The present disclosure relates generally to machines for cutting/shaping various materials including stone and other materials. More particularly, the present disclosure relates to materials for table tops for use on such machines and a method of mounting the table tops to the machines.
Various machines such as CNC router machines for cutting or shaping stone and similar materials are known in the art. Workpieces to be fabricated are placed on work tables of the machines and any number of predetermined cutting/routing operations are carried out. The table top material used for the work tables of such machines has to be carefully selected and requires a number of specific characteristics.
The cutting/routing operations provide for a harsh environment resulting in a lot of debris and water. Depending upon the water source used for the supply water for the cutting/routing operation, the pH level and the alkalinity of the water can vary. Certain supply water might also include a lot of additives such as chlorine and other chemicals. Thus, the table top material needs to display characteristics such as high corrosion resistance and low oxidation.
Low thermal expansion is another characteristic desired for the table top material. Changes in temperature can, otherwise, result in distortion of the table top and misalignment of the parts during fabrication.
Durability and impact resistance are also important for the table top material, especially in heavy stone fabrication applications. If a workpiece such as a heavy piece of stone is dropped on the table top, significant damage is likely to occur. It would be desirable to prevent dents, scratches, and dings. However, if damage were to occur, it would be desirable to provide a table top material that is easily repairable in the field and that does not require replacement of the entire top.
Furthermore, it is also desirable to provide a material that has a high static coefficient of friction to prevent unwanted movement/slippage of the workpieces or other workpiece holding structures that are in contact with the table top. In addition to a high static coefficient of friction, however, a smooth table top surface is also very important. For providing stability to the workpieces during the shaping process, various clamping techniques have been utilized on these machines. One known clamping arrangement includes the use of vacuum clamps. Vacuum clamps normally have two vacuum connections. A vacuum applied to a first connection fixes the vacuum clamp on the machine work table to prevent it from moving during the handling of the workpiece. A vacuum applied to a second connection clamps the workpiece to the vacuum clamp. Such vacuum clamps having hose connections are designed for universal use on CNC machines and tools. However, a smooth table top is necessary for proper operation of such clamps. An even surface lacking voids or imperfections and a high coefficient of friction are desired properties for table tops utilizing vacuum clamps. The holding forces produced by a vacuum clamp can reduce damage to the workpiece during fabrication and provide for high precision cuts.
The attributes listed, including the combination of a high static coefficient of friction and a smooth surface, significantly narrow the number of choices available for table top materials. In various prior art vacuum tables, materials such as granite have been used for the table tops. Those preferring lighter weight alternatives have turned to materials such as PVC polymer or aluminum. PVC polymers have proved dissatisfactory due to their high coefficient of thermal expansion. Certain types of aluminum such as K-100 Aluminum have also displayed undesired characteristics such as low corrosion resistance and rapid oxidation, making them less durable in aqueous environments. Certain types of aluminum may corrode or oxidize depending on the pH and alkalinity of the water source. K-100 Aluminum has been known to rapidly oxidize when exposed to highly chlorinated water. Other types of aluminum such as K-100S Aluminum have proved satisfactory in most applications but still lack the high impact resistance desired in most heavy stone fabrication applications. Since metal materials such as aluminum are not resistant to denting, if a workpiece such as a heavy piece of stone is dropped on the table top, significant damage is likely to occur. Scratches and dings are also difficult to repair on metal table tops and may require replacement of the table top.
Improvements and alternatives in table top materials for use in cutting/shaping machines such as CNC routing machines are desired. Reliable and simple techniques for mounting such table top materials to work tables are also desired.
One aspect of the present disclosure relates to a novel table top material for use on machines for cutting/shaping various materials including stone and other materials, such machines including CNC routing machines.
Another aspect of the present disclosure relates to a method of mounting the table top material to a work table of the machine such as a CNC routing machine.
Examples representative of a variety of inventive aspects are set forth in the description that follows. The inventive aspects relate to individual features as well as combinations of features. It is to be understood that both the forgoing general description and the following detailed description merely provide examples of how the inventive aspects may be put into practice, and are not intended to limit the broad spirit and scope of the inventive aspects.
The accompanying drawings are included to provide a further understanding of the inventive aspects of the present disclosure and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and together with the description serve to further explain the principles of the disclosure. Other aspects of the present disclosure and many of the advantages of the present disclosure will be readily appreciated as the present disclosure becomes better understood by reference to the following Detailed Description when considered in connection with the accompanying drawings, and wherein:
Referring to
It should be noted that, although the CNC routing machine 10 is depicted as a gantry-type material shaping machine, the inventive aspects of the disclosure also apply to other types of machines.
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As will be described in further detail below, the work table 20 of the CNC routing machine 10 shown in
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In accordance with the example inventive aspects of the disclosure, one example table top material M for use on the work table 20 is a combination silicon and epoxy material. According to one embodiment, the material M may include about 70% silicon and about 30% epoxy. One type of silicon/epoxy combination material M suitable for use on the work table is available from Durcon Inc. (Canton, Mich.). Another type of silicon/epoxy combination material M suitable for use on the work table is available from Epoxyn Products L.L.C. (Mountain Home, Ariz.).
The silicon/epoxy combination material M includes certain characteristics and advantages over metals such as aluminum, making the material M better suitable for use as a table top material in the types of machines discussed herein. For example, the silicon/epoxy combination material M does not corrode or oxidize and thus is more durable in aqueous environments. The silicon/epoxy combination material M is chemical resistant and is not likely to be damaged by any additives or flocculant that may be present in water recycling systems. Using the silicon/epoxy combination material M, the seams between the slabs of material M may be sealed so as to maintain a vacuum seal across the seams. With the use of the silicon/epoxy combination material M, scratches or dings may be repaired in the field by filling the damaged areas with the same material, which is not always possible with materials such as metal.
