Tag: CNC

Making parts with mathematics

Diamond Drag Tool Wear

The diamond drag tool now in the MPCNC LM3UU holder has appeared in several holders and suffered considerable misuse along the way:

Diamond Drag Tool tip – MPCNC

A closer look at the spalled section on the flank:

Diamond Drag Tool tip – MPCNC – detail

The tool in the (much better) CNC 3018XL LM6UU holder has engraved mostly plastic, plus a few hard drive platters, and seems only slightly rounded:

Diamond Drag Tool tip – CNC 3018

An unused tip comes to a neat point:

Diamond Drag Tool tip – unused A

As does its companion, arriving in a twofer deal from halfway around the planet:

Diamond Drag Tool tip – unused B

They’re brazed on 3 mm OD shanks and ground to a 60° included angle.

2020-02-27
Homage Tek CC Cursor: Pivot Milling
A test to mill the pivot hole in 0.5 mm PETG sheet worked perfectly:

Tek CC – cursor pivot hole milling

The cutter is a 3.175 mm = 1/8 inch router bit, one of a ten-pack that came with the CNC 3018 and to which I have no deep emotional attachment, held in a collet in the Sherline. The hole is 5.5 mm to fit an eyelet. The PETG is taped to a thin plywood scrap.

The hole happened by feeding G-Code manually into LinuxCNC, after touching off XYZ=0 at the center of the pivot and jogging up a bit:
```
g0 y-1.1625
f1000
g0 z0.5
g2 p5 z-1.5 i0 j1.1625
```
Yes, I engraved the hairline using a diamond drag tool on the CNC 3018, cut the cursor outline with a drag knife on the MPCNC, then milled the pivot hole on the Sherline. This seems way over the top, even to me, but that’s just how the tooling worked out right now.

In actual practice, I’d probably mill a stack of cursors and pivot holes on the Sherline in one setup, then engrave the hairlines in a suitable fixture. I think I know enough to fit a spring-loaded diamond drag bit into the Sherline’s 10 mm ID spindle or, worst case, conjure a block for the Z-axis carrier in place of the entire spindle mount.

At least now I can remember what I did to make the hole.
2020-01-22
Monthly Image: Digital Machinist 14.4 Cover

I ain’t getting richer, but I did get ma h pitcher onna cover of th’ Digital Machinist:

Digital Machinist Cover DM14.4 – Winter 2019

I just caught George Bulliss in a weak moment. [grin]

It’s the diamond drag holder on the CNC 3018-Pro, before the XL axis extension hackage., with the probe camera stuck to the left side.

You can say you knew me before …

2020-01-15
Drag Knife Cuttery: Entry & Exit Moves
The first pass at cutting laminated decks for the Homage Tektronix Circuit Computer left little uncut snippets at the starting point of the cut. The point of the drag knife blade trundles along behind the cutting edge and, when the ending point equals the starting point, leaves an un-cut sliver as it’s retracted vertically:

Drag Knife – LM12UU – knife blade detail

The knife blade isn’t aligned in any particular direction, so it can leave a nick on either side as it enters the deck vertically at the start of the cut.

Gradually entering the deck along the cut line gives the blade enough time to swivel around to the proper alignment before it gets down to serious cutting. Continuing the final cut past the starting point then allows the blade to recut anything remaining from the entry move.

The middle and top decks have windows exposing the scales:

Tek CC – radial text example

The paths are basically two arcs connected by semicircular cuts, but with ramps on each end recutting the entry and exit paths:

Top Deck – Window Cut Path

The entry path in the upper left slants downward from the TravelZ level of 1.5 (-ish) mm to Z=0, with the nose of the blade holder flush against the surface and the blade sunk to its full length. The vertical path to Z=-2 (-ish) increases the cutting pressure from roughly the preload value to preload + 2*(spring rate), so the blade won’t ride up under the cutting forces.

The path then goes completely around the window at Z=-2, then ramps up to the TravelZ level again.

All of which produces a neat cutout that sticks to the Cricut mat when I peel the rest of the deck off:

Tek CC – MPCNC drag knife

That’s a middle deck before I started laminating them, but you get the general idea.

The GCMC code (extracted from the complete lump) looks like this:
```
  local WindowArc = 54deg;

  local ac = -17 * ScaleArc + ScaleRT/2;   // center of window arc
  local r0 = DeckRad - ScaleHeight;        // outer
  local r1 = DeckRad - 2 * ScaleHeight;    // inner

  local aw = WindowArc - to_deg(atan(ScaleHeight,(r0 + r1)/2));    // window arc minus endcaps

  p0 = r0 * [cos(ac + aw/2),sin(ac + aw/2),-];
  p1 = r0 * [cos(ac - aw/2),sin(ac - aw/2),-];
  local p2 = r1 * [cos(ac - aw/2),sin(ac - aw/2),-];
  local p3 = r1 * [cos(ac + aw/2),sin(ac + aw/2),-];

  goto(p3);
  arc_cw(p0 +| [-,-,0],ScaleHeight/2);    // blade enters surface
  move([-,-,KnifeZ]);                     // apply pressure

  arc_cw(p1,r0);                          // smallest arc
  arc_cw(p2,ScaleHeight/2);               // half a circle
  arc_ccw(p3,r1);
  arc_cw(p0,ScaleHeight/2);

  arc_cw(p1 +| [-,-,TravelZ],r0);         // exit from cut

  goto([0,0,-]);
  goto([-,-,SafeZ]);
```
Having measured the angular position of the window and its size on the original Tek CC, I compute the coordinates of the four points where the semicircular “end caps” meet the longer arcs, then connect the dots with arc_xx() functions to generate the G-Code commands. As always, using the proper radius signs requires trial & error.

While I was at it, I added entry & exit moves for the deck’s central pivot hole and outer perimeter.

I’m pretty sure the right CAM package would take care of that, but GCMC operates well below the CAM level.
2019-12-30

Homage Tektronix Circuit Computer: Pen Plotter Version

A reproduction circular slide rule from the mid-1960s may not be the cutting edge of consumer demand, but the pen version of a Tektronix Circuit Computer came out pretty well:

Homage Tektronix Circuit Computer - green on white laminated — Homage Tektronix Circuit Computer – green on white laminated

A Bash script compiles the GCMC code with eight different parameter combinations to produce pairs of G-Code files to draw (“engrave” being aspirational) and cut (“mill”, likewise) the three decks and the cursor.

The CNC 3018XL with a Pilot V5RT pen draws the deck scales on white paper:

Pilot V5RT holder - installed — Pilot V5RT holder – installed

Better paper definitely produces better results, so I must rummage through the Big Box o’ Paper to see what lies within. Laminating the decks improves their durability and matches the original Tek surface finish.

The MPCNC with a drag knife blade cuts through a laminated deck like butter:

Tek CC - MPCNC drag knife — Tek CC – MPCNC drag knife

Setting the XY origin to dead center on each deck requires carefully calibrating the USB video camera, with the end result accurate to maybe ±0.1 mm around the entire perimeter. Both machines move equal linear distances along both axes, which was definitely comforting.

Having made half a dozen cursors from various bits of acrylic, none of which look particularly good, demonstrates my engraving hand is too weak for a complete slide rule:

Tek Circuit Computer - cursor hairline — Tek Circuit Computer – cursor hairline

With logarithmic scales in hand, however, adapting the GCMC source code to produce general-purpose circular slide rules with only two decks and smaller diameters may be the way to improve my engraving-fu, as a full-scale Tektronix Circuit Computer would chew up three square-foot plastic sheets.

A general-purpose slide rule would need multi-color (well, at least bi-color) labels and digits for red “inverse” scales to remind you (well, me) they read backwards. Some slipsticks use left-slanting italics, left-pointing markers (“<2”), or other weirdness, but they’re all different.

An early small-scale version engraved on ABS came out OK, modulo poor ink fill:

Tek CC bottom - ABS 160g 2400mm-min — Tek CC bottom – ABS 160g 2400mm-min

Engraving the decks on hard drive platters doesn’t count:

Tek CC - bottom deck - scaled to HD platter — Tek CC – bottom deck – scaled to HD platter

All in all, it’s been an interesting exercise and, as you may have guessed, will become a Digital Machinist column.

