From 4ef0e0df72efb88ff1c22133c978ab93b78b82fb Mon Sep 17 00:00:00 2001 From: lovebird Date: Sun, 15 Sep 2024 17:51:48 +0200 Subject: [PATCH] latest :) --- .../casters/105_80/105x80-Caster.SLDASM | 4 +- .../casters/105_80/Alex-2-3751-105_80.SLDASM | 4 +- .../skf/6205-2z/skf_bearing_6205-2z_2.SLDASM | 4 +- .../6205-2z/skf_bearing_6205-2z_2_02.SLDPRT | 4 +- .../6205-2z/skf_bearing_6205-2z_2_05.SLDPRT | 4 +- .../motion/hgh/20/740-Rail-HGH20CA-40.SLDASM | 4 +- .../622_Motor-Flange-Mod3_KM90_35.SLDPRT | 4 +- .../cad/Global-GH-35000HL.SLDASM | 4 +- .../material/hdpe/assets/conclusion.md | 66 +++++++++ .../extruded-130x130/assets/DSC02965.JPG | 3 + .../extruded-130x130/assets/DSC02967.JPG | 3 + .../extruded-130x130/assets/raw/DSC02964.ARW | 3 + .../extruded-130x130/assets/raw/DSC02965.ARW | 3 + .../extruded-130x130/assets/raw/DSC02967.ARW | 3 + .../hdpe/assets/extruded-130x130/readme.md | 30 ++++ .../material/hdpe/assets/inc/DSC02956.JPG | 3 + .../material/hdpe/assets/inc/DSC02957.ARW | 3 + 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sha256:d6cf749bc4fe8e7be53afa7352f4b5d98676ffe1c05eeec3d57be6494db4ed7b -size 1184862 +oid sha256:90d607c393175d4165798192925c2c7d2c3017b96b0965989facbc4ebf393adf +size 1185166 diff --git a/components/hardware/casters/105_80/Alex-2-3751-105_80.SLDASM b/components/hardware/casters/105_80/Alex-2-3751-105_80.SLDASM index a40220405..2ce6d1733 100644 --- a/components/hardware/casters/105_80/Alex-2-3751-105_80.SLDASM +++ b/components/hardware/casters/105_80/Alex-2-3751-105_80.SLDASM @@ -1,3 +1,3 @@ version https://git-lfs.github.com/spec/v1 -oid sha256:1b9259e46737bf716b2b23f3f891ebf43e3890d2ddfbdd944ca1bbf665188169 -size 50908 +oid sha256:7384bed784edd35e189246fd3f5650d91ed44466d0aaa6c771993d5f3b7a4bcd +size 51825 diff --git a/components/mechanics/bearings/skf/6205-2z/skf_bearing_6205-2z_2.SLDASM b/components/mechanics/bearings/skf/6205-2z/skf_bearing_6205-2z_2.SLDASM index 10ba06b18..c1bf534bf 100644 --- a/components/mechanics/bearings/skf/6205-2z/skf_bearing_6205-2z_2.SLDASM +++ b/components/mechanics/bearings/skf/6205-2z/skf_bearing_6205-2z_2.SLDASM @@ -1,3 +1,3 @@ version https://git-lfs.github.com/spec/v1 -oid sha256:e37b28c41396b52476f97702d1f74e1fe64b04dc442273555bf741b612093835 -size 430406 +oid sha256:6f481d554065bca5874ba37558d27b0032d966c7233dd34c8acddeba402b4019 +size 429053 diff --git a/components/mechanics/bearings/skf/6205-2z/skf_bearing_6205-2z_2_02.SLDPRT b/components/mechanics/bearings/skf/6205-2z/skf_bearing_6205-2z_2_02.SLDPRT index 9329dea8c..ae51c5e9a 100644 --- a/components/mechanics/bearings/skf/6205-2z/skf_bearing_6205-2z_2_02.SLDPRT +++ b/components/mechanics/bearings/skf/6205-2z/skf_bearing_6205-2z_2_02.SLDPRT @@ -1,3 +1,3 @@ version https://git-lfs.github.com/spec/v1 -oid sha256:2f48be96620e06deb415842fb423a0aac7b35359fc64e592da43b4a40ea27422 -size 126862 +oid sha256:82b843d4f2dab4c7deadf056770587de983441b78d2cd42b533d817ca2bf2300 +size 126193 diff --git a/components/mechanics/bearings/skf/6205-2z/skf_bearing_6205-2z_2_05.SLDPRT b/components/mechanics/bearings/skf/6205-2z/skf_bearing_6205-2z_2_05.SLDPRT index 44625f1d5..1ee61ee99 100644 --- a/components/mechanics/bearings/skf/6205-2z/skf_bearing_6205-2z_2_05.SLDPRT +++ b/components/mechanics/bearings/skf/6205-2z/skf_bearing_6205-2z_2_05.SLDPRT @@ -1,3 +1,3 @@ version https://git-lfs.github.com/spec/v1 -oid sha256:858d425415392cae41c0c3a2ba8ef4d8604be1c0ea1cdc555a6c8eee83b6fad9 -size 297002 +oid sha256:23b04203b5c75c83767202a6c8859aeb80cc978692d2a6a702b942f9f0067e76 +size 297876 diff --git a/components/mechanics/motion/hgh/20/740-Rail-HGH20CA-40.SLDASM b/components/mechanics/motion/hgh/20/740-Rail-HGH20CA-40.SLDASM index c2f81bd08..1cecd5976 100644 --- a/components/mechanics/motion/hgh/20/740-Rail-HGH20CA-40.SLDASM +++ b/components/mechanics/motion/hgh/20/740-Rail-HGH20CA-40.SLDASM @@ -1,3 +1,3 @@ version https://git-lfs.github.com/spec/v1 -oid sha256:a16dd39c7b0e75cf5841112833097c5ec28e3a6d12e7881b7b3243012e5ab060 -size 2966091 +oid sha256:3bf59db5113ec82d664fb36cefbb454dfee12927875db622c49e412480d28611 +size 2966360 diff --git a/injection/components/1500_MotorBrackets/622_Motor-Flange-Mod3_KM90_35.SLDPRT b/injection/components/1500_MotorBrackets/622_Motor-Flange-Mod3_KM90_35.SLDPRT index d50ccae51..b9fbdb40f 100644 --- a/injection/components/1500_MotorBrackets/622_Motor-Flange-Mod3_KM90_35.SLDPRT +++ b/injection/components/1500_MotorBrackets/622_Motor-Flange-Mod3_KM90_35.SLDPRT @@ -1,3 +1,3 @@ version https://git-lfs.github.com/spec/v1 -oid sha256:0129738e8838f6dfd4fab99dbe80191033f5e9d8c9fa778a3619579a78d1aa25 -size 250655 +oid sha256:ecfa824846573f32207bb0add1b68df1894691b8e8d69f4db35e98114147246b +size 233146 diff --git a/injection/components/2000_Clamps/OSR-300-40-30-25-80/cad/Global-GH-35000HL.SLDASM b/injection/components/2000_Clamps/OSR-300-40-30-25-80/cad/Global-GH-35000HL.SLDASM index d31fa181f..5943d3dc1 100644 --- a/injection/components/2000_Clamps/OSR-300-40-30-25-80/cad/Global-GH-35000HL.SLDASM +++ b/injection/components/2000_Clamps/OSR-300-40-30-25-80/cad/Global-GH-35000HL.SLDASM @@ -1,3 +1,3 @@ version https://git-lfs.github.com/spec/v1 -oid sha256:1154c2991810a3521b0770b0a5e4b201217ccfc5e7b5da5d6690f48dc9928426 -size 404230 +oid sha256:96de3892d096d4e131a16f395100d90f8867bac1835911c8ad2baa9731f07990 +size 416976 diff --git a/products/poly-mech/resources/material/hdpe/assets/conclusion.md b/products/poly-mech/resources/material/hdpe/assets/conclusion.md new file mode 100644 index 000000000..b5f594448 --- /dev/null +++ b/products/poly-mech/resources/material/hdpe/assets/conclusion.md @@ -0,0 +1,66 @@ + + +# Sheetpress Experiments - Cassandra - 650 - EDC - RC1 - Conclusion + +--- + +## 10 mm + +A one-stage process suitable for up to 10 mm thickness, though prone to warping effects. + +### Conclusions + +- Minor flatness errors were observed, typically 0.5-1 mm. +- Warping and material shrinking occurred, especially near corners. + +### Recommendations + +- Reheat at 140°C and press again to minimize shrinkage and warping. +- For a better finish, repeat the press with a harder surface. + + +--- + +## 20 mm + +A two-stage method offering better control at greater thickness. + +### Conclusions + +- The inclusion of intermediate dies reduced warping and improved overall flatness. + +### Recommendations + +- Incremental heating and controlled die insertion are recommended. +- Use presses with adequate pressure (20 tons minimum) for thicker sheets. + +--- + +## 30 mm + +A two-stage method offering better control at greater thickness. + +### Conclusions + +- The inclusion of intermediate dies reduced warping and improved overall flatness. + +### Recommendations + +- Incremental heating and