X-Carve: Example Carve

This tutorial is Part 3 of the X-Carve Router practice example. This portion of the example will explain how to set up the coordinates for your carve, and carve your example part. If you haven't yet, go complete Part 1 and Part 2 first.

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Part 1: Creating Geometry and Features

Part 2: Setting Up the Machine

Part 3: Carving the Part

Connecting the Computer to the Controller

Only the computer in the Woodshop should be used to run X-Carve programs. It is freely accessible for any members with Woodshop Access.

Step 1:		Log into the computer using following credentials: User Name: Spark Password: User
Step 2:		Open a web browser Go to the Easel login page (the image to the left is a link) Enter your Easel user name and password to log into your Easel account Open the class project you programmed in Part 1
Step 3:		Ensure the E-stop on the X-carve controller is reset by twisting it clockwise.

Homing and Jogging The Machine

You're almost ready to cut your project on the X-Carve. Before you get to carving, there's a few things you'll need to know about controlling the X-Carve spindle position using the computer.

KEEP HANDS AND FINGERS CLEAR OF THE X-CARVE WHEN IT IS OPERATING

Step 1:		There are two buttons in the upper right corner of the Easel window. Depending on the state of the X-Carve controller, they may be blue or green. If the buttons are blue, the X-Carve controller is not connected to the computer. After resetting the E-stop, it may take up to 60 seconds for the controller connection to recover If the buttons are still blue after 60 seconds: Ensure the green Power LED is glowing on the front of the X-Carve controller. If it is not: Ensure the power cord is firmly inserted into the back of the controller Ensure the power cord is plugged into the power strip next to the computer Ensure the power switch on the back of the controller is turned on If the Power LED still does not light, contact the Woodshop Leads for help Ensure the USB cord is fully seated in the front of the controller, and the front of the computer
Step 2:		Once the buttons have turned green, the X-Carve controller is correctly connected to the computer. The Carve... button will be used later. Right now, click the button with four arrows to open the Jog controls.
Step 3:		Easel will ask you to unlock the machine prior to allowing access to the jog controls. Be aware that the machine can start moving by itself from this point forward. Keep hands, fingers, etc. clear of the machine table. Click the Unlock button to access the jog control panel.
Step 4:		Jogging is a method of moving the spindle manually, by directly controlling the machine motors. Jogging the machine does not respect the limit switches. The machine will follow user directions, even when it will damage the machine. Users must use the jog commands carefully and responsibly to prevent breaking the X-Carve. The Jog Machine panel has several sections, which are described in additional detail below. Two general controls should be mentioned first, however. Keyboard Controls: It is easy to overrun the machine travel limits using keyboard commands. Users are requested to limit themselves to the mouse interface. Layout: The layout of the jog panel was recently changed in Easel. The new panel is recommended, and will be used in this guide.
Step 5:		The first part of the jog panel shows the buttons for direction controls. Each set of arrow buttons control a single axis. Home: The Home position of the spindle is in the lower left corner of the table, closest to the controller, with the spindle raised to it's highest possible position. The Home position, relative to the other axes, is represented by the house icon. X-Axis: The X-axis is from the left to right of the machine. Y-Axis: The Y-axis is from front to rear of the machine. Z-Axis: The Z-axis is from up to down relative to the machine table. Also shown is a set of coordinates on all three axes. In this image at left, the machine is in the Home position, and all three coordinate values are zero. Clicking the arrow buttons for each axis will move the spindle in the associated direction. Care should be taken when near the edges of the table to prevent exceeding the limits of machine travel.
Step 6:		The next part of the jog panel shows the options for travel rate, or interval. The interval is the distance traveled by the spindle for each click on one of the directional controls. The standard settings are factors of 10 in inches, but the interval can be set in to millimeters, or set for custom interval values. Due to control issues, users are advised to use only the lower three settings. The travel rate, particularly in the Z-axis, using the highest setting is dangerous for the machine.
Step 7:		The last portion of the jog panel has two buttons on it. Home: This will bring the spindle to the Home position. Pressing the Home button will first bring the Z-axis to the uppermost position, then the X and Y axes to the Home corner. "Homing the machine" is recommended, but not required. It is particular advantageous when multiple carving steps are required, or the same carve is being repeated several times. Work Zero: This will bring the spindle first to the Home position, then to the last Work Zero position. The work zero position is set as part of the Carve setup. The Work Zero button is useful if cutting a project is interrupted. It allows the user to check the work zero, without having to set it again. Additional information on the work zero is found in the carving portion of the example, below.

Carving!

Finally, it's time to actually make chips. There are three portions of this step: preparing the cut, setting up the work zero, and cutting the part.

Preparing

Step 1:		Press the Carve... button in the upper right corner of the Easel window.
Step 2:		Confirm the thickness of the workpiece is correct. It should match the project material defined in Part 1 Confirm the type of material is correct. It should match your workpiece, and the project material defined in Part 1 If material thickness and type are both correct, click the blue Confirm material thickness button
Step 3:		Confirm the workpiece is securely clamped down. Reach over, give it a shove, and make sure it doesn't wiggle. If it's not secure, go back to Part 2 and clamp it down snug. If it is secure, click on the blue Material is secure button.
Step 4:		Confirm that the correct bit is installed in the the spindle router. If the cutting bit in the spindle is correct, but the image on the screen is wrong, go back to Part 1 to correct it. It it possible to change the bit definition in this screen if the diameter does not change, and you're using the Easel automatic feeds and speeds. If the cutting bit on the screen is correct, but doesn't match the one in the spindle router, go back to Part 2 to install the correct bit. If the cutting bit in the spindle router matches the cutting bit on the screen, click the blue Confirm bit size button

Setting Work Zero

Defining the work zero means telling the X-Carve where the tip of the cutting bit is, and where the workpiece is. There are two was to do with: with the Z-axis probe, and by manually touching the tip of the cutting bit to the corner of the workpiece. Using the probe is usually faster and more accurate. It is also less likely to break or damage very small cutting bits. For this example, Spark recommends using the probe, but both methods are described below.