The GCMC and Bash source code as a GitHub Gist:

	// Tektronix Circuit Computer Reproduction
	// Ed Nisley KE4ZNU – 2019-11

	//—–
	// Library routines

	include("tracepath.inc.gcmc");
	include("engrave.inc.gcmc");

	TekOD = to_mm(7.75in); // orginal Tek Circuit Computer diameter

	FALSE = 0;
	TRUE = 1;

	//—–
	// Command line parameters

	// -D various useful tidbits
	// add unit to speeds and depths: 2000mm / -3.00mm / etc

	if (!isdefined("BaseOD")) {
	BaseOD = TekOD;
	}
	comment("Base OD: ",BaseOD);

	SizeRatio = BaseOD / TekOD; // overall scaling for different base diameters
	comment(" scale factor: ",SizeRatio);

	if (!isdefined("SelectPart")) {
	SelectPart = "Bottom";
	}
	comment("Part: ",SelectPart);

	if (!isdefined("Operation")) {
	Operation = "Engrave";
	}
	comment("Operation: ",Operation);

	if (!isdefined("ScaleSpeed")) {
	ScaleSpeed = 2400mm;
	}

	if (!isdefined("TextSpeed")) {
	TextSpeed = 2400mm;
	}

	// Engraving & drag knife force is proportional to depth, but you must know the coefficent!

	if (!isdefined("EngraveZ")) {
	EngraveZ = -1.0mm;
	}

	if (!isdefined("KnifeZ")) {
	KnifeZ = -2.0mm;
	}

	if (!isdefined("KnifeSpeed")) {
	KnifeSpeed = 1000mm;
	}

	//—–
	// Define useful constants

	SafeZ = 10.00mm; // above all obstructions
	TravelZ = 1.00mm; // within engraving area

	//—–
	// Overall values

	ScaleHeight = to_inch(3.0/8.0) * SizeRatio; // scale-to-scale distance
	WindowHeight = ScaleHeight; // cutout window opening

	DeckBottomOD = BaseOD; // deck sizes depend on scale height
	DeckMiddleOD = DeckBottomOD – 2*ScaleHeight;
	DeckTopOD = DeckMiddleOD – 2*(ScaleHeight + WindowHeight);

	ScaleArc = 18deg; // angular length of one decade: +CCW
	ScaleExdent = 0.20; // log spacing at end of scales to identifiers

	Scale2Pi = log10(2pi()) ScaleArc; // angular offset for scales using 2*pi
	ScaleRT = log10(2.197225) * ScaleArc; // angular offset for risetime

	TauAngle = 150deg; // arbitrary offset to 1.0 on tau scales
	TitleAngle = -50deg; // … to Tek title, then +180deg to logo

	INWARD = -1; // text and tick alignment (used as integers)
	OUTWARD = 1;

	TEXT_LEFT = -1; // text justification
	TEXT_CENTERED = 0;
	TEXT_RIGHT = 1;

	TextFont = FONT_HSANS_1_RS;

	TitleTextSize = 3.1 * SizeRatio * [1.0mm,1.0mm];
	LegendTextSize = 1.8 * SizeRatio * [1.0mm,1.0mm];
	ScaleTextSize = 1.4 * SizeRatio * [1.0mm,1.0mm];

	//—-
	// Define tick layout for scales
	// Numeric values = scale position, tick length
	// These are not algorithmic!

	TickMajor = 3.2mm * SizeRatio; // length of tick marks
	TickMid = 1.9mm * SizeRatio;
	TickMinor = 1.2mm * SizeRatio;

	TickScaleNarrow = {
	[1.0,TickMajor],
	[1.1,TickMinor],[1.2,TickMinor],[1.3,TickMinor],[1.4,TickMinor],
	[1.5,TickMid],
	[1.6,TickMinor],[1.7,TickMinor],[1.8,TickMinor],[1.9,TickMinor],
	[2.0,TickMajor],
	[2.2,TickMinor],[2.4,TickMinor],[2.6,TickMinor],[2.8,TickMinor],
	[3.0,TickMajor],
	[3.2,TickMinor],[3.4,TickMinor],[3.6,TickMinor],[3.8,TickMinor],
	[4.0,TickMajor],
	[4.5,TickMinor],
	[5.0,TickMajor],
	[5.5,TickMinor],
	[6.0,TickMajor],
	[6.5,TickMinor],
	[7.0,TickMajor],
	[7.5,TickMinor],
	[8.0,TickMajor],
	[8.5,TickMinor],
	[9.0,TickMajor],
	[9.5,TickMinor]
	};

	TickScaleWide = {
	[1.0,TickMajor],
	[1.1,TickMinor],[1.2,TickMinor],[1.3,TickMinor],[1.4,TickMinor],
	[1.5,TickMid],
	[1.6,TickMinor],[1.7,TickMinor],[1.8,TickMinor],[1.9,TickMinor],
	[2.0,TickMajor],
	[2.1,TickMinor],[2.2,TickMinor],[2.3,TickMinor],[2.4,TickMinor],
	[2.5,TickMid],
	[2.6,TickMinor],[2.7,TickMinor],[2.8,TickMinor],[2.9,TickMinor],
	[3.0,TickMajor],
	[3.2,TickMinor],[3.4,TickMinor],[3.6,TickMinor],[3.8,TickMinor],
	[4.0,TickMajor],
	[4.2,TickMinor],[4.4,TickMinor],[4.6,TickMinor],[4.8,TickMinor],
	[5.0,TickMajor],
	[5.5,TickMinor],
	[6.0,TickMajor],
	[6.5,TickMinor],
	[7.0,TickMajor],
	[7.5,TickMinor],
	[8.0,TickMajor],
	[8.5,TickMinor],
	[9.0,TickMajor],
	[9.5,TickMinor]
	};

	TickLabels = [1,2,5]; // labels only these ticks, must be integers
	TickGap = 0.50 * ScaleTextSize.y; // gap between text and ticks

	PivotOD = 5.0mm; // center bolt OD

	Legend1 = "Ed Nisley – KE4ZNU";
	Legend2 = "softsolder.com";


	//—————————————————————————–
	// Text & Scale Engraving

	//—–
	// Write text on a radial line

	function RadialText(TextPath,CenterPt,Radius,Angle,Justify,Orient) {

	local pl = TextPath[-1].x; // path length

	local ji = (Justify == TEXT_LEFT) ? 0mm : // justification, assume OUTWARD
	(Justify == TEXT_CENTERED) ? -pl/2 :
	(Justify == TEXT_RIGHT) ? -pl :
	0mm;

	if (Orient == INWARD) {
	TextPath = rotate_xy(TextPath,180deg);
	ji = -ji;
	}

	TextPath += [Radius + ji,0mm];

	return rotate_xy(TextPath,Angle) + CenterPt;

	}

	//—–
	// Draw a radial legend
	// Offset in units of char height: 0 = baseline on radius, +/- = above/below

	function RadialLegend(Text,Center,Radius,Angle,Justify,Orient,Offset) {

	local tp = scale(typeset(Text,TextFont),LegendTextSize) + [0mm,Offset * LegendTextSize.y];
	local tpr = RadialText(tp,Center,Radius,Angle,Justify,Orient);

	feedrate(TextSpeed);
	engrave(tpr,TravelZ,EngraveZ);

	}

	//—–
	// Bend text around an arc

	function ArcText(TextPath,CenterPt,Radius,BaseAngle,Justify,Orient) {

	local pl = TextPath[-1].x; // path length
	local c = 2pi()Radius;
	local ta = to_deg(360 * pl / c); // subtended angle

	local ja = (Justify == TEXT_LEFT ? 0deg : // assume OUTWARD
	(Justify == TEXT_CENTERED) ? -ta / 2 :
	(Justify == TEXT_RIGHT) ? -ta :
	0deg);

	ja = BaseAngle + Orient*ja;

	local ArcPath = {};

	local pt,r,a;
	foreach(TextPath; pt) {
	if (!isundef(pt.x) && !isundef(pt.y) && isundef(pt.z)) { // XY motion, no Z
	r = (Orient == OUTWARD) ? Radius – pt.y : Radius + pt.y;
	a = Orient * 360deg * (pt.x / c) + ja;
	ArcPath += {[rcos(a) + CenterPt.x, rsin(a) + CenterPt.y,-]};
	}
	elif (isundef(pt.x) && isundef(pt.y) && !isundef(pt.z)) { // no XY, Z up/down
	ArcPath += {pt};
	}
	else {
	error("ArcText – Point is not pure XY or pure Z: " + to_string(pt));
	}
	}

	return ArcPath;