controlled die insertion are recommended. +- Use presses with adequate pressure (20 tons minimum) for thicker sheets. + +--- + +## 40 mm + +A three-stage process for 40 mm sheets with significant handling challenges. + +### Conclusions + +- Height differences were observed, particularly on the die-engaged side (up to 5 mm). +- Air pockets and corner warping were frequent issues. + +### Recommendations + +- Implement intermediate reheating steps. +- Introduce controlled cooling phases to mitigate height inconsistencies. diff --git a/products/poly-mech/resources/material/hdpe/assets/extruded-130x130/assets/DSC02965.JPG b/products/poly-mech/resources/material/hdpe/assets/extruded-130x130/assets/DSC02965.JPG new file mode 100644 index 000000000..0800ae811 --- /dev/null +++ b/products/poly-mech/resources/material/hdpe/assets/extruded-130x130/assets/DSC02965.JPG @@ -0,0 +1,3 @@ +version https://git-lfs.github.com/spec/v1 +oid sha256:6e4744c31629b9fef03f66ec218c573caa1c8e3eb6d8530e7ca730ba79009149 +size 196199 diff --git a/products/poly-mech/resources/material/hdpe/assets/extruded-130x130/assets/DSC02967.JPG b/products/poly-mech/resources/material/hdpe/assets/extruded-130x130/assets/DSC02967.JPG new file mode 100644 index 000000000..a8233807e --- /dev/null +++ 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+++ b/products/poly-mech/resources/material/hdpe/assets/extruded-130x130/readme.md @@ -0,0 +1,30 @@ +## Settings + +- **Mould Size**: 43 x 35cm x 2cm +- **Mould height**: 40mm +- **Mould sheets**: 1x sanded stainless | 1x polished stainless +- **Mould release**: none + +- **Temp - UP**: 170 +- **Temp - DOWN**: 170 +- **Heat**: Cold Start + +- **Duration-Melt**: 95 min +- **Duration-Pre-Cool**: 20 min (heater off) +- **Duration-Cooling-Final**: 8h + +- **Preparation**: 2x layers: 7cm, another 3cm after compressing +- **Excess**: none +- **Method**: Mould frame, 2 passes + +- **Die Material**: sanded stainless +- **Die Penetration**: 10mm + +- **Thickness Error**: 1mm per 50cm +- **Flatness Error**: 1mm per 50cm +- **Final sheet thickness**: 30.0 mm +- **Contraction / Shrinkage**: 10mm per 50cm +- **Surface Quality**: good + +## Probing / Flatness Report (on CNC, straightened) + diff --git a/products/poly-mech/resources/material/hdpe/assets/inc/DSC02956.JPG 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b/products/poly-mech/resources/material/hdpe/assets/summary.md @@ -0,0 +1,132 @@ + + +# Sheetpress Experiments - Cassandra - 650 - EDC - RC1 + +--- + +## 10 mm + +A one-stage process, suitable for up to 10 mm thickness, requires careful setting and timing to avoid warping effects. + +### Description + +One-stage process for plastic sheet pressing. + +### Settings + +- Temperature: **155-160°C** +- Cool-down temperature: **130°C** +- Duration: **1 hour** for mold closing, **30 minutes** for cool-down + +### Requirements + +1. Place a stainless sheet inside the mold. +2. Fill with plastic, carefully pressing. +3. Avoid contact between the mounting edge and the mold. +4. Wait **10 minutes** before full pressing. +5. Wait **1 hour** for full mold closure. +6. Cool to **130°C** and wait **30 minutes**. +7. Remove the mold and access the formed sheet. +8. For shiny/flat finish, press again with a harder surface. + +### Results + +- Small flatness errors (0.5-1 mm) based on press quality and plastic