I took another crack at the "raster-like" CNC photo-engraving this weekend. In my first attempt described in a previous post I got less than satisfactory results by using about a 30-degree angle V-bit in the CNC (engraving on right side of photo above). There just wasn't enough change in width of the V-bit as it advanced deeper into the wood to show the carving relief needed to make the image visible.
For this second try, I used a 90-degree angle V-bit (made by Proxxon) because I couldn't find a 60-degree bit from my usual sources. The 90-degree bit worked MUCH better and the image is very legible in the wood (engraving on left side of photo above). I think some of the detail of the image was lost because a 90-degree bit is too wide for this application, but it was a big improvement. It looks to me like 60-degrees would be perfect, but I can't find anyone yet that makes a 1/8" shaft bit with a 60-degree angle. This is going to take some Internet research.
Photo of the rubber chair end attached to a 1/4" bolt that I used to make the attachment of the stepper motors to the EAS removable. The bolt is then attached to the motor with automotive vacuum line.
Over the weekend I successfully used the "7th" to engrave a photo of my daughter onto a piece of wood. Turned out very well. This was just a test cut, so I just used some scrap hardwood plywood. I'll do it again on real wood later.
I used a carbide v-bit as the cutter and attached the plywood to the y-axis table with double-sided tape (after cutting through a clamp with the cutter on an earlier attempt!).
This engraving used the raster-to-vector method. Essentially converting certain highlights and edges on the photo to vectors using various freeware and shareware software routines. I took a digital photo of my daughter and loaded it into WinTopo (the freeware addition). In Wintopo I converted the raster photo to vector and then eliminated a lot of the "noise" vectors that were created to get a fairly clean drawing. I then saved the vectors out of WinTopo as a DXF file. I then used Acer (freeware DXF to g-code converter) to convert the DXF file to g-code. I set the maximum z-axis cut to 0.1 inches in depth. The g-code was then loaded into the my CNC machine's PC and I used TurboCNC (shareware CNC controller software) to run the machine.
The CNC machine took about 1 hour and 45 minutes to cut the picture (engraving is about 13" x 9"). I ran the machine slowly about about 6 ipm for this test run. Everything worked beautifully.
I rubbed a cherry stain over the finished piece to darken the engraving marks.
First piece made with the machine! Was supposed to say "Mason's Room" (my son). but I misjudged the length and size.
Front view. Close-up of the x-axis and z-axis. Spindle is an old Sears Craftsman motor-tool (made by Dremel for Sears). Spindle runs very smoothly with little run-out considering that is is just a cheap tool.
Rear view before wiring cleanup.
Note that the controller board's power supply is mounted inside of the left gantry frame and the "black box" mounted on the back of the gantry cross-bar contains the controller board.
side view. This side has two power-strips mounted to the gantry frame. This provides for separate power switches for the spindle motor (Dremel) and the stepper motors (and controller board). Also, this allow these two components to be plugged in to different house current circuits so that the spindle motor doesn't create electronic "noise" on the stepper motor power.
Photo of the finished machine. I have mounted it on an old kitchen cabinet that I put on small wheels. The PC that drives the machine resides inside of the cabinet. Makes a nice portable setup.
Cutter carriage from the back
Note modified motor bracket and the addition of the metal "L" brackets to reinforce the motor mount. I was getting too much flexing in the original design.
Side view of carriage.
Note modified rail brackets behind carriage.
CNC control electronics
The box on the left contains the FET-3 controler board...on the right is an old power supply.
Based on John K's design. Machine does not yet have the chip guard installed.
Progress on the WoodTurtle. Does not yet have the chip guard installed.