	}



	//—–
	// Draw scale legend

	function ArcLegend(Text,Radius,Angle,Orient) {

	local tp = scale(typeset(Text,TextFont),LegendTextSize);
	local tpa = ArcText(tp,[0mm,0mm],Radius,Angle,TEXT_CENTERED,Orient);

	feedrate(TextSpeed);
	engrave(tpa,TravelZ,EngraveZ);

	}


	//—–
	// Draw a decade of ticks & labels
	// ArcLength > 0 = CCW, < 0 = CW
	// UnitOnly forces just the unit tick, so as to allow creating the last tick of the scale

	function DrawTicks(Radius,TickMarks,TickOrient,UnitAngle,ArcLength,Decade,LabelOrient,UnitOnly) {

	feedrate(ScaleSpeed);

	local a,r0,r1,p0,p1;

	if (Decade == 1 \|\| UnitOnly) { // draw unit marker
	a = UnitAngle;
	r0 = Radius + TickOrient * (TickMajor + 2*TickGap + ScaleTextSize.y);
	p0 = r0 * [cos(a),sin(a)];
	r1 = Radius + TickOrient * (ScaleHeight – 2*TickGap);
	p1 = r1 * [cos(a),sin(a)];

	goto(p0);
	move([-,-,EngraveZ]);
	move(p1);
	goto([-,-,TravelZ]);
	}

	local ticklist = UnitOnly ? {TickMarks[0]} : TickMarks;

	local tick;
	foreach(ticklist; tick) {
	a = UnitAngle + ArcLength * log10(tick[0]);
	p0 = Radius * [cos(a), sin(a)];
	p1 = (Radius + TickOrienttick[1]) [cos(a), sin(a)];

	goto(p0);
	move([-,-,EngraveZ]);
	move(p1);
	goto([-,-,TravelZ]);
	}

	feedrate(TextSpeed); // draw scale values

	local lrad = Radius + TickOrient * (TickMajor + TickGap);

	if (TickOrient == INWARD) {
	if (LabelOrient == INWARD) {
	lrad -= ScaleTextSize.y; // inward ticks + inward labels = offset inward
	}
	}
	else {
	if (LabelOrient == OUTWARD) {
	lrad += ScaleTextSize.y; // outward ticks + outward labels = offset outward
	}
	}

	ticklist = UnitOnly ? [TickLabels[0]] : TickLabels;

	local ltext,lpath,tpa;
	foreach(ticklist; tick) {
	ltext = to_string(Decade * to_int(tick));
	lpath = scale(typeset(ltext,TextFont),ScaleTextSize);
	a = UnitAngle + ArcLength * log10(tick);
	tpa = ArcText(lpath,[0mm,0mm],lrad,a,TEXT_CENTERED,LabelOrient);
	engrave(tpa,TravelZ,EngraveZ);
	}

	}

	//—–
	// Mark key locations

	function MarkPivot() {

	comment("Mark center point");
	feedrate(ScaleSpeed);

	if (TRUE) {
	goto([-,-,SafeZ]);
	goto([PivotOD/2,0,-]);
	move([-,-,EngraveZ]);
	circle_cw([0,0]); // outline pivot

	move([-PivotOD/2,0,-]); // draw X line
	goto([-,-,TravelZ]);
	goto([0,PivotOD/2,-]);
	move([-,-,EngraveZ]);
	move ([0,-PivotOD/2,-]); // draw Y line
	goto([-,-,TravelZ]);
	}

	}

	//—–
	// Draw attribution

	function DrawAttribution(AttribRad) {

	comment("Attribution at: ",AttribRad);

	feedrate(TextSpeed);

	local tp,tpa;
	if (Legend1) {
	tp = scale(typeset(Legend1,TextFont),TitleTextSize);
	tpa = ArcText(tp,[0mm,0mm],AttribRad,0deg,TEXT_CENTERED,OUTWARD);
	feedrate(TextSpeed);
	engrave(tpa,TravelZ,EngraveZ);
	}

	if (Legend2) {
	tp = scale(typeset(Legend2,TextFont),TitleTextSize);
	tpa = ArcText(tp,[0mm,0mm],AttribRad,180deg,TEXT_CENTERED,OUTWARD);
	feedrate(TextSpeed);
	engrave(tpa,TravelZ,EngraveZ);
	}

	if (FALSE) { // test code to verify ArcText
	comment("ArcText test");
	ctr = [0mm,0mm];

	tp = scale(typeset("Right Inward",TextFont),ScaleTextSize);
	tpa = ArcText(tp,ctr,30mm,45deg,TEXT_RIGHT,INWARD);
	engrave(tpa,TravelZ,EngraveZ);
	tp = scale(typeset("Right Outward",TextFont),ScaleTextSize);
	tpa = ArcText(tp,ctr,30mm,45deg,TEXT_RIGHT,OUTWARD);
	engrave(tpa,TravelZ,EngraveZ);

	tp = scale(typeset("Center Inward",TextFont),ScaleTextSize);
	tpa = ArcText(tp,ctr,20mm,45deg,TEXT_CENTERED,INWARD);
	engrave(tpa,TravelZ,EngraveZ);
	tp = scale(typeset("Center Outward",TextFont),ScaleTextSize);
	tpa = ArcText(tp,ctr,20mm,45deg,TEXT_CENTERED,OUTWARD);
	engrave(tpa,TravelZ,EngraveZ);

	tp = scale(typeset("Left Inward",TextFont),ScaleTextSize);
	tpa = ArcText(tp,ctr,10mm,45deg,TEXT_LEFT,INWARD);
	engrave(tpa,TravelZ,EngraveZ);
	tp = scale(typeset("Left Outward",TextFont),ScaleTextSize);
	tpa = ArcText(tp,ctr,10mm,45deg,TEXT_LEFT,OUTWARD);
	engrave(tpa,TravelZ,EngraveZ);

	goto([0mm,0mm,-]);
	move([40mm,40mm,-]);
	}

	if (FALSE) { // test code to verify RadialText
	comment("RadialText test");
	ctr = [0mm,0mm];
	r = 20mm;

	a = 0deg;
	tp = scale(typeset("Left Inward",TextFont),LegendTextSize);
	tpr = RadialText(tp,ctr,r,a,TEXT_LEFT,INWARD);
	feedrate(TextSpeed);
	engrave(tpr,TravelZ,EngraveZ);
	tp = scale(typeset("Left Outward",TextFont),LegendTextSize);
	tpr = RadialText(tp,ctr,r,a,TEXT_LEFT,OUTWARD);
	feedrate(TextSpeed);
	engrave(tpr,TravelZ,EngraveZ);

	a = 90deg;
	tp = scale(typeset("Right Inward",TextFont),LegendTextSize);
	tpr = RadialText(tp,ctr,r,a,TEXT_RIGHT,INWARD);
	feedrate(TextSpeed);
	engrave(tpr,TravelZ,EngraveZ);
	tp = scale(typeset("Right Outward",TextFont),LegendTextSize);
	tpr = RadialText(tp,ctr,r,a,TEXT_RIGHT,OUTWARD);
	feedrate(TextSpeed);
	engrave(tpr,TravelZ,EngraveZ);


	a = 180deg;
	tp = scale(typeset("Center Inward",TextFont),LegendTextSize);
	tpr = RadialText(tp,ctr,r,a,TEXT_CENTERED,INWARD);
	feedrate(TextSpeed);
	engrave(tpr,TravelZ,EngraveZ);
	tp = scale(typeset("Center Outward",TextFont),LegendTextSize);
	tpr = RadialText(tp,ctr,r,a,TEXT_CENTERED,OUTWARD);
	feedrate(TextSpeed);
	engrave(tpr,TravelZ,EngraveZ);

	a = 270deg;
	RadialLegend("Offset to radius",ctr,r,a,TEXT_CENTERED,INWARD,-0.5);
	goto(ctr);
	move([0,-2*r,EngraveZ]);

	goto([r,0mm,-]);
	circle_cw(ctr);