characteristics. + +### Problems + +Warping and material shrinking, especially in corners. + +### Proposed Solutions + +Add reheating steps at **140°C** and press again to minimize shrinkage and warping. + +| | | +|-|-| +| Mould | ![Mould](cas-650-hdpe-10.jpg) | +| Top-side | ![Top-side](cas-650-hdpe-10.jpg) | +| Back-side | ![Back-side](cas-650-hdpe-10.jpg) | + +--- + +## 20 mm + +A two-stage process for thicker sheets with a more controlled heating and pressing cycle. + +### Description + +Two-stage process for enhanced material control and heating distribution. + +### Settings + +- Temperature: **155°C**, cooling at **130°C** +- Duration: **90-100 minutes** for initial heating, **30 minutes** cool-down with die insertion + +### Requirements + +1. Reheat the plastic to **130°C**. +2. Insert a die with **3-4 mm** thickness once melted. +3. Cool the mold for **30 minutes** before opening. +4. For thicker molds, ensure the press has **20 tons** of power. + +### Results + +Reduction in warping and improved flatness by using intermediate dies. + +### Problems + +Requires a significant amount of time to ensure proper penetration of heat. + +### Proposed Solutions + +Incremental heating and die insertion at controlled temperatures to minimize air pockets. + +| | | +|-|-| +| Mould | ![Mould](cas-650-hdpe-20.jpg) | +| Top-side | ![Top-side](cas-650-hdpe-20.jpg) | +| Back-side | ![Back-side](cas-650-hdpe-20.jpg) | + +--- + +## 40 mm + +A challenging process with long melting times, leading to potential warping and deformation. + +### Description + +3-stage process for very thick sheets. Manual handling needed to prevent air pockets and deformities. + +### Settings + +- Temperature: **175°C** +- Duration: **2 hours** of heating, **3 hours** cool-down +- Mould: **55mm** +- Die: **10mm** + +### Requirements + +1. Heat to **175°C** for at least **2 hours** to melt the thick plastic layers. +2. Insert a die (10mm) to ensure no air pockets form. +3. Let the plastic cool with a **3-hour** rest while engaged with the die. +4. Reheat corners at **140°C** and press again, for 15 minutes, with no mould (careful). + +### Results + +Height differences up to **5 mm** on die-engaged side. + +### Problems + +Long melting times, air pockets, and corner deformities leading to warping on one side. + +### Proposed Solutions + +Intermediate reheating and more controlled cooling periods to mitigate height differences. + +| | | +|-|-| +| Mould | ![Mould](cas-650-hdpe-55.jpg) | +| Top-side | ![Top-side](cas-650-hdpe-55.jpg) | +| Back-side | ![Back-side](cas-650-hdpe-55.jpg) | + +--- \ No newline at end of file diff --git a/products/poly-mech/resources/material/hdpe/assets/washed-3-stage-1-40mm/DSC02960.JPG b/products/poly-mech/resources/material/hdpe/assets/washed-3-stage-1-40mm/DSC02960.JPG new file mode 100644 index 000000000..e42e3a341 --- /dev/null +++ b/products/poly-mech/resources/material/hdpe/assets/washed-3-stage-1-40mm/DSC02960.JPG @@ -0,0 +1,3 @@ +version https://git-lfs.github.com/spec/v1 +oid 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Settings + +- **Mould Size**: 43 x 35cm x 2cm +- **Mould height**: 55mm +- **Mould sheets**: 1x sanded stainless | 1x polished stainless +- **Mould release**: none + +- **Temp - UP**: 175 +- **Temp - DOWN**: 175 +- **Heat**: Cold Start + +- **Duration-Melt**: 110 min +- **Duration-Pre-Cool**: 