Other advantages of the silicon/epoxy combination material M over different types of metals such as aluminum include a higher static coefficient of friction. This aspect is important in machines utilizing movable bridge and carriage assemblies. The higher static coefficient of friction also provides advantages when using clamping arrangements such as vacuum clamps.
Dial indicators 70 were positioned to measure movement between the bottom of a vacuum cup 80 and a wet table top surface 43.
The chart below illustrates the results of the Pull Test.
Illustrated below are also the results of a Coefficient of Friction Test that was performed on the four different wet surfaces listed above. It should be noted that if a body is resting on an incline plane, the body is prevented from sliding down because of the frictional resistance. If the angle of the plane is increased, there will be an angle at which the body begins to slide down the plane. This angle is the angle of response and the tangent of this angle is the same as the coefficient of friction.
It has been noted that the silicon/epoxy combination material M may also provide cost savings over aluminum, the silicon/epoxy combination material M being about 25% of the cost of K-100S aluminum.
Depending upon the features of the machine and features of the work table, the silicon/epoxy combination material M may need some fabrication, as noted in the above tests, before being mounted to a mounting surface of a work table.
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It should be noted that the following description provides for an inventive method of fabricating the silicon/epoxy slabs 50 that is specifically tailored for the work table 20 shown in
According to one example method shown in
Once a slab specified to required dimensions is obtained, the table top material M is drilled and counterbored. As shown in
Once the appropriate holes 57 are fabricated, the slabs 50 are fastened to the mounting surface 44 of the work table 20 as shown in
The mounting surface 44 (e.g., of steel) of the work table base 34 includes prefabricated holes 56 for receiving the bolts 54. It will be understood that the silicon/epoxy material M may be used either as a retrofit measure and replace existing table top materials such as aluminum or granite or may be mounted on the work table 20 during initial assembly of the machine 10.
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A top plug 60 made of PVC polymer or of the same material as the silicon/epoxy material M is friction fit or glued into each of the fabricated holes 57 as shown in
Since the slabs 50 are placed on the table 20 prior to machining of the vacuum surface and machined by the same machine 10 that will utilize the silicon/epoxy material M as the table top, a substantially perpendicular relationship is obtained between the spindle 28 of the material shaping assembly 26 and the table top.
If silicon/epoxy material M available from Epoxyn Products L.L.C. is being utilized for the table top, the two 5′×8′×1″ slabs (end slabs) and one 6′×8′×1″ (middle slab) are normally mounted face down and only one side of the slabs 50 are machined as described above. It has been found that some impurities may be found after machining 0.030″ off back side. Thus, 0.060″ stock removal to clean up the surface may be required as discussed above. It has been found that during final fabrication of the vacuum surface, a 0.005″ flatness may be achieved under normal operating conditions with two styles of cutting tools. As discussed above, the first cutting tool may be a cobalt/nickel bond diamond tool rotated at 4500 rpm and at 40″/min feed rate, with a thickness of 0.060″ as the recommended max cut. Another possible cutting tool may include PCD (poly crystalline diamond) inserts and rotated at 666 rpm and at 40″/min feed rate with a 0.030″ recommended max cut.
If silicon/epoxy material M available from Durcon Inc. is being utilized for the table top, the slabs 50 from Durcon must be machined on both sides. These slabs 50 are normally mounted face up because of some porosity issues on the back side, even after machining.
Since both sides of the Durcon slabs must be machined and a minimum of 0.060″ stock removal may be required to provide full clean-up of the slab face, Durcon slabs may require the purchase of 1¼″ slabs, rather than 1″ slabs as in Epoxyn.
A cobalt/nickel bond diamond tool at 4500 rpm and at 40″/min feed rate with a 0.060″ recommended max cut may be used to first process the back side of a Durcon slab. Once the holes 57 are drilled and the Durcon slabs are mounted face up, the top face of the Durcon slab 50 is then machined using again a cobalt/nickel bond diamond tool at 4500 rpm and at 40″/min feed rate with a 0.060″ recommended max cut. With a cobalt/nickel bond diamond tool at 4500 rpm and at 40″/min feed rate with a 0.060″ recommended max cut, a 0.005″ flatness can be achieved after machining of the slab 50.
It will be understood that the above described method of fabrication and mounting of the silicon/epoxy material M, including the tools utilized, the parameters specified, the dimensions required, is one example of an inventive method in accordance with the present disclosure. The method described herein is tailored to the specific CNC routing machine 10 shown and described herein and that certain aspects of the method may be modified depending upon features found in different machines.
The above specification provides examples of how certain inventive aspects may be put into practice. It will be appreciated that the inventive aspects can be practiced in other ways than those specifically shown and described herein without departing from the spirit and scope of the inventive aspects.
This application is a continuation of U.S. patent application Ser. No. 14/178,508, filed Feb. 12, 2014, which is a continuation of U.S. patent application Ser. No. 12/763,031, filed Apr. 19, 2010, which claims priority to U.S. Provisional Application Ser. No. 61/170,434, filed Apr. 17, 2009, which applications are incorporated herein by reference in their entirety.
Number | Date | Country | |
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61170434 | Apr 2009 | US |
Number | Date | Country | |
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Parent | 14178508 | Feb 2014 | US |
Child | 14823544 | US | |
Parent | 12763031 | Apr 2010 | US |
Child | 14178508 | US |