I really like your graphical interface. It is very clean and looks intuitive
Stock dimensions and machine width seem to be perfect as well as speed synchronization between the two wings.
However there are still a few important features which are (possibly) missing.
I already mentionned the “delta” shape of wings (horizontal shift of one profile vs the other)
Here are also two important features :
adding “carbon rods” into the wings (red line). and
adding “precut ailerons” into the profiles.
This can be done outside GrblGru when designing the two dxf profiles.
But it is mandatory that start of cut of these features occurs precisely at the same instant to be sure that the “hole” or the “slot” is a straight line.
On this picture “carbon rod” is the red line while ailerons cuts are the green ones.
Note why it is important to start at these synchro points : carbon rod is straight and perpendicular to the fuselage axis, while ailerons cuts are “per wing” and parallel to the leading edge.
I know that these features are not easy to implement. But cutting foam wings absolutely need them…
Thanks for the info. I understand that these cutouts are necessary, but I still have some questions:
Are these cutouts and the profile made in one movement ?
Or are the cutouts created in a second pass?
Or would it make more sense to make the cutouts first because the block is still stable at that point ?
It is also possible to cut DXF files. Would it be a solution to draw the cutouts in a DXF sketch ? I have made a video for this, but only with German text. I hope it still shows the function.
Hi,
Thanks for your answer.
Yes it is totally feasible to draw these cut outs with a CAD software and to export all this into the dxf. (it’s indeed my prefered workflow !)
These cut outs AND the profiles are cut in one single pass to avoid any motion into the polystyrene block.
To do so there should be a way to tell where are the synchro points. Here is an example of cut path into jedicut software
The small squares are the sync points. Must be same number for both profiles.
You can add as many sync points you want (need). Here I have synched the starting points into the wing, then the first cut into ailerons, then the Leading edge, then second cut into the ailerons, then exit point into the Trailing Edge.
Note also that I start the cut by the trailing edge. This is to insure a very soft curve at the leading edge (and without stopping the motion). But you can do the opposite by flipping the profiles!
There is the possibility to add horizontal and vertical motions to enter/exit into/from the foam block. I could have added this horizontal motion on the leading edge (right most sync point) to cut half of the profile and then restart for instance by the trailing edge…
By convention the cut starts from the left side of the first profle
In the new version V5.2.15 you can now place the first cut-outs with the help of the CutOut dialog. As with the profiles, it is also possible to use DXF files for this.
What I didn’t like so far was the fixed connection of the foam block to the position of the A-axis. I have now changed this so that you can move the cutting wire to where you have mounted the block.
Now press the “Set workpiece zero point” button.
The front lower edge of the block is then positioned 20 mm in front of the wire.
See the video, unfortunately again only with German text.
I’ll continue after my Easter vacation.
I wish you all a happy and peaceful Easter.
On my side I am glad to say that I have modified my “MM2001” board to allow to drive it with Gcode (ESP32 board + FluidNC GRBL).
And It works ! (both the 4 motors and the wire temperature control).
“So tests can resume when ready to generate Gcode.”
That’s great! Then you can cut a test profile.
If you can’t access the machine directly, you can copy the GCode using the button in the toolbar.
I’m very curious to see if it works.
First of all, sorry for only getting back to you now.
I’ve been so busy at work lately that I just haven’t gotten around to it.
Thanks also for the two DXF files.
However, I still have some questions. I assume that you are using metric dimensions. The profiles are then very small. The larger one is only 56 mm long and the smaller one 30 mm? The slots are also very narrow at 0.05 and 0.02 mm ?
I must be doing something wrong, but I don’t know what.
However, I can’t use these profiles directly. The program needs the profiles without any CutOuts . The CutOuts are added in a separate geometry, so that the remaining sections are moved evenly. The “syncho points” you described are set automatically.
I have now removed the CutOuts from your profiles once and then added 2 CutOuts . I made the short video.
A new version V5.2.16 is now also available on my website.
There is a new version V5.2.17 on my website.
Now you can also cut the lower or upperside individually.
Therefore there is now the choice of the order combined with
WHAT should be cut. So: Only upper, or only lower or first upper and then lower, or vice versa. There should be something for everyone. See pics below.
You can now select TANGENTIAL or STRAIGHT for the outlet.
With STRAIGHT, you simply run an adjustable section at the start and straight out at the end. This gives you the necessary templates to make the planking.
Oups… Sorry for that. You are right the profiles are too small. I didn’t notice it because jedicut do not care of this as you have to manually enter the “cord” size (corde emplanture value and corde saumon value).
The slots are also very very small to allow the hot wire to make a up/down motion. The kerf due to radiation gives a consistant 1mm width when cut !
Your newer version seems extremly good.
I will download it and try to use it. I keep you informed.
BTW : sorry for my late answers I was also a little busy these days !
Yep I am also quite happy with the synchro when cuttting the slot ! Good job.
All this process is also very clean (much more than jedicut !).
A few questions (before testing)
can we have more than one slot ?
is it possible to have a “key hole” slot. I mean enter into the bottom (or top) of the foam/wing vertically then perform a circle (or rectangle) then exit by the same slot down to the bottom ?
finally as motion speeds on fuselage side and wing tip side are obviously not the same (wing tip speed can be twice smaller than fuselage), the kerf of the hot wire should be balanced accordingly. (small kerf on the fuselage and big kerf on the wing tip).
This is a trial an error process involving cutting a stack of x square profiles then measuring the total height and dividing by x (I hope it’s clear ) and this being done at different speeds to allow the user (or the software) to compute kerf for the choosen speed (at fuselage and wing tip)
here an exemple of this kerf on a simple profile :
I have found hidden into the jedicut site a “blog” where there are some interresting behaviors of jedicut almost explained.
