Designing and creating some samples by using Denford application.pdf

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Slemani Polytechnic University
Slemani Technical Institute
Department Of Mechanic CAD-CAM
Designing and creating some samples by using
Denford application
Denford Digital Workshop
Prepared by:
Rebin Abdulrahman Ahmad
Rawa Esmail Muhamadamin
Supervised by:
Sherzad Muhamad Salih
2021-2022

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Contents
❖ Objective …………………………………………………………….... 5
❖ Introduction ……………………………………...………………....…. 5
❖ Tools & Equipment …………………………………………………… 9
❖ Procedure ………………………………………………...……….…… 9
❖ CAM Procedure ……………………………….………….……………. 9
❖ CAD Procedure ………………………………………………..…….. 19
❖ Machining Procedure ………………………………………………… 24
❖ Result ……………………………………….………………………… 28
❖ Discussion ……………………………………………………………. 32
❖ Reference ………………………………………………………..…… 32

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Project name: Designing and creating some samples by using Denford
application.
Objective:
❖ Designing and creating 4 signs for classrooms and labs with Denford CNC
milling machine.
Introduction:
❖ What is CAD/CAM?
CAD stands for ‘Computer-Aided Design’ and CAM stands for ‘Computer-
Aided Manufacturing’. CAM preceded CAD by some years.
CAM is based on Computer Numerical Control (CNC) where pre-programmed
computer software dictates the movement of factory tools and machinery.
CAD is the software used to create electronic files for print, machining and other
manufacturing operations. CAD arrival increased the productivity of designers
and improved the quality of design amongst other benefits. The software CAD is
used to support both engineers and designers across a range of industries,
including architecture, automotive and aviation.
While the two terms describe distinct things, CAM has increasingly used CAD
and the two terms are often used together as CAD/CAM .(1)

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❖ When Denford Engineering was Founded?
In 1930's Denford was founded by Horace Stanley Frederick Denford,
grandfather of the present Chief Executive. Horace was already an
experienced engineer when he came to Halifax from London to escape the
bombing during the blitz; and in the closing years of the war, he established
Denford Engineering, at Box Tree Mills in Halifax – a company which
manufactured a range of engineering inspection/measuring equipment and
tool holders.
Horace Stanley Frederick Denford

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Denford moved part of their manufacturing operation to Box Tree Mills in
Wheatley, Halifax, in the closing years of the war. Having set up in the “Box
Mill” plant, a new company named “Denford Machine Tools” was created, and
manufacture started of two small precision bench lathes branded “Box-Ford”.
These machines were offered for sale at a suggested price of around £175, and
had a production run in excess of 400 units!
In the 1950’s Denford moved their manufacturing operation to Birds
Royd, Brighouse, and by the end of the 1950’s Denford were
manufacturing a variety of metal and wood turning lathes, tool
sharpening equipment, grinders and polishers. Viceroy lathes (wood
and metal) manufactured by Denford can still occasionally be found in
school Design & Technology Departments today!
Horace’s son Gerald Denford took over the company in 1962 and had a huge
influence in steering the company into the start of the CNC machine tool era up
until the current (third) generation of the Denford family took over in 1987 and
again developed new technologies for use in education and training. Gerald’s son
Andrew is the present Chief Executive and his daughter Nicola is Corporate
Affairs Director.
Gerald Denford

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In December 2010 Denford Limited moved to a new purpose-designed 18,500 sq
ft facility at Armytage Road, Brighouse. The new premises incorporate the
company’s manufacturing facilities, including 3,200 sq ft of office space, as well
as a dedicated showroom, demonstration and training facility.
In recent times, Denford has expanded its product range to include the design and
manufacture of a comprehensive range of CNC mills, lathes and routers which
have been specifically designed for education. Denford machines are a familiar
fixture in Design and Technology and Engineering laboratories around the world.
New product development continues as a key strategy for Denford Limited, and
as confirmation of this, Denford products are constantly being updated, keeping
the traditions of design and manufacture firmly based in Brighouse, West
Yorkshire.(2)

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Tools & Equipment:
❖ Denford machine (Triton Pro)
❖ Three workpieces of MDF wood (150 by 250)mm
❖ Computer
❖ Applications:
- AutoCAD 2017
- Denford app (VR Milling V5)
Procedure:
1. CAD Procedure:
1-1.We started designing the texts in AutoCAD program , according to
the following isometrics:

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1-2. Run the AutoCAD program , then specify the limits of drawing ,
which equals to the surface workpieces measurement.
We can specify the drawing limits by writing the (LIMITS) on the
keyboard in command bar.
(0,0) is considered as the first point of the drawing limits.
And the next point must be equals to the surface workpieces measurement,
that (250,150).

