Christian Rattat began his career on a Commodore Amiga 2000 in the 1980s and has been developing software ever since. He works for large corporations in Microsoft and Unix environments, and also builds and implements software for microcontroller-based applications. In his free time, he builds and flies multirotors—a hobby that gives him plenty of excuses to experiment with CNC routers and 3D printers. Christian Rattat CNC Milling for Makers Basics – Techniques – Applications Translated by Jeremy Cloot CNC Milling for Makers Christian Rattat [email protected] English translation: Jeremy Cloot Editor: Dr. Michael Barabas Copy-Editing: Patricia Pane Layout: Ulrich Borstelmann Production: Susanne Bröckelmann Cover design: Helmut Kraus, www.exclam.de Printer: M.P. Media-Print Informationstechnologie GmbH, 33100 Paderborn, Germany This book is a co-publication by dpunkt.verlag and Rocky Nook ISBN 978-3-86490-472-1 (dpunkt.verlag) ISBN 978-1-68198-302-8 (Rocky Nook) Copyright of the English edition © 2017 dpunkt.verlag GmbH Copyright of the original German edition © 2016 dpunkt.verlag GmbH Wieblinger Weg 17 69123 Heidelberg Rocky Nook Inc. 1010 B Street, Suite 350 San Rafael, CA 94901 USA Distributed in the U.S. by Ingram Publisher Services Distributed in the UK and Europe by Publishers Group UK and dpunkt.verlag GmbH All rights reserved. No part of the material protected by this copyright notice may be reproduced or utilized in any form, electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without written permission of the publisher. Many of the designations in this book used by manufacturers and sellers to distinguish their products are claimed as trademarks of their respective companies. Where those designations appear in this book, and dpunkt.verlag/Rocky Nook was aware of a trademark claim, the designations have been printed in caps or initial caps. All product names and services identified throughout this book are used in editorial fashion only and for the benefit of such companies with no intention of infringement of the trademark. They are not in-tended to convey endorsement or other affiliation with this book. While reasonable care has been exercised in the preparation of this book, the publisher and author as-sume no responsibility for errors or omissions, or for damages resulting from the use of the information con-tained herein or from the use of the discs or programs that may accompany it. This book is printed on acid-free paper. Printed in Germany 5 4 3 2 1 0 Content Overview 1 Introduction 2 Your Own CNC Router 3 Milling Tools 4 2D Milling in Practice 5 Machine Upgrades 6 Advanced Milling Techniques 7 Looking Ahead Glossary Table of Contents 1 Introduction 1.1 What Is Milling? 1.2 Gantry Milling for Hobbyists 1.2.1 The Machine Table 1.2.2 The Milling Motor 1.2.3 Feed Rate 1.2.4 All About Milling Tools 1.2.5 Features and Add-ons 1.3 Raw Materials 1.4 CNC Milling 1.4.1 CAD 1.4.2 CAM 1.4.3 Machine Control Systems 1.5 Alternatives to Milling 1.6 Personal Safety and Risks 1.6.1 Motor and Cutters 1.6.2 Electricity 1.6.3 Fire Hazards 1.6.4 Hazardous Materials 1.6.5 Safety in the Workplace 2 Your Own CNC Router 2.1 Choosing the Machine for this Book 2.1.1 Inventables X-Carve 2.1.2 Stepcraft-2/600 2.1.3 Other Models 2.1.4 Making a Decision 2.2 Assembling the Kit 2.3 Step 1: Assembling the X-Z Connector 2.4 Step 2: Mounting the Z Axis 2.5 Step 3: Assembling the X Lead Screw and the Sides of the Gantry 2.6 Step 4: Assembling the Gantry 2.7 Step 5: Assembling the Main Frame 2.8 Step 6: Final Mechanical Assembly 2.9 Step 7: Installing the Electronics 2.10 Step 8: Assemble the Machine Table (5 minutes) 2.11 Step 9: Installation and Startup (30 minutes) 2.11.1 Grease the Rails and the Lead Screws 2.11.2 Install the Software 2.11.3 Prepare to Align the Lead Screws 2.11.4 Connect Your Machine 2.11.5 Align the Lead Screws 2.12 Alternative Software 2.12.1 Installing the Hardware 2.12.2 Installing and Configuring UCCNC 2.12.3 Running a Test Job 2.13 Your First Workpiece 3 Milling Tools 3.1 Milling Tools 3.1.1 Teeth and Flutes 3.1.2 Cutting Length and Shank Types 3.1.3 End Mill Materials 3.1.4 Cutting Speed and Feed Rate 3.1.5 Cooling and Lubrication 3.2 Which Tool for Which Material?