	}

	}

	//—————————————————————————–
	// Deck Engraving


	//———-
	// Engrave bottom deck

	function EngraveBottom() {

	// Mark center pivot

	MarkPivot();

	comment("Inductance scale");
	Radius = DeckRad – ScaleHeight;

	MinLog = -9;
	MaxLog = 6;
	Arc = -ScaleArc;

	dec = 1;
	offset = 0deg;
	for (logval = MinLog; logval < MaxLog; logval++) {
	a = offset + logval * Arc;
	DrawTicks(Radius,TickScaleNarrow,OUTWARD,a,Arc,dec,INWARD,FALSE);
	dec = (dec == 100) ? 1 : 10 * dec;
	}

	a = offset + MaxLog * Arc;
	DrawTicks(Radius,TickScaleNarrow,OUTWARD,a,Arc,1000,INWARD,TRUE);

	r = Radius + TickMajor + 2*TickGap + LegendTextSize.y;

	logval = MinLog + 1.5;
	a = offset + logval * Arc;
	ArcLegend("nH – nanohenry x10^-9",r,a,INWARD);

	logval += 3;
	a = offset + logval * Arc;
	ArcLegend("μH – microhenry x10^-6",r,a,INWARD);

	logval += 3;
	a = offset + logval * Arc;
	ArcLegend("mH – millihenry x10^-3",r,a,INWARD);

	logval += 3;
	a = offset + logval * Arc;
	ArcLegend("H – henry",r,a,INWARD);

	logval += 3;
	a = offset + logval * Arc;
	ArcLegend("kH – kilohenry x10^3",r,a,INWARD);

	r = Radius + TickMajor + TickGap;

	logval = MinLog – ScaleExdent; // scale identifiers
	a = offset + logval * Arc;
	tp = scale(typeset("L Scale →",TextFont),LegendTextSize);
	tpa = ArcText(tp,[0mm,0mm],r,a,TEXT_RIGHT,INWARD);
	engrave(tpa,TravelZ,EngraveZ);

	logval = MaxLog + ScaleExdent;
	a = offset + logval * Arc;
	tp = scale(typeset("← L Scale",TextFont),LegendTextSize);
	tpa = ArcText(tp,[0mm,0mm],r,a,TEXT_LEFT,INWARD);
	engrave(tpa,TravelZ,EngraveZ);

	comment("Inductive frequency scale");

	Radius = DeckRad – 2*ScaleHeight;

	MinLog = 0;
	MaxLog = 9;
	Arc = 2*ScaleArc; // double-length scale for square roots

	dec = 1;
	offset = -(18 * ScaleArc – Scale2Pi); // using 18 degree arc length
	for (logval = MinLog; logval < MaxLog; logval++) {
	a = offset + logval * Arc;
	DrawTicks(Radius,TickScaleWide,OUTWARD,a,Arc,dec,OUTWARD,FALSE);
	dec = (dec == 100) ? 1 : 10 * dec;
	}

	a = offset + MaxLog * Arc;
	DrawTicks(Radius,TickScaleWide,OUTWARD,a,Arc,1000,OUTWARD,TRUE);

	feedrate(TextSpeed); // draw prefix legends

	r = Radius + TickMajor + 2TickGap + 2LegendTextSize.y;

	logval = MinLog + 0.5;

	for (i = 0; i < 3; i++) {
	a = offset + (i + logval) * Arc;
	ArcLegend("Hz – hertz",r,a,OUTWARD);
	}

	for (i = 3; i < 6; i++) {
	a = offset + (i + logval) * Arc;
	ArcLegend("kHz – kilohertz x10^3",r,a,OUTWARD);
	}

	for (i = 6; i < 9; i++) {
	a = offset + (i + logval) * Arc;
	ArcLegend("MHz – megahertz x10^6",r,a,OUTWARD);
	}

	r = Radius + TickMajor + TickGap + LegendTextSize.y;

	logval = MinLog – 0.5; // scale identifier
	a = offset + logval * Arc;
	ArcLegend("←——- FL Scale ——-→",r,a,OUTWARD);

	comment("Inductive TC / Risetime scale");
	Radius = DeckRad – 3*ScaleHeight;

	MinLog = -12;
	MaxLog = 3;
	Arc = -ScaleArc;

	dec = 1;
	offset = -TauAngle;

	for (logval = MinLog; logval < MaxLog; logval++) {
	a = offset + logval * Arc;
	DrawTicks(Radius,TickScaleNarrow,OUTWARD,a,Arc,dec,INWARD,FALSE);
	dec = (dec == 100) ? 1 : 10 * dec;
	}

	a = offset + MaxLog * Arc;
	DrawTicks(Radius,TickScaleNarrow,OUTWARD,a,Arc,1000,INWARD,TRUE);

	feedrate(TextSpeed); // prefix legends

	r = Radius + TickMajor + 2*TickGap + LegendTextSize.y;

	logval = MinLog + 1.5;

	a = offset + logval * Arc;
	ArcLegend("ps – picosecond x10^-12",r,a,INWARD);

	logval += 3;
	a = offset + logval * Arc;
	ArcLegend("ns – nanosecond x10^-9",r,a,INWARD);

	logval += 3;
	a = offset + logval * Arc;
	ArcLegend("μs – microsecond x10^-6",r,a,INWARD);

	logval += 3;
	a = offset + logval * Arc;
	ArcLegend("ms – millisecond x10^-3",r,a,INWARD);

	logval += 3;
	a = offset + logval * Arc;
	ArcLegend("s – second",r,a,INWARD);

	r = Radius + TickMajor + TickGap;

	logval = MinLog – ScaleExdent; // scale identifiers
	a = offset + logval * Arc;
	tp = scale(typeset("τL Scale →",TextFont),LegendTextSize);
	tpa = ArcText(tp,[0mm,0mm],r,a,TEXT_RIGHT,INWARD);
	engrave(tpa,TravelZ,EngraveZ);

	logval = MaxLog + ScaleExdent;
	a = offset + logval * Arc;
	tp = scale(typeset("← τL Scale",TextFont),LegendTextSize);
	tpa = ArcText(tp,[0mm,0mm],r,a,TEXT_LEFT,INWARD);
	engrave(tpa,TravelZ,EngraveZ);

	//—–
	// Add construction notes

	comment("Attribution begins");

	r = DeckTopOD/2 – 2*ScaleHeight – WindowHeight;
	DrawAttribution(r);

	if (FALSE) {
	t = "Disk OD: " + to_string(DeckBottomOD) + " " +
	to_string(DeckMiddleOD) + " " +
	to_string(DeckTopOD) + " mm";
	tp = scale(typeset(t,TextFont),LegendTextSize);
	tpa = ArcText(tp,[0mm,0mm],r,90deg,TEXT_CENTERED,OUTWARD);
	engrave(tpa,TravelZ,EngraveZ);
	}

	goto([-,-,SafeZ]); // done, so get out of the way
	goto([0,0,-]);

	comment("Bottom deck ends");

	}

	//———-
	// Engrave middle deck

	function EngraveMiddle() {

	// Mark center pivot

	MarkPivot();

	comment("Capacitance scale");
	Radius = DeckRad;