The Z-probe is three pieces, connected by wires. There is a barrel plug, with one black wire and one red wire coming out. The black wire connects to a spring clip. The red wire connects to a brass touch plate. The Z-probe should be stored in the cart tool tray when not in use.

Probe Work Zero

Step 1:		Click the blue Probe button
Step 2:		Use the jog controls to move the spindle over the workpiece Care should be taken to avoid striking any of the clamp parts while jogging, to prevent damage to the clamp or cutting bit The tip of the cutting bit should be at least 3/4-inch above the workpiece Once the spindle is in position, click the blue Confirm position button
Step 3:		Plug the barrel plug into the silver jack on the X-Carve. The jack can be found behind the router on the top of Z-axis carriage The checkbox after Plug the lead into the carriage will automatically turn green, and move you to the next step
Step 4:		Attach the black spring clip to the collet assembly on the spindle router. The metal jaws of the clip must make contact with the metal of the collet assembly When the black spring clip is installed, click on the blue Clip is attached button
Step 5:		Gently touch the brass touch plate to the cutting bit. The No contact light will turn to Contact and automatically move you to the next step
Step 6:		Place the brass touch plate directly below the cutting bit Click the blue Touch place it in place button
Step 7:		Press the Start probing button
Step 8:		The X-Carve will automatically move the Z-axis down until the tip of the cutting bit contacts the touch plate, then retract.
Step 9:		Gently pull the barrel plug from the jack on the X-Carve Disconnect the black spring clip from the collet assembly Put the Z-probe back in the cart tool tray Click the blue Z-Probe is put away
Step 10:		Jog the tip of the cutting bit to above the corner of the workpiece Avoid crashing the cutting bit into clamps, fixtures, or jigs on the table Job intervals should be reduced as the cutting bit gets closer to the workpiece The tip of the cutting bit can be any height above the workpiece When the tip of the cutting bit is just above the lower left corner of the workpiece, click the blue Set XY zero button. There is also a Use last XY zero button. This button may be used when: Multiple cutting operations are being performed on the same part with the same cutting bit Multiple instances of identical parts are being cut using a fixed alignment jig

Manual Work Zero

Step 1:		Click the blue Manual button
Step 2:		Jog the tip of the cutting bit to just touch the corner of the workpiece Avoid crashing the cutting bit into clamps, fixtures, or jigs on the table Care must be taken when making contact to prevent damage to the cutting bit or workpiece Job intervals should be reduced as the cutting bit gets closer to the workpiece When the tip of the cutting bit is just touching the lower left corner of the workpiece, click the blue Use new position button. There is also a Use last position button. This button may be used when: Multiple cutting operations are being performed on the same part with the same cutting bit Multiple instances of identical parts are being cut using a fixed alignment jig

Carve Start and Operation

After setting the work zero, you're finally ready to power up the spindle router and carve your part!

Step 1:		There are two controls on top of the spindle router: Speed dial: The speed is set using the speed dial. In almost all cases, it should be set to 1. The speed dial goes from 1 to 6 (16,000 to 27,000 RPM) Speed can be changed while the spindle router is running, but should only be done when the X-Carve is stationary. Power Switch: Turns the router on and off. Switch the power on to start the spindle router
Step 2:		Once the spindle router is spinning, click the blue The spindle is on button
Step 3:		Ensure the X-Carve machine table is clear of everything but your workpiece and clamps Click the blue Carve! button to start the automatic cutting operations STAY WITH REACH OF THE E-STOP BUTTON UNTIL THE CARVING IS COMPLETE
Step 4:		While the X-Carve is running, watch it carefully. Don't be afraid to hit the E-stop button if the machine does anything unexpected! While the X-Carve is running, there are a few useful controls in the upper right corner of the Easel window. Feed Rate: The plus and minus button allow adjustment of the feed rate, in 10% increments, while cutting Percent Complete: This shows the calculated percentage of the work done, and an estimate of the remaining time Pause / Run Button: Pausing the carve allows the user to check on progress, or move clamps to prevent crashing. Once paused, the button is clicked again to pick up the carve where it was paused. Stop Button: This ends the carve at the current completion point
Step 5:		Turn the spindle router power switch to off Your project is finished cutting! If it didn't come out quite as planned, clicking the left logo will bring you to some basic troubleshooting information. Clicking the right button will summarize your feeds and speeds. Clicking the X in the upper right will bring you back to the Easel window.
Step 6:		When done with the X-Carve, please ensure it is clean and ready for the next user. Remove the cutting bit and collet assembly Return the collet assembly and wrench to the cart tool tray If the cutting bit belongs to Spark, return it to the cart tool tray Remove all clamp pieces (arms, bases, screws) from the tool table, and return them to the cart tool tray Brush, sweep, and vacuum to remove all chips from the X-Carve table Ensure the E-Stop button is pressed down before walking away from the X-Carve