25 min (heater off) +- **Duration-Cooling-Final**: 8h + +- **Preparation**: 1x layers: 11cm +- **Excess**: none +- **Method**: Mould frame, 3 passes (intial melt, die pressing, surface cure/melt) + +- **Die Material**: sanded stainless +- **Die Penetration**: 10mm + +- **Thickness Error**: 2mm per 50cm +- **Flatness Error**: 2mm per 50cm +- **Final sheet thickness**: 40.0 mm +- **Contraction / Shrinkage**: 10mm per 50cm +- **Surface Quality**: good +- **Air voids**: 2-4mm @ 80% of the inner section \ No newline at end of file diff --git a/products/poly-mech/resources/sheets/tests/2024_09_14_22_42_34.mp3-sum.md b/products/poly-mech/resources/sheets/tests/2024_09_14_22_42_34.mp3-sum.md new file mode 100644 index 000000000..56936cbcf --- /dev/null +++ b/products/poly-mech/resources/sheets/tests/2024_09_14_22_42_34.mp3-sum.md @@ -0,0 +1,11 @@ + + +# Summary of the Process for Plastics Manufacturing + +- **First stage or one-stage process** only +- Suitable for **up to 10mm** material thickness +- Precision **not necessary** in this case +- Plastic will **shrink in all dimensions** upon cooling + - Expect up to **10mm loss** in mold dimensions + - Thickness reduction of **1-2mm** +- Result: **Sheet press** no longer engaging the plastic, causing **warping** \ No newline at end of file diff --git a/products/poly-mech/resources/sheets/tests/2024_09_14_22_43_37-sum-sum.md b/products/poly-mech/resources/sheets/tests/2024_09_14_22_43_37-sum-sum.md new file mode 100644 index 000000000..57984f927 --- /dev/null +++ b/products/poly-mech/resources/sheets/tests/2024_09_14_22_43_37-sum-sum.md @@ -0,0 +1,20 @@ + + +# Summarize, as Markdown, bullet points, determine chapter, mark times as **bold** + +- Start by placing stainless sheet inside mold with a precise fit. +- Fill and press plastic slowly under heat (**HDPE: 155-160°C**). +- For **10 mm** sheet: add **30 mm** plastic as mounting. +- Avoid mounting edge touching the mold, prevents overflow during pressing. +- Wait **10 minutes** before fully pressing sheet against plastic. +- Plastic tends to stick and form well after this waiting period. +- For **10 mm**, wait **1 hour** for mold to fully close. +- Then reduce to **130°C**, wait another **30 minutes**. +- Mold can be removed, turned around, and stainless sheet accessed easily. +- Remove protection sheet, keep stainless one still connected to plastic. +- Insert die or hard material, e.g., **gips carton** or stainless sheet (**3-4 mm**). +- For **10 mm**, reheating is not usually necessary. +- Press again to ensure a smooth, shiny, and flat result. +- Wait **3-4 hours** before removing the sheet. +- Sheet quality can vary based on plastic uniformity, cleanliness, and flake size. +- Flatness errors of **0.5-1 mm** are common depending on press quality. \ No newline at end of file diff --git a/products/poly-mech/resources/sheets/tests/2024_09_14_22_48_49-sum-sum.md b/products/poly-mech/resources/sheets/tests/2024_09_14_22_48_49-sum-sum.md new file mode 100644 index 000000000..b8f195942 --- /dev/null +++ b/products/poly-mech/resources/sheets/tests/2024_09_14_22_48_49-sum-sum.md @@ -0,0 +1,17 @@ + + +# Summary of the two-stage process for molds + +- **10 millimeter molds**: + - Use a die between 3-4mm. + - Place a 2mm protection sheet inside. + - Ensures perfect flatness and surface quality. + +- **20 millimeter