Sign Project

[Keith Butzgy CNC Software Inc.]

I was given the task of cutting a sign for a friend of mine. Thankfully...I didn't have to paint it. I figured I'd share some pictures of the finished job. This was a result of Engraving, Mastercam Art, your standard 2D pocketing toolpaths and a little remachining. The material is MDF, unpainted. The engraved letters were cut with a 120 degree cutter, and the dog shape was roughed with a 1/2 endmill and finished with a 1/4 ball. I used the "Art Based Surface from Image" to create the surfaces to machine.

 

 

 

 

 

-Keith

[Trevor Bailey]

i like it. i have almost finished the design of the one i showed you at solidworks world. i am very lost at the color scheme to use though and how to go about it.

 

i have some pretty trick stuff coming for a prospect of mine. do you think you will have some time to go over a few ideas later this week?

[Keith Butzgy CNC Software Inc.]

Yeah no problem! Let me know!

[machtek]

Nice work CNC,

 

Will you share feeds and speeds, tool geometries and coatings?

 

I have the first Art project on my router right now, thanks to all of the help from this board and the kind and paitent help from the folks at CNC

 

Dennis

[Keith Butzgy CNC Software Inc.]

No problem,

 

For the lettering, I used the engraving toolpath and a 120 degree cutter from Amana Tool and cut at a speed of 90 ipm and a SS of 13,000 rpm (I think). Max Z depth was -0.239, I just did a finish pass, no roughing.

 

For the textures on the dog, I used a “Parallel – Contained” Art toolpath. I roughed with a 0.50 in straight cutter, 200 IPM, 2 depth cuts at .187 each, 35% stepover, 0.05 stock to leave in Z. Finished it with a 0.250 ball, 10% stepover at a speed of 150 ipm. Shortly after I started this finishing pass I upped the speed because it was too slow. I forget what I changed it to.

 

I'd have to check what the tool coatings were, but nothing special. Hope this helps! I'll post more projects as they come along.

 

-Keith

[machtek]

Thanks CNC_KFB,

 

This helps, I have developed all of my speeds-feeds myself and just wanted to see what others were having sucess with.

 

At least 90% of what I cut is MDF laminated in 2.25 and 3.00 thick sheets. Some of the parameters I have tried take out tools quick, also some of the uncoated tools I use won't even last a day.

 

My current arsenal that I cut a large percentage with are ISCAR inserted tools, for instance: 3/4 2fl heliquad IC 325 coated inserts 22000 rpm 850 ipm .250 depth 55% stepover, this will last between 1 and 3 weeks as a rougher (we cut at least 4-6 of these 48" blocks a day) I make molds with them. I will share more if you're interested.

[Keith Butzgy CNC Software Inc.]

Machtek,

What kind of molds do you make with MDF?

[machtek]

Keith,

We make cast stone. This is like wet pour precast concrete, but the mix is much like brown sugar then it's air-hammered into the mold manually and sets up much like natural stone.

 

Dennis

[Keith Butzgy CNC Software Inc.]

Thanks Dennis,

Very interesting. Any pictures you can provide when you get a chance? I was thinking of making 6-10 various interlocking stepping stones for my patio.

-Keith

[machtek]

Our website is currently under construction but it has a few pictures under photo gallery.

 

linky

[Trevor Bailey]

machtek .....how heavy is that material once it is set....lets say for a 4' x 2' x 2" sign?

[machtek]

Hi Trevor,

 

This stuff weighs approx 140# per cu ft. I make that sign 4.8 cu ft and that would make 672#.

 

Check my figures, I don't sell or ship the stuff only make molds so my math may be off.

 

Dennis

[Robert Critelli]

it is exactly 140 lbs per cubic ft, coming from another caststone guy web page

[michaels123]

Keith,

 

Really nice sign. What machine did you cut it on?

[Keith Butzgy CNC Software Inc.]

I cut it on a Shopbot PRT 96.