	MinLog = -15;
	MaxLog = 0;
	Arc = ScaleArc;

	dec = 1;
	offset = 0deg;
	for (logval = MinLog; logval < MaxLog; logval++) {
	a = offset + logval * Arc;
	DrawTicks(Radius,TickScaleNarrow,INWARD,a,Arc,dec,INWARD,FALSE);
	dec = (dec == 100) ? 1 : 10 * dec;
	}

	a = offset + MaxLog * Arc;
	DrawTicks(Radius,TickScaleNarrow,INWARD,a,Arc,1000,INWARD,TRUE);

	r = Radius – ScaleHeight + TickGap;

	logval = MinLog + 1.5;
	a = offset + logval * Arc;
	ArcLegend("fF – femtofarad x10^-15",r,a,INWARD);

	logval += 3;
	a = offset + logval * Arc;
	ArcLegend("pF – picofarad x10^-12",r,a,INWARD);

	logval += 2.5; // offset for L/R window;
	a = offset + logval * Arc;
	ArcLegend("nF – nanofarad x10^-9",r,a,INWARD);

	logval += 4; // … likewise
	a = offset + logval * Arc;
	ArcLegend("μF – microfarad x10^-6",r,a,INWARD);

	logval += 2.5; // … restore normal spacing
	a = offset + logval * Arc;
	ArcLegend("mF – millifarad x10^-3",r,a,INWARD);

	r = Radius – ScaleHeight – TickGap – LegendTextSize.y; // into blank space

	logval = MinLog; // scale identifiers
	a = offset + logval * Arc;
	tp = scale(typeset("←— C Scale",TextFont),LegendTextSize);
	tpa = ArcText(tp,[0mm,0mm],r,a,TEXT_RIGHT,INWARD);
	engrave(tpa,TravelZ,EngraveZ);

	logval = MinLog + 6;
	a = offset + logval * Arc;
	tp = scale(typeset("←— C Scale —→",TextFont),LegendTextSize);
	tpa = ArcText(tp,[0mm,0mm],r,a,TEXT_CENTERED,INWARD);
	engrave(tpa,TravelZ,EngraveZ);

	logval = MaxLog;
	a = offset + logval * Arc;
	tp = scale(typeset("C Scale —→",TextFont),LegendTextSize);
	tpa = ArcText(tp,[0mm,0mm],r,a,TEXT_LEFT,INWARD);
	engrave(tpa,TravelZ,EngraveZ);

	comment("Capacitive TC / risetime scale");
	Radius = DeckRad – 4*ScaleHeight;

	MinLog = -12;
	MaxLog = 3;
	Arc = ScaleArc;

	dec = 1;
	offset = 3 * ScaleArc;
	for (logval = MinLog; logval < MaxLog; logval++) {
	a = offset + logval * Arc;
	DrawTicks(Radius,TickScaleNarrow,OUTWARD,a,Arc,dec,INWARD,FALSE);
	dec = (dec == 100) ? 1 : 10 * dec;
	}

	a = offset + MaxLog * Arc;
	DrawTicks(Radius,TickScaleNarrow,OUTWARD,a,Arc,1000,INWARD,TRUE);

	r = Radius + TickMajor + 2*TickGap + LegendTextSize.y;

	logval = MinLog + 1.5;
	a = offset + logval * Arc;
	ArcLegend("ps – picosecond x10^-12",r,a,INWARD);

	logval += 3;
	a = offset + logval * Arc;
	ArcLegend("ns – nanosecond x10^-9",r,a,INWARD);

	logval += 3;
	a = offset + logval * Arc;
	ArcLegend("μs – microsecond x10^-6",r,a,INWARD);

	logval += 3;
	a = offset + logval * Arc;
	ArcLegend("ms – millisecond x10^-3",r,a,INWARD);

	logval += 3;
	a = offset + logval * Arc;
	ArcLegend("s – second",r,a,INWARD);

	r = Radius + TickMajor + TickGap;

	logval = MinLog – ScaleExdent; // scale identifiers
	a = offset + logval * Arc;
	tp = scale(typeset("← τC Scale",TextFont),LegendTextSize);
	tpa = ArcText(tp,[0mm,0mm],r,a,TEXT_LEFT,INWARD);
	engrave(tpa,TravelZ,EngraveZ);

	logval = MaxLog + ScaleExdent;
	a = offset + logval * Arc;
	tp = scale(typeset("τC Scale →",TextFont),LegendTextSize);
	tpa = ArcText(tp,[0mm,0mm],r,a,TEXT_RIGHT,INWARD);
	engrave(tpa,TravelZ,EngraveZ);

	logval = MinLog – 2.5;
	a = offset + logval * Arc;
	tp = scale(typeset("←— τC Scale —→",TextFont),LegendTextSize);
	tpa = ArcText(tp,[0mm,0mm],r,a,TEXT_CENTERED,INWARD);
	engrave(tpa,TravelZ,EngraveZ);

	comment("Inductive frequency scale legend");
	r = DeckRad – ScaleHeight – ScaleTextSize.y;
	a = 58deg; // arbitrary text placement
	ArcLegend("FL Scale",r,a,OUTWARD);

	comment("Index for resonance calculations");
	Index = -(18*ScaleArc + Scale2Pi); // negative to read reciprocal of product

	r = DeckRad – 1.5ScaleHeight + 0.5LegendTextSize.y;
	ArcLegend("Frequency",r,Index,OUTWARD);

	r = DeckRad – ScaleHeight – LegendTextSize.y;
	ArcLegend("⇑",(r – TickGap),Index,INWARD);

	r = DeckRad – 2*ScaleHeight + LegendTextSize.y;
	ArcLegend("⇑",(r + TickGap),Index,OUTWARD);

	r0 = DeckRad – ScaleHeight;
	r1 = r0 – TickMajor;

	goto(r0 * [cos(Index),sin(Index)]);
	move([-,-,EngraveZ]);
	move(r1 * [cos(Index),sin(Index)]);
	goto([-,-,TravelZ]);

	r0 = DeckRad – 2*ScaleHeight;
	r1 = r0 + TickMajor;

	goto(r0 * [cos(Index),sin(Index)]);
	move([-,-,EngraveZ]);
	move(r1 * [cos(Index),sin(Index)]);
	goto([-,-,TravelZ]);


	//—–
	// Draw the attribution

	comment("Attribution begins");

	r = DeckTopOD/2 – 2*ScaleHeight – WindowHeight;
	DrawAttribution(r);

	goto([-,-,SafeZ]); // done, so get out of the way
	goto([0,0,-]);

	comment("Middle deck ends");

	}

	//———-
	// Engrave top deck

	function EngraveTop() {

	// Mark center pivot

	MarkPivot();

	comment("Resistance scale");
	Radius = DeckRad;

	MinLog = -1;
	MaxLog = 8;
	Arc = -ScaleArc;

	dec = 100;
	offset = 0deg;
	for (logval = MinLog; logval < MaxLog; logval++) {
	a = offset + logval * Arc;
	DrawTicks(Radius,TickScaleNarrow,INWARD,a,Arc,dec,INWARD,FALSE);
	dec = (dec == 100) ? 1 : 10 * dec;
	}

	a = offset + MaxLog * Arc;
	DrawTicks(Radius,TickScaleNarrow,INWARD,a,Arc,100,INWARD,TRUE);

	r = Radius – ScaleHeight + TickGap;

	logval = MinLog + 0.5;
	a = offset + logval * Arc;
	ArcLegend("mΩ – milliohm",r,a,INWARD);

	logval = MinLog + 2.5;
	a = offset + logval * Arc;
	ArcLegend("Ω – ohm",r,a,INWARD);

	logval += 3;
	a = offset + logval * Arc;
	ArcLegend("kΩ – kilohm x10^3",r,a,INWARD);

	logval = MaxLog – 1;
	a = offset + logval * Arc;
	ArcLegend("MΩ – megohm x10^6",r,a,INWARD);

	r = Radius – ScaleHeight – TickGap – LegendTextSize.y;

	logval = MinLog + 4;
	a = offset + logval * Arc;
	ArcLegend("←— R XC XL Scale —→",r,a,INWARD);

	comment("Capacitive frequency scale");
	Radius = DeckRad;

