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Old Feb 13, 2013, 03:19 PM
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CNC Molds and Cores for DLG's

I have had my CNC for about 1 yr now and just now getting the time to do some real work on it.

So I have cut some Corian Molds for a DLG. They turned out great. Now I have been trying to cut the cores. Just about got it. on the first attempt.
But I ran into a problem I have a vacuum table to hold the core down so I could cut the second side.


Russ
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Old Feb 13, 2013, 06:15 PM
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An air leak is an easy way to "turn it down".
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Old Feb 13, 2013, 06:34 PM
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Thanks I will have work on that.

Russ
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Old Feb 13, 2013, 07:48 PM
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A sliding or pivoting gate over a hole works good. Or a valve on the hose open to the air.
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Old Feb 13, 2013, 08:06 PM
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have also seen where someone uses a rubber 1/16th flap on the inside of the bucket, then the flap just opens what it needs to before caving in the bucket similar to a diaphragm.

doug
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Old Feb 13, 2013, 08:08 PM
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is your other vacuum hold down for the initial block of foam just a flat rectangle on the inside?

Nice work,
doug
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Old Feb 14, 2013, 10:32 AM
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Doug,

Yes. the holdown is just a flat rectangle.

Do you think I should make a new Vacuum table with a bull nose bit?

Russ
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Old Feb 14, 2013, 01:31 PM
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More info on your vacuum table with bullbose bit?
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Old Apr 30, 2013, 03:31 AM
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Russ,
What are your speeds and feeds to cut Corian? Is the material too abrasive on the cutters? I have a home made MDF CNC router and I am not sure if it can handle tough materials. I am making molds in basswood covered with resin wood finish and although is not a mirror finish it looks fine to me.
Eduardo
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Old May 01, 2013, 06:57 AM
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Eduardo,
Corian is very easy to cut. Use a carbide bit and it will cut very nicely. I have been turned on to these bits. http://www.lakeshorecarbide.com/corn...sendmills.aspx and they work great.(I use the 60 deg radius bits.)

As of feed rates and RPM’s I would have to look at my program. (Mach3)

I just look at the chips and listen to the chatter of the bit and adjust from there.
But I really like these bits they work well.

I have cut some more molds I will have to post some pics soon.

Russ
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Old May 01, 2013, 07:48 AM
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Totally depends on the machine, the bit, and what you're trying to do.

Last night I cut some finish passes with 1/4 ball mill in a Joe's 4x4 with a 3 1/4hp Hitachi router at 10000 rpm and 60ipm. That seems to be a good finish speed for my machine in Corian.

Roughing is typically 1/2 ballmill or 1/4 ballmill with deeper cuts, larger steps, and around 40ipm. My machine is limited by the lack of cutting power in my router, not by the machine's mechanics.

Looking forward to the pictures Russ. I just did another fuse mold / canopy mold and after four years I feel like I'm starting to get pretty good at this stuff. Scary how much I still don't know though.
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Old May 02, 2013, 09:10 PM
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I understand... I use an edge trimmer at 27000 rpm and 1/4" end mill for roughing. I think I get good results for the set up I have. As I said, its a MDF machine with Nema 23 steppers. Nothing fancy but it does the job. Attached, a picture of the CNC machine and the mold for a BD I cut in basswood.
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Old May 03, 2013, 05:00 AM
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nice work eghelman
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Old May 03, 2013, 07:58 AM
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That is some nice work.
I built a Joe's CNC and I have a cutting surface of 47"x57"

Russ
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Old May 28, 2013, 01:13 AM
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I have a cnc router 8x16'
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