Spinning Top

This part named “Spinning Top” will have profiling on the OD (Outside Diameter).

  1. Select MODE to get to the control’s Main Menu.
  2. From the Main Menu – select DRO to enter manual operation mode.

To make the part, we are going to separate it into two sections as shown below. This approach is due to part and tool geometry. The right-hand face tool that will be used for turning operation cannot perform undercuts defined by the part.

We will start by machining Side A profile.

The following are steps for machining Side A.

Step 1 – Setting Raw Material

  • Calibrate the right-hand face tool (tool #1) and the cut-off tool (tool #6) as specified in Setting Up Tools Tutorial.
  • Obtain 1” diameter aluminum stock from stock area, about 3” long.
  • Hold stock in 1” collet and secure collet on chuck using ratchet. About 1.5” stock should stick out from collet/chuck. Use a chuck key to secure collet firmly.
  • Select tool #1 by pressing tool # soft key then enter [1] and press Abs Set.
  • Press Spin Speed, enter [1000], and press Inc Set to set the spindle speed to 1000 revolutions per minute (RPM)

  • Turn on spindle and face part as demonstrated in Setting Up Tools Tutorial and set Z = 0 on faced side
  • Move tool away from part and turn off spindle

Now we move on to the process of defining the part contour.

This step resembles an “Etch-A-Sketch” like process of identifying the endpoints of line segments that define our contour.

Note that Z coordinates are negative and X coordinates are given by the diameter of the part.

We will utilize the DO ONE and GO TO functions to machine the part profile.  Under DO ONE function list, we will use the TAPER, RADIUS, and FILLET functions.

TAPER function enables user to machine a positive angle between two points by positioning tool at one point and entering the angle value on the screen prompt. To machine, the user turns the hand wheels with Z hand wheel for coarse feed and X hand wheel for fine feed.

RADIUS function enables user to machine a radius, positive or negative, by positioning tool on one point and specifying radius value on screen prompt. User has to use hand wheels as in the TAPER function operation.

FILLET function enables user to machine a fillet by positioning tool at one point then defining a radius on the screen prompt.

Step 2 – Machining Side A Profile

Since we are using manual operations, the following steps will be iterative. Nonetheless, they require the machinist to observe discipline by verifying instructions prior to machining.

  • Press GO TO, then press x coordinate key. Enter [0.19] and press Abs Set. Press z coordinate, enter [-0.375], and press Abs Set.
  • Start Spindle and move tool to Z = 0.2, X = 1.000 by turning the hand wheels. Ensure jog keys are set to fine feed by pressing F key on the computer panel.
  • Turn 0.04” increment in the –X direction to about 0.96”.
  • Turn Z hand wheel to machine along the z direction to the set Z GO TO limit of -0.375.
  • With the spindle spinning. Press RETURN to exit GO TO function.
  • Press DO ONE FILLET then enter [0.125] and press Abs Set to set the fillet radius.
  • Turn the X hand wheel clockwise to machine fillet. Turn hand wheel until tool stops moving.
  • Press RETURN twice.
  • Move tool away from part in +Z direction to about Z = 0.5 or until tool is clear off part in the Z direction.
  • Press GO TO function and turn z hand wheel make another 0.04” decrement in the –X direction from last machined position. For instance, move tool to X = 0.92 for the second cut.
  • Repeat steps 4 to 9 until the set X GO TO limits. NOTE: Spindle should be spinning whenever tool is in contact with part to preserve tool life and minimize damage to tool holder. Move tool away from part in case you pause operations. 

Step 3 – Machining Chamfer

To machine the chamfer at the edge of Side A, we will use the TAPER function.

  • Press GO TO, then press x coordinate key. Enter [0.15] and press Abs Set. Press z coordinate, enter [0], and press Abs Set.
  • Start Spindle and move tool to Z = 0, X = 0.15 by turning the hand wheels. Ensure jog keys are set to fine feed by pressing F key on the computer panel.
  • Press RETURN to exit GO TO function.
  • Press DO ONE TAPER then enter [45] to set chamfer angle to 45 degrees.
  • Turn the X hand wheel clockwise to machine fillet. Turn hand wheel until tool clears the part.
  • Press RETURN, move tool away from part, and stop the spindle

Using a micrometer, inspect the final diameter of side A.

Step 4 – Cutting Off Part

We are going to cut off the part from the stock material.

