STEP 1: First the Rhino three dimensional model needs to be moved to Origin and aligned horizontal using the move and rotate command respectively. It should be noted that the model should be located in the positive side of the XY axis.
STEP 2: Next a box is placed accordind to the size of the foam available such that the entire 3d model fits inside.
STEP 3: Using the box as reference the stok is set to ‘stok from selection’ This helps see the model within the foam.
STEP 4: First Horizontal Roughing is done by selecting a tool from Mop Set1. This is a wider tool Ball Mill, is of 26mm in diameter and is used to extract the excess material from the foam. This is a quick process done before the second detailing part of the milling.
STEP 5: Some settings to be noted are as follows: Clearance is set to ‘Stock Max Z + Dist’ = 6 In Cut Parameters the direction is set to ‘Mixed’ to allow milling in both directions In Cut Levels, Stepdown Control(dz)=%Tool Diameter and Cut Levels Ordering=’Depth first’ In Feeds and Speed the speed can be adjusted as needed. Toolpath visibily for horizontal roughing is checked to be able to see milling done by it.
STEP 6: Similarly another tool Ball Mill2 is generated. This has a flat milling point, used for parallel detailing with a diameter of 3mm. This is responsible to give detail to the model. The contours, and other built up structures are milled by it.
STEP 7: All other settings are kept similar for the Flat milling tool and the tool is generated. Then similate-Play is allowed to run and we can observe the whole milling process.
STEP 8: Initially the Horizontal roughing romoves the excess material from the foam block. This is accomplished in a short duration itself.
STEP 9: After similation with the horizontal roughing tool the next tool Flat Mill, for Parallel Detailing is allowed to start Milling the foam model.
STEP 10: This is the level of detail obtained from the Flat Milling tool.
STEP 11: Smooth contours can be obtained. Detail of monuments and other existing structures is done efficiently by the Horizontal Detailing tool.To obtain the roads and paths a little intruded we had to use two additional flat Parallel detailing tools of 4 and 1mm diameter respectively. These were used to mill only those two layers to create depth, which would help highlight the circulation paths.
STEP 12: Once the milled model is checked for any errors the file can be sent for printing. After selecting the machine the file is saved in an extension type that is compatible with that CNC Milling machine.