Here is the link : Jerome | Jedicut
Yes, you can insert several CutOuts. At the moment you only have to keep to the order from left to right when entering. However, I will sort the CutOuts later.
Yes, “key hole” CutOuts are possible
I didn’t know “Kerf” before and have now tried to learn something about it.
But I still have problems understanding it.
The gap that the wire cuts is mainly dependent on the feed rate.
And the feed rate is inversely proportional to the length of the profile. Does not only the “root” profile have to be provided with a small but constant equidistant, whereas the “tip” profile has to be provided with a slightly larger but also constant equidistant?
I therefore do not understand your graphic. What is the dark gray line and what is the light gray line? I don’t recognize an equidistant.
Thank you for the German Jedicut translation. It contains some important information for me.
Sorry… light gray and dark grey are the same equidistant “kerf” around the profile . But as it is a “extruded” profile it gives this false color due to the perspective of the 3D drawing…
I should have only drawn the 2D profile + the constant “kerf” outside of it !
A few dfficulties with these “kerfs”:
There should be one kerf for the fuselage profile assuming that it is cut at constant speed
And another one for wing tip. This one is bigger because the speed is lower.
Kerf compensation inside “key hole” can give strange and unexpected results if the small part of the keyhole is smaller than the wire diameter. Software usually add kerf on “outside” of the cut and thus can widen the keyhole where no compensation would be better (it’s better to cut “in the middle of the key hole line” to minimize a slot width)
Jedicut has an option to adapt kerf compensation while cutting. So it tries to take into account the speed and to adapt the kerf accordingly.
I have never tried this option and prefer to use the “constant speed” (single fixed kerf value) option.
Here is a proper drawing showing where to cut with a 1mm kerf and a small blue wire. All this at constant speed all around the profile
It’s basically exactly what does a CNC with cutter compensation. But you have to estimate the diameter of the mill bit. This diameter as you said will depend on speed and temperature. It’s a error and trial process
I have successfully entered a “no slot” profile.
I know how to modify parameters into the wing creator (nice BTW)
I know how to modify the stock parameters.
But I am still missing where I can position the stock into the machine
I would like to know where is the stock (green line) into the machine
And I don’t know how to fix the origin for the cut.
I don’t know if it is the reason but when starting the job, the wire “jumps” to the back and starts cutting there. (It follows the profile but not into the foam)
I have also generated the gcode.
Here are the first lines :
Job: Left Left → FoamCut Wings )
( ------------------------------- )
( Job mode = 7, FOAM_CUT )
( Type of tool = 0, SPINDLE )
( FoamCutter )
( Length = 180.0 mm )
( Height = 17.0 mm )
( Width = 309.0 mm )
( Points = 200.0 )
( Feed = 800.0 mm/min )
( Wire heat = 55.0 % )
( Process Order = UPPER_LOWER )
( First Point = FRONT )
( Type of In / Outlet = TANGENTIAL )
( In / Outlet = 10.000 )
( Go to Startposition )
( Start profile )
G1 G90 G93 F 1 X5.761 Y0.000 U4.062 Z0.000
G1 G90 G93 F 27 X5.761 Y-30.110 U4.062 Z-29.092
G1 G90 G93 F 80 X10.000 Y-21.004 U10.000 Z-21.004
G1 G90 G93 F 262 X11.415 Y-18.298 U10.035 Z-21.137
G1 G90 G93 F 493 X12.831 Y-17.505 U10.069 Z-20.649
G1 G90 G93 F 564 X14.196 Y-17.118 U10.219 Z-20.144
G1 G90 G93 F 605 X15.455 Y-16.710 U10.618 Z-19.894
G1 G90 G93 F 617 X16.701 Y-16.352 U11.045 Z-19.687
G1 G90 G93 F 626 X17.941 Y-16.044 U11.489 Z-19.498
G1 G90 G93 F 634 X19.173 Y-15.770 U11.949 Z-19.345
G1 G90 G93 F 639 X20.402 Y-15.533 U12.417 Z-19.203
G1 G90 G93 F 643 X21.628 Y-15.326 U12.890 Z-19.072
G1 G90 G93 F 647 X22.852 Y-15.140 U13.371 Z-18.965
G1 G90 G93 F 649 X24.074 Y-14.976 U13.855 Z-18.866
G1 G90 G93 F 651 X25.294 Y-14.830 U14.342 Z-18.774
G1 G90 G93 F 652 X26.514 Y-14.694 U14.832 Z-18.701
G1 G90 G93 F 653 X27.732 Y-14.576 U15.323 Z-18.631
G1 G90 G93 F 655 X28.951 Y-14.477 U15.816 Z-18.563
G1 G90 G93 F 655 X30.168 Y-14.384 U16.311 Z-18.510
G1 G90 G93 F 656 X31.385 Y-14.304 U16.806 Z-18.460
G1 G90 G93 F 656 X32.602 Y-14.233 U17.303 Z-18.414
G1 G90 G93 F 657 X33.818 Y-14.166 U17.800 Z-18.378
Something is unclear for me. I asked for a F800 feedrate.
And into the file the Feedrate is not constant and close to 656.
Could you please explain this ? Is it due to the synchro between profiles ?
With jedicut if I choose the constant feedrate. Then the speed is constant and the feedrate is applied to the fuselage side (longest chord). Then of course the wing tip profile is cut at slower speed and need a bigger “kerf” compensation.
