Part with Arc Profile

For milling operations follow these steps and machine the part as shown: 

  1. Get a 4” x .25” Aluminum 6061 from the stock area. Cut the stock to about 4” on the Italian saw and deburr the cut piece using the Belt Sander.
  2. Make sure the Mill is in clean condition and ready for use. Follow the Maintenance and Cleaning Steps tapped on the side of each mill in the Machine Shop.
  3. Locate the saw cut piece in the milling machine vise so that about 1/4” is sticking out from the edge of the right hand jaw on the vise.
  4. Load a 2 - Flute 1/2” End Mill and Climb mill 0.03 from the side of the part sticking out of the vise.
  5. Remove the piece from the vise and remove any burs with a file. 
  6. If you have a piece of material that has smooth factory edges on the long side of the part proceed to step #10 if not continue to step #7
  7. Clean the inside faces of the vise jaws and the bottom of the vise with a paper towel and then clamp the part back into the vise with the side you machined in step #4  located on the bottom of the part.
  8.  Machine the top surface of the part with the face of the end mill 
  9. Remove the part from the vise and remove any burrs with a file.
  10. Place the part back into the vise atop 2 parallels with the two flat and parallel surfaces against the front and back vise jaws. (make sure that when the part is resting on the parallels there is at least 1/8” above the top surface of the vise jaws).  Ensure at least 2 inches of the part is sticking out to the right of the vice.
  11. Alternatively, you can clamp the part to a sacrificial plate.
  12. Edge find the upper left corner of the work piece. Set the X axis edge of the part at X=0. Set the Y axis edge of the part at Y=0. Make sure to correct these values for the radius of the edge finder (add or subtract 0.1”).
  13. Setting the tool parameters:
  • MODE – SET UP – TOOL TABLE
    • Since the program will be set to run with tool #1, scroll using DATA UP or DATA DOWN to get to tool #1.
    • Type 0.25 then press ABS SET.
    • Type 4 for Finish End Mill and press ABS SET
    • Return to DRO and load the 2-Flute 1/4” End Mill.
    • Set Z origin on the top surface of the part by touching off the base of the tool against the surface and type Z = 0 then press ABS SET.

    14. Erasing old program in memory (if one exists):

  • MODE – EDIT – ERASE PROG- YES

    15. Make sure the mill is in 2 axis mode. If in 3 axis, press SYS – GO TO 2 AXIS – MODE

    16. Programming the single mill pocket event:

  • PROG – GO TO BEGIN – ARC
    • For “X Begin”, type 2.797 and press ABS SET
    • For “Y Begin”, type and press ABS SET
    • For “X End”, type 3.073 and press ABS SET
    • For “Y End”, type -.917 and press ABS SET
    • For “X Center”, type 2.797 and press ABS SET
    • For “Y Center”, type -.5 and press ABS SET
    • For “Conrad”, In our case we have a milling event to connect, therefore type 0 and press ABS SET
    • For “Direction”, type 1 for clockwise and press ABS SET
    • For “Tool Offset”, type 2 to offset to the left of the path then press ABS SET
    • For “RPM” type 3000 and press ABS SET
    • For “Feed rate”, type 6 and press ABS SET
    • For “Tool #”, type 1 then press ABS SET
    • For “Continue”, type 1 for yes and press ABS SET
    • Press LOOK to confirm profile

    17. Program the mill event:

  • CONTINUE MILL
  • For “X Begin”, type 0 and press INC SET (0 Inc set allows to start where we left the last event on the x axis)
  • For “Y Begin”, type 0 and press INC SET (0 Inc set allows to start where we left the last event on the y axis)
  • For “X End”, type 0.709 and press ABS SET
  • For “Y End”, type -2.485 and press ABS SET
  • For “Conrad”, In our case we have a milling event to connect, therefore type 0 and press ABS SET
  • For “Continue”, type 1 for Yes and press ABS SET
  • Press LOOK to confirm profile

    18. Program the final mill event:

  • CONTIN MILL
  • For “X End”, type -0.5 and press ABS SET. This will ensure the mill will cut all the way through the end of the part. 
  • For “Y End”, type -2.485 and press ABS SET
  • For “Continue”, type 2 for No and press ABS SET
  • Press LOOK to confirm profile

    19. Checking tool path exists:

  • MODE – SET UP- TOOL PATH Note: Consult a TA or instructor if an error message occurs

    20. Conducting a trial run: (Note: The spindle must be retracted from the part surface before carrying out the trial run)

  • Close guard doors.
  • Click MODE – RUN – TRIAL RUN – GO
  • Ensure that the machine follows the correct tool path, and that THE TOOL WILL NOT CRASH INTO THE VICE DURING THE PROGRAM

    21. Running the program:

  • Close guard doors
  • MODE – RUN – START - GO
  • Start the spindle, adjust the air then press GO for “CNC RUN”. Note: Pressing TRACKING overrides automated control, enabling user to mill manually by turning the electronic hand wheels.
  • When prompted to SET Z, move the spindle down to z = -0.125” and lock the quill.
  • Press GO to run the program.
  • Raise the spindle when program prompted to CHECK Z, then press GO.
  • Rerun the program and move spindle down to Z =-0.26” when prompted to SET Z.
  • Turn off spindle and air then inspect part.
  • Un-clamp part and use a Deburring Toolor file to remove burrs from machined edges.
  • Your part is ready for inspection
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