  • Mount cut-off tool (tool #6) on the tool holder.
  • Select tool #6 by pressing tool # soft key then enter [6] and press Abs Set.
  • Press Spin Speed, enter [1000], and press Inc Set to set the spindle speed to 1000 revolutions per minute (RPM)
  • Press GO TO then press x coordinate key. Enter [0] and press Abs Set. Press z coordinate, enter [-0.9], and pressAbs Set. We aim to cut-off a slightly larger part than given dimensions then turn it to accurate size in the succeeding steps.
  • Start Spindle and move tool to Z = -0.9, X = 1.2 by turning the hand wheels. Ensure jog keys are set to fine feed by pressing F key on the computer panel.
  • Turn on coolant by pressing the accessory key on the computer, then adjust the coolant jet to the cutting edge of the tool. Use the tap at the base of the coolant pipe to regulate flow.
  • Turn the X hand wheel ONLY to cut off part. Turn hand wheel continuously at a moderate rate.
  • After part falls off, move tool away from the chuck then stop the spindle

The following are steps for machining Side B.

Step 5 – Setting Raw Material

  • Remove collet from chuck using the ratchet. NOTE: You may have to use the chuck key to loosen the collet before using the ratchet.
  • Hold Side A of part in a 13/64” collet and secure collet on chuck using ratchet. Side not machined should stick out from collet/chuck. Use a chuck key to secure collet firmly.
  • Select tool #1 by pressing tool # soft key then enter [1] and press Abs Set.
  • Press Spin Speed, enter [1000], and press Inc Set to set the spindle speed to 1000 revolutions per minute (RPM)
  • Start spindle and touch off tool #1 on the side sticking out and set Z = 0. Recall, that size of part that was cut off is 0.9”.
  • Press GO TO then press x coordinate key. Enter [0] and press Abs Set. Press z coordinate, enter [-0.25], and pressAbs Set. We aim to cut-off excess material and dimension part as specified on part drawing.
  • Start Spindle and move tool to Z = -0.03, X = 1.2 by turning the hand wheels. Ensure jog keys are set to fine feed by pressing F key on the computer panel.
  • Turn the X hand wheel ONLY to face off part to X = 0. Turn hand wheel continuously at a slow rate.
  • Move tool away from part in +X direction to about X = 1.2 then make another 0.03” increment along –Z direction to about Z = -0.06. Turn the X hand wheel ONLY to face off part to X = 0. Turn hand wheel continuously at a slow rate. Repeat this to the set Z GO TO limit.
  • After last pass, press RETURN to exit GO TO function then press Z coordinate key and enter [0] and press Abs Set. This sets a new origin for the part. 
  • Move tool away from part and stop the spindle.

Step 6 – Machining Tapered Side

To machine Side B, we will use the TAPER function.

  • Press GO TO, then press x coordinate key. Enter [0] and press Abs Set. Press z coordinate, enter [0], and pressAbs Set.
  • Start Spindle and move tool to Z = 0, X = 0.96 by turning the hand wheels. Ensure jog keys are set to fine feed by pressing F key on the computer panel.
  • Press RETURN to exit GO TO function.
  • Press DO ONE TAPER then enter [57.987] to set chamfer angle to 57.987 degrees.
  • Turn the X hand wheel clockwise to machine fillet. Turn hand wheel until tool clears the part.
  • Press RETURN to exit DO ONE function.
  • Move tool away from part in +Z direction to about Z = 0.2 then make another 0.03” increment along –X direction to about X = 0.92.
  • Press GO TO and move tool to X = 0.92, Z = 0.
  • Repeat steps 3 to 7 to the set GO TO limits i.e. X = 0, Z = 0.

Step 6 – Machining 0.05 corner radius

To machine the Conrad, we will use the RADIUS function.

  • Press GO TO, then press x coordinate key. Enter [0.85] and press Abs Set. Press z coordinate, enter [-0.2826], and press Abs Set.
  • Start Spindle and move tool to Z = -0.2826, X = 0.85 by turning the hand wheels. Ensure jog keys are set to fine feed by pressing F key on the computer panel.
  • Press RETURN to exit GO TO function.
  • Press DO ONE RADIUS then enter [0.05] to set radius dimension.
  • Turn the X hand wheel clockwise to machine fillet. Turn hand wheel until tool clears the part.
  • RETURN to exit DO ONE function.
  • Move tool away from part and stop the spindle.
  • Inspect the part and make any adjustments

Your part is ready.

Reference

(TRAK TRL SX Lathes, PROTOTRAK SLX CNC - Safety, Programming, Operating and Care Manual)

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