	MinLog = 0;
	MaxLog = 9;
	Arc = ScaleArc;

	dec = 1;
	offset = 18 * -ScaleArc;
	for (logval = MinLog; logval < MaxLog; logval++) {
	a = offset + logval * Arc;
	DrawTicks(Radius,TickScaleNarrow,INWARD,a,Arc,dec,OUTWARD,FALSE);
	dec = (dec == 100) ? 1 : 10 * dec;
	}

	a = offset + MaxLog * Arc;
	DrawTicks(Radius,TickScaleNarrow,INWARD,a,Arc,1000,OUTWARD,TRUE);

	r = Radius – (TickMajor + 2*TickGap + LegendTextSize.y);

	logval = MinLog + 1.5;

	a = offset + logval * Arc;
	ArcLegend("Hz – hertz",r,a,OUTWARD);

	logval += 3;
	a = offset + logval * Arc;
	ArcLegend("kHz – kilohertz x10^3",r,a,OUTWARD);

	logval += 3;
	a = offset + logval * Arc;
	ArcLegend("MHz – megahertz x10^6",r,a,OUTWARD);

	r = Radius – ScaleHeight – TickGap – LegendTextSize.y;

	logval = MaxLog – 3;
	a = offset + logval * Arc;
	ArcLegend("←— FC Scale —→",r,a,OUTWARD);

	comment("RC Circuit Pointers");

	local ctr = [0mm,0mm];

	r0 = DeckRad – 2*ScaleHeight;
	r1 = r0 – ScaleHeight;

	a = -(17 * ScaleArc);

	goto(r0 * [cos(a),sin(a)]);
	move([-,-,EngraveZ]);
	move(r1 * [cos(a),sin(a)]);
	goto([-,-,TravelZ]);
	ArcLegend("⇓",(r0 – TickGap),a,OUTWARD);

	RadialLegend(" Time Constant",ctr,r1,a,TEXT_LEFT,INWARD,-0.5);

	a += ScaleRT;

	goto(r0 * [cos(a),sin(a)]);
	move([-,-,EngraveZ]);
	move(r1 * [cos(a),sin(a)]);
	goto([-,-,TravelZ]);
	ArcLegend("⇓",(r0 – TickGap),a,OUTWARD);

	RadialLegend(" Risetime",ctr,r1,a,TEXT_LEFT,INWARD,-0.5);

	a -= ScaleRT/2;

	RadialLegend(" RC",ctr,r0 – 2*ScaleTextSize.y,a,TEXT_LEFT,INWARD,-0.5);

	comment("L/R Circuit Pointers");

	r0 = DeckRad;
	r1 = r0 – ScaleHeight;

	a = -TauAngle;

	goto(r0 * [cos(a),sin(a)]);
	move([-,-,EngraveZ]);
	move(r1 * [cos(a),sin(a)]);
	goto([-,-,TravelZ]);
	ArcLegend("⇓",(r0 – TickGap),a,OUTWARD);

	RadialLegend("Time Constant ",ctr,r1,a,TEXT_RIGHT,OUTWARD,-0.5);

	a -= ScaleRT;

	goto(r0 * [cos(a),sin(a)]);
	move([-,-,EngraveZ]);
	move(r1 * [cos(a),sin(a)]);
	goto([-,-,TravelZ]);
	ArcLegend("⇓",(r0 – TickGap),a,OUTWARD);

	RadialLegend("Risetime ",ctr,r1,a,TEXT_RIGHT,OUTWARD,-0.5);

	a += ScaleRT/2;

	RadialLegend("L/R ",ctr,r0 – 2*ScaleTextSize.y,a,TEXT_RIGHT,OUTWARD,-0.5);

	comment("Title and logo");

	feedrate(TextSpeed);

	r = 0.65*DeckRad;
	tp = scale(typeset("Homage",TextFont),TitleTextSize);
	tpa = ArcText(tp,[0mm,0mm],r,TitleAngle,TEXT_CENTERED,INWARD);
	engrave(tpa,TravelZ,EngraveZ);

	r -= 1.5*TitleTextSize.y;
	tp = scale(typeset("Tektronix",TextFont),TitleTextSize);
	tpa = ArcText(tp,[0mm,0mm],r,TitleAngle,TEXT_CENTERED,INWARD);
	engrave(tpa,TravelZ,EngraveZ);

	r -= 1.5*TitleTextSize.y;
	tp = scale(typeset("Circuit Computer",TextFont),TitleTextSize);
	tpa = ArcText(tp,[0mm,0mm],r,TitleAngle,TEXT_CENTERED,INWARD);
	engrave(tpa,TravelZ,EngraveZ);

	r -= 1.5*TitleTextSize.y;
	if (TRUE) {
	tp = scale(typeset("TEK 003-023",TextFont),LegendTextSize);
	}
	else {
	tp = scale(typeset("https://vintagetek.org/tektronix-circuit-computer/",TextFont),LegendTextSize);
	}
	tpa = ArcText(tp,[0mm,0mm],r,TitleAngle,TEXT_CENTERED,INWARD);
	engrave(tpa,TravelZ,EngraveZ);

	r = 0.3*DeckRad;
	a = TitleAngle + 180deg;
	tp = scale(typeset("Ed Nisley",TextFont),LegendTextSize);
	tpa = ArcText(tp,[0mm,0mm],r,a,TEXT_CENTERED,OUTWARD);
	engrave(tpa,TravelZ,EngraveZ);

	r += 1.5*TitleTextSize.y;
	tp = scale(typeset("KE4ZNU",TextFont),LegendTextSize);
	tpa = ArcText(tp,[0mm,0mm],r,a,TEXT_CENTERED,OUTWARD);
	engrave(tpa,TravelZ,EngraveZ);

	r += 1.5*TitleTextSize.y;
	tp = scale(typeset("softsolder.com",TextFont),LegendTextSize);
	tpa = ArcText(tp,[0mm,0mm],r,a,TEXT_CENTERED,OUTWARD);
	engrave(tpa,TravelZ,EngraveZ);

	goto([-,-,SafeZ]); // done, so get out of the way
	goto([0,0,-]);

	comment("Top deck ends");

	}

	//———-
	// Engrave cursor hairline

	function EngraveCursor() {

	// Mark center pivot

	MarkPivot();

	comment("Cursor hairline");

	feedrate(ScaleSpeed);

	goto([-,-,TravelZ]);

	repeat(2) {
	goto([DeckTopOD/2 – 2.25*ScaleHeight,0,-]); // slight overlap on arrows
	move([-,-,EngraveZ]);
	move([DeckBottomOD/2 + ScaleHeight,0,-]);
	goto([-,-,TravelZ]);
	}

	goto([-,-,SafeZ]); // done, so get out of the way
	goto([0,0,-]);

	}

	//—————————————————————————–
	// Deck milling
	// Assumes adhesive clamping to avoid protrusions above work area

	//—–
	// Bottom deck

	function MillBottom() {
	comment("Mill Bottom");

	feedrate(KnifeSpeed);

	goto([-,-,TravelZ]);

	local r = PivotOD/2;
	goto([0,r,-]); // entry move to align knife
	arc_cw([r,0,0],r); // blade enters surface

	move([-,-,KnifeZ]); // apply cutting force
	circle_cw([0,0]);
	arc_cw([0,-r],r); // cut past entry point
	goto([-,-,TravelZ]);

	r = DeckRad;
	local a = 5deg;
	local p0 = r * [cos(a),sin(a),-]; // entry point
	local p1 = r * [cos(-a),sin(-a),-]; // exit point

	goto(p0);
	arc_cw([r,0,0],r); // blade enters surface

	move([-,-,KnifeZ]); // apply cutting force
	circle_cw([0,0]); // cut circle

	arc_cw(p1,r); // cut past entry point
	goto([-,-,TravelZ]);

	goto([0,0,-]);
	goto([-,-,SafeZ]);

	}

	//—–
	// Middle deck

	function MillMiddle() {

	FLNotchArc = 85deg; // width exposing FL scale
	FLRampArc = 7deg; // … width of entry & exit ramps
	FLNotchOffset = 2deg; // … start angle from 0°

	comment("Mill Middle");

	feedrate(KnifeSpeed);

	goto([-,-,TravelZ]);

	local r = PivotOD/2;
	goto([0,r,-]); // entry move to align knife
	arc_cw([r,0,0],r); // blade enters surface

	move([-,-,KnifeZ]); // apply cutting force
	circle_cw([0,0]);
	arc_cw([0,-r],r); // cut past entry point
	goto([-,-,TravelZ]);

