SolidWorks Model
Therefore, while trying to wind up my articles on HSMWorks, I decided to try something unique to ensure HSMWorks is the right choice for students.
I designed a place setting with SolidWorks and created the toolpaths to cut it out. I opted for this configuration for the challenge of getting the tool paths properly set up.
To ensure I would have a thickness suitable for the cuts, I Gorilla Glued two scrap pieces of Medium Density Fiberboard (MDF) together. This gave me 1.5 inches or 3.8 cm to play with.
MDF wood is a composite of sawdust particles and glue. It is formed under pressure and cut into various sizes and thicknesses.
As a tip, I rarely use any kind of fixtures to hold pieces in place for the cutting operations. After all, you do not want them to be accidentally cut into when using router bits that are intended for woods.
Additionally, I like to work from Centers for all of my jobs unless I have a reason to do it differently. In the end, it comes in handy to have a consistent reference point for your projects.
Simulation (Left), Facing Operation (Right).
As for the tool paths for this 3D carving job, I first ran quite a few simulations to make sure HSMWorks was going to do everything I wanted. The final result will need some light sanding and paint to give this 3D carving a realistic look.
A facing operation was performed to smooth out any high spots on the surface to one thousandths of an inch. However, HSMWorks has to also calculate the jumps over items to carve the proper shape.
Tool path Step 1 (left), Step 2 (right)
Undoubtedly this could have been optimized better with more experience. However, this will give the results that I am after.
This is my two inch facing tool. It is has razor sharp cutting edges on the outside. This bit cannot exceed 12000 rpm's according to the manufacturer’s recommendations. I therefore only ran it at 9000 rpm with a slow feed rate. The results are very gratifying.
Step 1 tool bit (Left) and Step 2 cutting (right).
I used a half inch Ball Nose Router Bit for step 2. I was very happy to see an outline of a plate, fork and knife appear.
The Finished Product.
I finished off the project with a few coats of paint and polyurethane. I also cut out a custom laser cut box to send the place setting as a gift to my corpulent friend. If he uses this instead of what he has been he should lose some weight.
This project has taught me that HSMWorks is a very capable program. I believe it is perfect for those early school grades.