Using the Foam Cutter

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1 Using the Foam Cutter Some things to keep in mind: Axes: X is positive toward the wall (away from you) and y is positive up. Wire extension: The wire elongates when it heats up. This is especially noticeable when you try to make a rough cut to shape your foam. When doing a straight rough cut, you will need to command much larger travel than the thickness of your foam (generally ~1.5 or 2 times) to make sure the wire goes all the way through without getting stuck inside when it cools down at the end of the prescribed cut distance. Trailing edge: It is very easy to get ragged trailing edges because the wire melts a significant thickness of foam. Don't expect airfoils with small trailing edge angle to cut cleanly. If you have to use an airfoil with a small trailing edge angle, allow extra kerf. This will prevent the foam cutter from trying to cutting down to a point at the trailing edge, and will usually result in a thin sheet of foam extending from the trailing edge to the position where the wire enters the foam block. You will likely need to manually cut off the foam sheet at the trailing edge, which will give you a thicker trailing edge, but a much cleaner/more consistent one than you could get with smaller kerf. Wire Cleaning: As you use the wire, it will gradually accumulate globs of melted foam residue. Use the heat wire function (under Zero Axis in the GMFC menu) and wipe the wire periodically to remove this, or it can detach on your wing and melt small pits into the surface. The Box: The foam cutter is controlled via the circuitry in the clear acrylic box to the left of the cutting table. The power switch is on the back of the box (toward the cutting area).

2 The Home Screen of the Control Program (GMFC) This screen shows you the root and tip panels for your current cut setup with their relative positions. The black line is the outline of the airfoil coordinates and the red line is the path to be traced by the wire.

3 Important Menus in the Control Program 1. GMFC a. Foam Management: Define presets for cutting speed, heat, and kerf. Since the wire will melt more foam at lower speeds, give it more kerf for speed S/2 than speed S. The settings already saved on the Room 055 computer for pink foam and blue foam are pretty reasonable.

4 b. Zero Axis: i. Single step moves and Distance: Set the wire position >> all cutting is done relative to the starting wire position (e.g., if the wire is not horizontal when you start cutting, your trailing edge angle will be offset by the initial wire angle). 1. You should typically zero the wire position such that it aligns with your cutting surface (i.e., where you place the foam block you want to cut). 2. Use the Distance section in the middle of the window to move the wire in specific increments. ii. Heat: This is one way to clean the wire by burning off accumulated foam residue. Be sure to also wipe the wire clean after the heat test to remove any remaining residue. Removing residue helps reduce pitting in the foam surface.

5 2. Project a. Panel Parameters: i. Global: Tell the cutter what foam thickness to expect and how far apart the panels (streamwise sections) you defined are placed, as well as the (LE) sweep (so it offsets the tip chord appropriately in the x-direction). ii. Root, Tip: Define the root and tip airfoils. (*.dat files are best. You should order the points so they start at the trailing edge, progress along the upper surface, around the leading edge, and back to the trailing edge along the lower surface. Normalize to a chord length of 1.0.) Define chord, washout (twist), margins at LE and TE (How far the machine expects the leading and trailing edges to be relative to where you tell it the foam block is placed - see Cut.Panel_cut in menu), basic height (offset of airfoil origin in the y-direction). iii. Advanced: Check Different Root/Tip to define a tip airfoil with aerodynamic or geometric twist, taper, or dihedral. Check Skin to hollow out the interior of the airfoil. Dihedral in degree lets you bypass calculating the y-direction (basic height) offset for dihedral and just let the software find the necessary offset given your span and angular dihedral.

6 3. Cut a. Panel Cutting: i. Cut: Right wing or Left wing determines relative positions of root and tip sections. The cut will be made with the trailing edge toward you (nose of airfoil points in the positive x- direction). ii. Block Position: X,Y,Z offsets measured to lower front left corner of the theoretical block (i.e., block with exact dimensions be careful if your foam block is not exactly the size you input in Project.Panel_Parameters. 1. If you re cutting a wing with large taper or large twist, you may find get errors because the required wire motion takes the ends of the wire beyond their position limits. Sometimes this can be corrected by moving the block position further up (y) or further back (x). iii. Cut parameters: apply defaults you saved in GMFC.Foam_Management for kerf and cut speed (speed can be overridden).

7 iv. When you tell it to cut, it will give a summary of settings and predicted cut time (see right). The cut usually takes around 1/4 to 1/2 the predicted time. b. Foam Cut: i. This is useful for doing rough cuts of the foam to get a faced surface for proper alignment. Specify cut height (go for about twice the actual foam thickness), position the foam block over the wire (you may need to use GMFC.Zero_Axis to get the wire low enough), and hit the Raise Wire button.

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