	// FL scale notch

	local r0 = DeckRad;
	local a0 = FLNotchOffset; // end of notch ramp
	local p0 = r0 * [cos(a0),sin(a0),-];

	local a1 = a0 + FLNotchArc; // start of notch ramp
	local p1 = r0 * [cos(a1),sin(a1),-];

	goto(p0);
	arc_cw([r0,0,0],r0); // blade enters surface
	move([-,-,KnifeZ]); // apply cutting force
	arc_cw(p1,-r0); // largest arc to start of notch

	local r1 = r0 – ScaleHeight;
	local a3 = a1 – FLRampArc; // start of notch base
	local p3 = r1 * [cos(a3),sin(a3),-];

	local a4 = a0 + FLRampArc; // end of notch base
	local p4 = r1 * [cos(a4),sin(a4),-];

	move(p3);
	arc_cw(p4,r1); // smallest arc on notch base

	move(p0); // end of notch ramp
	arc_cw([r0,0,-],r0); // round off corner

	local p5 = r0 * [cos(-a0),sin(-a0),-]; // small overtravel past entry point
	arc_cw(p5,r0);

	goto([-,-,TravelZ]);

	// L/R τ and RT Scale window

	local WindowArc = 39deg;

	ac = -6 * ScaleArc; // center of window arc
	r0 = DeckRad – ScaleHeight; // outer
	r1 = DeckRad – 2 * ScaleHeight; // inner

	aw = WindowArc – to_deg(atan(ScaleHeight,(r0 + r1)/2)); // window arc minus endcaps

	p0 = r0 * [cos(ac + aw/2),sin(ac + aw/2),-]; // endcap entry & exit
	p1 = r0 * [cos(ac – aw/2),sin(ac – aw/2),-];
	p2 = r1 * [cos(ac – aw/2),sin(ac – aw/2),-];
	p3 = r1 * [cos(ac + aw/2),sin(ac + aw/2),-];

	goto(p3); // cut entry point
	arc_cw(p0 +\| [-,-,0],ScaleHeight/2); // blade enters surface
	move([-,-,KnifeZ]); // apply pressure

	arc_cw(p1,r0); // smallest arc
	arc_cw(p2,ScaleHeight/2); // half a circle
	arc_ccw(p3,r1);
	arc_cw(p0,ScaleHeight/2);

	arc_cw(p1 +\| [-,-,TravelZ],r0); // exit from cut

	goto([0,0,-]);
	goto([-,-,SafeZ]);

	}


	//—–
	// Top deck

	function MillTop() {
	comment("Mill Top");

	feedrate(KnifeSpeed);

	goto([-,-,TravelZ]);

	local r = PivotOD/2;
	goto([0,r,-]); // entry move to align knife
	arc_cw([r,0,0],r); // blade enters surface

	move([-,-,KnifeZ]); // apply cutting force
	circle_cw([0,0]);
	arc_cw([0,-r],r); // cut past entry point
	goto([-,-,TravelZ]);

	r = DeckRad;
	local a = 5deg;
	local p0 = r * [cos(a),sin(a),-]; // entry point
	local p1 = r * [cos(-a),sin(-a),-]; // exit point

	goto(p0);
	arc_cw([r,0,0],r); // blade enters surface

	move([-,-,KnifeZ]); // apply cutting force
	circle_cw([0,0]); // cut circle

	arc_cw(p1,r); // cut past entry point
	goto([-,-,TravelZ]);

	// RC τ and RT Scale window

	local WindowArc = 54deg;

	local ac = -17 * ScaleArc + ScaleRT/2; // center of window arc
	local r0 = DeckRad – ScaleHeight; // outer
	local r1 = DeckRad – 2 * ScaleHeight; // inner

	local aw = WindowArc – to_deg(atan(ScaleHeight,(r0 + r1)/2)); // window arc minus endcaps

	p0 = r0 * [cos(ac + aw/2),sin(ac + aw/2),-];
	p1 = r0 * [cos(ac – aw/2),sin(ac – aw/2),-];
	local p2 = r1 * [cos(ac – aw/2),sin(ac – aw/2),-];
	local p3 = r1 * [cos(ac + aw/2),sin(ac + aw/2),-];

	goto(p3);
	arc_cw(p0 +\| [-,-,0],ScaleHeight/2); // blade enters surface
	move([-,-,KnifeZ]); // apply pressure

	arc_cw(p1,r0); // smallest arc
	arc_cw(p2,ScaleHeight/2); // half a circle
	arc_ccw(p3,r1);
	arc_cw(p0,ScaleHeight/2);

	arc_cw(p1 +\| [-,-,TravelZ],r0); // exit from cut

	goto([0,0,-]);
	goto([-,-,SafeZ]);


	}

	//———-
	// Cut cursor outline

	CursorHubOD = 1.0in;
	CursorTipWidth = to_inch(9.0/16.0);
	CursorTipRadius = to_inch(1.0/16.0);

	function MillCursor() {

	// Mark center pivot

	MarkPivot();

	comment("Cursor outline");

	local dr = DeckBottomOD/2;
	local hr = CursorHubOD/2;
	local a = atan(hr – CursorTipWidth/2,dr); // rough & ready approximation

	local p0 = hr * [sin(a),cos(a),-]; // upper tangent point on hub

	local c1 = [dr – CursorTipRadius,CursorTipWidth/2 – CursorTipRadius*cos(a),-];
	local p1 = c1 + [CursorTipRadiussin(a),CursorTipRadiuscos(a),-];

	local p2 = c1 + [CursorTipRadius,0,-]; // around tip radius

	feedrate(KnifeSpeed);

	goto([-,-,TravelZ]);
	goto([-hr,0,-]);
	move([-,-,EngraveZ]);

	repeat(3) {
	arc_cw(p0,hr);
	move(p1);
	arc_cw(p2,CursorTipRadius);

	move([p2.x,-p2.y,-]);
	arc_cw([p1.x,-p1.y,-],CursorTipRadius);
	move([p0.x,-p0.y,-]);
	arc_cw([-hr,0,-],hr);
	}

	goto([-,-,SafeZ]); // done, so get out of the way
	goto([0,0,-]);

	}

	//—————————————————————————–
	// The actual machining sequences!

	//—–
	// Bottom Deck

	if (SelectPart == "Bottom") {

	DeckOD = DeckBottomOD;
	DeckRad = DeckOD / 2;

	comment(" OD: ",DeckOD);

	if (Operation == "Engrave") {
	EngraveBottom();
	}
	elif (Operation == "Mill") {
	MillBottom();
	}
	else {
	error("Invalid operation: ",Operation);
	}


	}

	//——
	// Middle Deck

	if (SelectPart == "Middle") {

	DeckOD = DeckMiddleOD;
	DeckRad = DeckOD / 2;

	comment(" OD: ",DeckOD);

	if (Operation == "Engrave") {
	EngraveMiddle();
	}
	elif (Operation == "Mill") {
	MillMiddle();
	}
	else {
	error("Invalid operation: ",Operation);
	}

	}

	//—–
	// Top Deck

	if (SelectPart == "Top") {

	DeckOD = DeckTopOD;
	DeckRad = DeckOD / 2;

	comment(" OD: ",DeckOD);

	if (Operation == "Engrave") {
	EngraveTop();
	}
	elif (Operation == "Mill") {
	MillTop();
	}
	else {
	error("Invalid operation: ",Operation);
	}

	}

	//—–
	// Cursor

	if (SelectPart == "Cursor") {

	DeckOD = DeckBottomOD;
	DeckRad = DeckOD / 2;

	comment(" OD: ",DeckOD);

	if (Operation == "Engrave") {
	EngraveCursor();
	}
	elif (Operation == "Mill") {
	MillCursor();
	}
	else {
	error("Invalid operation: ",Operation);
	}

