Re(Calibrator) Phase11

Previously, I have presented the 3 axis CNC Router, that I used to  fabricate the piece of the geometry and now I would like to  look into the  CNC machining in more detail. Below is an example of a 3 axis CNC router with 15 HP HSK 63 Spindle and 24" Z Axis Travel and Clearance. http://www.5axiscncrouter.com/3axisCNCrouter.html

3 axis CNC router

CNC is the automation of machine tools, that are operated by computer programmed commands, using Computer Aided  Design CAD and Computer Aided Manufacturing  CAM programs. A quarter century ago, the very idea of CAD and CAM being linked was far-fetched and provocative to say the least. But today, production of a part is set in motion from a designer's graphic terminal. What CAD and CAM now constitute is one of the greatest technological and economic forces ever seen in industry.  http://www.americanmachinist.com/304/Issue/Article/False/9168/Issue
Parallel to the evolution of personal computers, Personal CNC has its roots in EMC and PC based control, but has evolved to the point where it can replace larger conventional equipment in many instances. http://en.wikipedia.org/wiki/Numerical_control Nowadays the most common programming language for CNC machining is the G-Code, which is more likely to be generated with the aid of a CAM software package.  The CAM software utilizes the dimensions from  a given design by assigning 2D or 3D geometry to the part and allocates a group of machining processes, such as drilling, facing, boring, pocketing, etc. to the geometry in the drawing.  Afterwards, the G-Code is generated(often this is several thousand lines long or more) automatically by the software and is ready to be used in the CNC machine. http://carlsonmfg.com/cnc-g-code-m-code-programming.html
The 3 axis CNC machine is the most basic 3D CNC machine, that performes  movement about the three primary axis X, Y and Z simultaneously, with the Z axis parallel  to the spindle. In the digram below, the Rz stands for the  rotation of the tool within the spindle.  http://www.engineersedge.com/manufacturing/three-axis-cnc-machining.htm

the 3 axis of the CNC router

On a 3 axis CNC machine, an object can be modified in space left and right, top to bottom, and forward and back. This kind of manufacturing is suitable for only relatively simple cavity  and boss fabrications, but when we have a more complex geometry, such as the one below, more  degrees of freedom are required.

complex geometry that can not be cut on 3 axis machine

The more axes on a CNC machine translates into a more complex piece of equipment. For example the axis CNC machining equipment has the advantage of the extra two axes aside from the x, y, and z planes. The extra axes may be a circular axis, a diagonal axis, etc. which are commonly called the Q and the B axis. The Q axis is normally associated with the rotation of the product whilst the B axis is associated with the tilting of the product. This is the nomenclature that is used in many 5 axis machines but it can always vary from machine to machine.  http://www.cncmachiningcompanies.net/147/what-is-5-axis-cnc-machining/#more-147   Below is an example of a custom 5 axis milling, where the A rotary table sits vertically on the mill table and the Spindle pivots on the B-Axis which is attatched to the Z-Axis.

5 axis diagram

Of course in this scenario, there will always be the one plane (which is the surface attached to the machine) that will remain untreated. http://www.cnc-toolkit.com/cnc_5axisMill.htm

5 axis milling

At this point I will be stepping into the realm of robotics and will be looking at two of the biggest manufacturers of Industrial Robots, the American Fanuc http://www.fanucrobotics.com/  and German Kuka http://www.kuka-ag.de/en . Both companies specialize in robot-supported automation of industrial manufacturing processess. Below is a 7 axis Kuka robot  working  on a sculpture.

Kuka robotic arm sculpting a complex form

And here is a Fanuc Model M-710iC milling a female sculpture.

Fanuc robot sculpting

The high quality of detail is astonishing and it leaves the viewer speechless somehow.
Below images show the different stages of machining the Beethoven bust with a Kuka robot. http://www.roboticmachining.com

Kuka robot starting to sculpt a bust of Beethoven

The sculpting in progress

The robot putting the finishing touches

These industrial robot arms are based on a model of a human arm and they posses base, shoulder, elbow  and wrist rotations. An extremely sophisticated computer generated software controls these movements, and a complex G code is required. The more basic version of these models is the simplest 6 axis robotic arm.

6 axis robot arm

The 6 axis indicates that this robot has six degrees of freedom, which is very limited compared to the human arm that has forty two degrees of freedom (page 30, Fundamentals of industrial robots and robotics). However the latest models of Kuka and Fanuc are almost as versatile as the human arm and can work with unrivalled precision and accuracy, without getting tired or bored.

Computation, Robotics and craftsmanship will hopefully collide in one great effort to produce glass in certain new discipline.