i am coming up to production speed
Currently i am at a speed of a shredder a week
Using the mill full production speed should be 2 shredders a week
parts are coming out pretty good i should have one assembled here pretty soon as i have most of the parts cut
i received another set of 1045 square shafts for driveshafts
and i am going to finalize the design of the front and back plate
then order the bearings so i can assemble first production prototype.
Dropping off steel today at my classroom shop for building plasma.
I got the arduino uno powered grbl controller 4 axis x,y,z,a. with 2.5 amp stepper drivers.
Going to be talking to my boss at the machine shop tommarow about machining the shredder on the Excel 10T-24. I will attach a picture bellow
He does want me to start doing some setup work which currently i am only running production. So when i get more comfortable with the setup it should be pretty easy to run the shredder especially with a tool changer.
Current idea for "recipe" for shredder on 10T-24:
Fasten plate (2'x2') to sacrificial board using industrial strength double back tape.
Use 1/4" roughing endmill to route out the profile of the blades and pocket out the center square.
Pocket out inner square with 1/4" roughing endmill
Leave about .020" - .025" (onion skin) for "low force" last pass on profile.
Finish the "low force" pass to remove profile from rest of plate.
Tool Chaned andCome back with a 1/8" end mill for finishing and get rid of extreme radius from 1/4"
Add 2nd fixture with the plate (2'x2') already attached. Run This plate with steps 1-3
While next set is being made run remove plate and add new plate and tape to first fixture plate.
Estimated runtime on the 10T-24 is about 1:15-1:30
Working on the last few dials to be filed in order to assemble the shredder. Been busy with midterms and work.
Then work on trying to heat treat the extra dials and note distortion.
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
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.
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
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.
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.
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.
Now currently finished with school yesterday. Off till mid to end January.
Looking into picking up a kit for a router to run at home. Also setting up workshop at home in my garage.
So i am going to need linear rails, grbl kit with nema 17/23, 2 HP low runnout air/water cooled spindle with vfd.
Otherwise tech shop is now under new management and they are wanting to re open shops but that is not a fur sure thing and don't know when this will happen.
also the current techshop business model is dead because it just didn't work. So i dont know if the new model will be viable for me
I would like to start operating out of the house because i have other stuff i need to get done around the house while the router is cutting out parts.
Working on getting the broach made but my adviser for my club is not responding anymore so might need to get a new adviser. he has to clear anything that gets made at school.