	}

view raw Tek Circuit Computer.gcmc hosted with ❤ by GitHub

	#!/bin/bash
	# Tek Circuit Computer Engraving
	# Ed Nisley KE4ZNU – 2019-11

	#OD='BaseOD=118mm' # CD = 120
	#OD='BaseOD=93mm' # hard drive = 95mm
	#EZ='EngraveZ=-5mm' # Engraving Z

	Flags='-P 3 –pedantic' # avoid leading hyphen gotcha

	# Set these to match your file layout

	ProjPath='/mnt/bulkdata/Project Files/Tektronix Circuit Computer/Firmware'

	LibPath='/opt/gcmc/library'

	Prolog='prolog.gcmc'
	Epilog='epilog.gcmc'

	ScriptPath=$ProjPath
	Script='Tek Circuit Computer.gcmc'

	#—–
	# params: deck operation

	function Runit {

	fn=TekCC-${1}-${2}.ngc
	echo "(File: "$fn")" > $fn

	sel='SelectPart="'$1'"'
	op='Operation="'$2'"'

	echo Output: $fn
	echo " "$sel
	echo " "$op

	if [ -e $fn ]
	then rm -f $fn
	fi

	gcmc -D "$OD" -D "$EZ" \
	-D "$sel" -D "$op" $Flags \
	–include "$LibPath" –prologue "$Prolog" –epilogue "$Epilog" \
	"$ScriptPath"/"$Script" >> "$fn"

	}

	#—–

	Runit Bottom Engrave
	Runit Bottom Mill

	Runit Middle Engrave
	Runit Middle Mill

	Runit Top Engrave
	Runit Top Mill

	Runit Cursor Engrave
	Runit Cursor Mill

view raw TekCC.sh hosted with ❤ by GitHub

2019-12-23

Tek Circuit Computer: Drag Knife Deck Cutting
Creating a paper version of the Tektronix Circuit Computer requires nothing more than a drag knife to cut the deck outlines:

Tek Circuit Computer – cursor hairline

The middle deck is a disk with a notch exposing the FL scale, a cutout window exposing the inductive time constant / risetime scale, and a wee circle for the Chicago screw in the middle:

Tek CC – middle deck outline

Three angles define the notch:
```
  FLNotchArc = 85deg;                   // width exposing FL scale
  FLRampArc = 7deg;                     // … width of entry & exit ramps
  FLNotchOffset = 2deg;                 // … start angle from 0°
```
Given those, along with the deck radius and notch height (equals the underlying scale height), calculate four points defining the start and end of the ramps and connect the dots:
```
  local a0 = FLNotchOffset;
  local p0 = DeckRad * [cos(a0),sin(a0),-];

  local a1 = a0 + FLNotchArc;
  local p1 = DeckRad * [cos(a1),sin(a1),-];

  goto(p0);
  move([-,-,KnifeZ]);
  arc_cw(p1,-DeckRad);          // largest arc

  local r = DeckRad - ScaleHeight;
  local a3 = a1 - FLRampArc;
  local p3 = r * [cos(a3),sin(a3),-];

  local a4 = a0 + FLRampArc;
  local p4 = r * [cos(a4),sin(a4),-];

  move(p3);
  arc_cw(p4,r);                 // smallest arc

  move(p0);                     // end of notch

  arc_cw([DeckRad,0,-],DeckRad);      // round off corner
```
The arc_cw() functions draw arcs, as you’d expect, with a positive radius tracing the shortest arc and a negative radius for the longest arc. Although I know how that works, I must still preview the result to verify the G-Code does what I want, not what I said.

The unhappy result of a wrong sign:

Tek CC – middle deck outline – wrong arc sign

GCMC uses the (signed) radius to generate the XY coordinates and IJ offsets for G2 commands in the preferred center format:
```
G0 X88.846 Y3.103
G1 Z-2.000
G2 X4.653 Y88.778 I-88.846 J-3.103
```
Cutting the window starts from its angular width and offset, which are hardcoded magic numbers from the Tek artifact, and proceeds similarly:
```
  local WindowArc = 39deg;

  local ac = -6 * ScaleArc;                  // center of window arc
  local r0 = DeckRad - ScaleHeight;         // outer
  local r1 = DeckRad - 2 * ScaleHeight;     // inner

  local aw = WindowArc - to_deg(atan(ScaleHeight,(r0 + r1)/2));    // window arc minus endcaps

  local p0 = r0 * [cos(ac + aw/2),sin(ac + aw/2),-];
  local p1 = r0 * [cos(ac - aw/2),sin(ac - aw/2),-];
  local p2 = r1 * [cos(ac - aw/2),sin(ac - aw/2),-];
  local p3 = r1 * [cos(ac + aw/2),sin(ac + aw/2),-];

  goto(p0);
  move([-,-,KnifeZ]);

  arc_cw(p1,r0);                          // smallest arc
  arc_cw(p2,ScaleHeight/2);               // half a circle
  arc_ccw(p3,r1);
  arc_cw(p0,ScaleHeight/2);
```
Trust me on this: incorrect radius signs generate unrecognizable outlines. Which, of course, is why you preview the G-Code before actually cutting anything:

Tek CC – MPCNC drag knife

A similar hunk of code cuts the top deck; the bottom deck is a simple circle.

The workflow, such as it is:
- Tape a sheet of paper (Index stock, Basis 110 = 10 mil = 0.25 mm) at the center of the 3018-ProXL platform
- Plot (“engrave”) the scales with a pen
- Affix paper to a Cricut sticky mat taped to the MPCNC platform
- Touch off the origin at the middle
- Drag-cut (“mill”) the outlines
Less complex than it may appear, but the GCMC file now spits out two G-Code files per deck: one to engrave / draw the scales on the 3018 and another to mill / cut the outlines on the MPCNC.
2019-12-09
Tek Circuit Computer: Acrylic Cursor Hairline
A slide rule needs a cursor with a hairline to align numbers on its scales:

Tek Circuit Computer – cursor hairline

The GCMC code generating the hairline is basically a move scratching one line into the surface with the diamond bit:
```
  feedrate(ScaleSpeed);

  goto([-,-,TravelZ]);

  repeat(2) {
    goto([DeckTopOD/2 - 3*ScaleHeight,0,-]);
    move([-,-,EngraveZ]);
    move([DeckBottomOD/2 + ScaleHeight,0,-]);
    goto([-,-,TravelZ]);
  }
```
Two passes make the scratch deep enough to hold engraving crayon / lacquer / ink, without making it much wider. Laser engraving would surely work better.

In lieu of actually milling the cursor, this code scratches the perimeter:
```
  local dr = DeckBottomOD/2;
  local hr = CursorHubOD/2;
  local a = atan(hr - CursorTipWidth/2,dr);   // rough & ready approximation

  local p0 = hr * [sin(a),cos(a),-];          // upper tangent point on hub

  local c1 = [dr - CursorTipRadius,CursorTipWidth/2 - CursorTipRadius*cos(a),-];
  local p1 = c1 + [CursorTipRadius*sin(a),CursorTipRadius*cos(a),-];

  local p2 = c1 + [CursorTipRadius,0,-];      // around tip radius

  feedrate(KnifeSpeed);

  goto([-,-,TravelZ]);
  goto([-hr,0,-]);
  move([-,-,EngraveZ]);

  repeat(3) {
    arc_cw(p0,hr);
    move(p1);
    arc_cw(p2,CursorTipRadius);

    move([p2.x,-p2.y,-]);
    arc_cw([p1.x,-p1.y,-],CursorTipRadius);
    move([p0.x,-p0.y,-]);
    arc_cw([-hr,0,-],hr);
  }
```
Three passes makes it deep enough to snap along the line:

Tektronix Circuit Computer – cursor outline

If you look closely, though, you’ll find a little divot over on the left along the bottom edge, so I really must machine the thing.

Were I to go into production, I’d have to figure out a fixture, but I think I can just clamp a rough-cut acrylic rectangle to the Sherline’s table, mill half the perimeter, re-clamp without moving anything, then mill the other half.

Subtractive machining is such a bother!

The pivot holding the cursor and decks together is a “Chicago screw“, a.k.a. a “sex bolt“. I am not making this up.
2019-12-05