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1-3. We want to display the grid only in the specified drawing limits , for
this purpose , we open the grid setting and disable the (Display grid beyond
Limits) in Grid behavior options.

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That's how it comes out to us:
1-4. We write these texts what we want , then we are resizing them , and
placing them into the drawing limits , and after that , we need them as lines
and arcs and drawings , for this purpose , we use (TXTEXP) command ,
and select these texts that we want to explode.

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1-5. As we see , some lines are made up with the texts during the exploding
them , we must remove them with help of (TRIM) command.
1-6.We done the same way to create and design other texts , then we got
these:

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Tip: For this one (Denford DIG. WSH.) , a rectangular is added to around the
text, because we want to machining the surface of the workpiece not the text.

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1-7.A label as a mark to Denford digital workshop is created.

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2.CAM Procedure:
2-1.The first design with DWG extension is imported to the VR Milling
V5 application , then the material of the workpiece is selected , after that
the file must be imported in metric units , then the measurements of the
workpiece are specified .
The measurements are should be determined in this way:
X=250 mm
Y=150 mm
Z=18 mm

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2-2.The Area clearance is selected to machining the workpiece, and we
should specify the tool number and depth of milling and select the texts to
machining , and click the apply to working.

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2-3. We can see that the design is completely converted to G-code.

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3. Machining procedure:
3-1.we click the machine icon to connect the machine to the computer.
3-2. The workpieces is placed on the machine jaw properly one by one for
all tasks.
Then the door of the machine is closed , the machine does not work until
the door is closed.

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3-3.The control panel is opened , we have to click the (Home) button to
get back the machine to the home of the machine.
3-4. We must make the axes work offset number zero to specify the (0,0,0)
point of the workpiece

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3-5. At Jog section we must move the tool cutter to the left-bottom corner
to get work offset and to specify the (0,0,0) point of the workpiece.
3-6.We need 2 cutting tools during machining the workpieces , with
(2.5mm) and (2mm) of diameter, the (2.5mm) is for the main cutting and
the (2mm) is for the label.
3-7.We got 3 axis number , we must put these numbers to the work offset
to considering this point as (0,0,0) point of the workpiece.
The machine position of the first task (Computer Lab. -1-) is:
X=-218.350
Y=-128.275
Z=-149.175
And for the Denford DIG. WSH. label Z=-150.440 with same X,Y
Note: The Z values is different because of different of the cutting tools
length. This is used for all tasks.
3-8.The same way is used for other machining tasks.
The machine position of the second task (Computer Lab. -2-) is:
X=-218.375
Y=-129.505
Z=-149.080

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The machine position of the third task (
‫ی‬
‫هۆڵ‬
١٧ ) is:
X=-216.980
Y=-124.270
Z=-148.930
3-9. We`ve started the machining of the workpieces one by one.
3-10. We`ve got painted the holes in the workpieces.
We will see the appearance of the workpieces in the Result section.

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Result:
After the cutting processes we got the required classroom sings , we going to
show them compare to the isometrics.
The isometric:
The Product:

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The isometric:
The product:

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The isometric:
The Product:

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The isometric:
*The product of this task is not exist , because of the lack of time.

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Discussion:
There are several reasons for errors during design and machining.
The first error is with the AutoCAD file , when we saved the file in (2013 dwg)
, while this version is not suitable for the CAM program (VR Milling) , because
the program is created in 2003 , and it only able to run the lower version than
2003 , and it can't run a high version of AutoCAD like (2007 dwg , 2013 dwg ,
2018 dwg , etc ...) , and for this purpose we must save the AutoCAD file with
(2000 dwg).
And the second error is occurred when we needed to change the cutting tool ,
the tool holder is stocked and can't change the tool automatically , due to the
machine is not used for a long time , until we pressed down the tool holder
manually , then the tool holder is worked properly.
References:
(1) From 8th
to 19th
line.
https://www.technicalfoamservices.co.uk/blog/blog-history-of-cad-cam/
(2) From 1st
to 38th
line
http://website.denford.ltd.uk/about/company-history/

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