molds**: + - Requires a bit more complexity. + - Melt for **90-100 minutes** at **155°C**. + - Use at least a 3cm mold with an 8-10mm die. + - Requires heating to around **130°C** (30°C below melting point), ensuring plastic relaxation and optimal die performance. + +- **Press setup**: + - A press with **20 tons** of power is ideal, more power would be beneficial for higher molds. \ No newline at end of file diff --git a/products/poly-mech/resources/sheets/tests/2024_09_14_22_51_39-sum-sum.md b/products/poly-mech/resources/sheets/tests/2024_09_14_22_51_39-sum-sum.md new file mode 100644 index 000000000..c99a0b182 --- /dev/null +++ b/products/poly-mech/resources/sheets/tests/2024_09_14_22_51_39-sum-sum.md @@ -0,0 +1,18 @@ + + +# Summarize, as Markdown, bullet points, determine chapter, mark times as bold + +- **Two-stage process** for **3 cm** plastic sheets +- Needed materials: + - **4 cm mold** + - Frame thickness: **at least 2 cm** + - Die: **min. 10 mm** +- **Heating**: + - Reheat plastic to **130-140 °C** before melting +- Avoid squeezing plastic under mold +- Fill mold with **8-10 cm** hand-pressed mountain +- Ensure no excess material leaves the mold +- Cool down for **30 minutes** for **4 cm flat sheets** +- Insert die at **140 °C** +- Watch pressing process carefully +- Result: Likely **up to 1 mm** flatness error \ No newline at end of file diff --git a/products/poly-mech/resources/sheets/tests/2024_09_14_22_54_22-sum-sum.md b/products/poly-mech/resources/sheets/tests/2024_09_14_22_54_22-sum-sum.md new file mode 100644 index 000000000..ae8dd8b98 --- /dev/null +++ b/products/poly-mech/resources/sheets/tests/2024_09_14_22_54_22-sum-sum.md @@ -0,0 +1,14 @@ + + +# Summarize, as Markdown, bullet points, determine chapter, mark times as **bold** + +- Used 55mm high mold; struggle with timings and temperatures. +- **155°C** was insufficient to penetrate 12cm of plastic, melting took around **2 hours**. +- Inserted die; air pocket built up in the center. +- Handled air pocket manually; had **3 tests**, final one was slow but had corner deformations due to deformable die. +- Cooled to **120°C**, let it rest for **3 hours** with die engaged, still had deformations. +- Reheated surface at **140°C** for **10 minutes** to melt away corner deformations. +- Warping observed on one side with corners **1 cm** higher, but one side kept flat. +- Die-engaged side had **5mm** height difference. +- Carefully melted corners to remove excess but avoided over-melting to prevent sheet skewing. +- Monitored sheet thickness throughout to ensure uniformity. \ No newline at end of file diff --git a/sheetpress/components/900_Moulds/450-15mm/910_MouldBase_x1_10mm_AL.SLDPRT b/sheetpress/components/900_Moulds/450-15mm/910_MouldBase_x1_10mm_AL.SLDPRT new file mode 100644 index 000000000..d89e0c127 --- /dev/null +++ b/sheetpress/components/900_Moulds/450-15mm/910_MouldBase_x1_10mm_AL.SLDPRT @@ -0,0 +1,3 @@ +version https://git-lfs.github.com/spec/v1 +oid sha256:88e1d717c26d3b1a973651f7b8552647afcff1fed563df8e7f2b4c72ec3ef69c +size 48618 diff --git a/sheetpress/components/900_Moulds/450-15mm/Mould-450-15.SLDASM b/sheetpress/components/900_Moulds/450-15mm/Mould-450-15.SLDASM index 5e71a752d..d176ead87 100644 --- a/sheetpress/components/900_Moulds/450-15mm/Mould-450-15.SLDASM +++ 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