ET 349 LABORATORY
4th AXIS POSITIONING: HEX FLATS

PURPOSE:
The purpose of this laboratory exercise is to introduce students to 4th axis machining using the positional indexing method .
CAM software will be used to produce a hexagonal shaped hub by 6 milling flats indexed at 60 degrees .  A 3D parametric file
in IGES format will be provided.  Additional steps will include making editorial changes, creating the appropriate tool paths,
generating CNC programs, simulating the program execution, and producing a final part on the HAAS VF1 vertical milling machine
equipped with a HAAS HRT 210 Rotary Table.  Illustration 1 shows a view of the project to be completed.
 

              Mount circular hub to shaft and mill flats at 60 degree intervals
 

Illustration 1:  Steps in producing the hexagonal hub for Lab 5.

OBJECTIVES:
 

After completing this laboratory exercise you should be able to do the following:
Manipulate a 3D model in preparation for 4th axis machining and generate a 3D iges file.
Import the iges file into a CAM package
Translate the axis for part zero
Select required geometry for milling flats
Select the appropriate tooling for machining operations
Set required feeds and speeds
Generate required tool paths for 4th axis positional machining
Run a simulation to verify part cut
Post Process a 4th Axis CNC program for the HAAS controller
Determine the appropriate “Part zero” work plane
Determine the appropriate tool offsets procedure

Part Orientation
Part Zero for 4th Axis
Rotary Indexing
4th Axis Machining
4th Axis Positioning

Laboratory Preparation and Procedures

1.  Study the drawing shown in Illustration 1, and note the set-up for the HAAS VF-1 and ROTARY TABLE.
     It should be noted that the rotary table tail stock will not be incorporated into this laboratory exercise.  The 3/4-13 UNC threaded shaft created
     in a previous lab will be mounted in a 3-jaw chuck, and a 3 inch diamter "hub" will be screwed onto the threaded shaft creating a counter lever
     type mounting as shown in Illustration 4.
 

 Illustration 3:  Front view of VF-1 showing rotary table ("A"-AXIS) configuration

           Illustration 4:  Front view showing 4th Axis and part mounting arrangement

                     Illustration 5:  Isometric 3D model of completed part

2.  Create a 3D parametric model of the part extruded in the lateral reference plane (DTM for ProE).  Extrude the part such that the  left surface
     of the circular hub is at X=0.  Note that the center of the HUB will be (0,0,0).   Establishing this convention during modeling of the part
     will make setting part zero a much easier task when importing into the CAM package.   The reference planes and extrusion direction for
     modeling the part is shown in Illustration 5.

4.  Import your iges file into OneCNC as shown below:

5.  Set view to ISOMETRIC.

6.  From the CNC Manager set to 4th Axis position.

7.  In OneCNC select Model/Extract Single Edge and select the surface boundry to be machined as shown below in blue.

8. Next slect CREATE PLANE/ FROM SURFACE as shown below:

9.  Next select the surface, then select FLIP PLANE as shown below:

Note the plane should turn from red to GREEN (make sure of this before continuing.
10.  Next select NC STOCK toolpaths as shown.

11,  Under stock toolpaths, select FACING as shown below:

12.  Next select the bound then right click to select position.  You should then see the tool selection option:

13.  Click NEXT, then enter data as shown below:

14.  Click NEXT then FINISHED.  You should see a backplot of your tool path similar to the one below:

!5. Next got to Edit SINGLE SELECT and select the current surface boundry (shown in blue) then hit delete.

16.Repeat the previous EDITING and NC steps for each face on the HEX.

After you have finished, preview your tool path and verify that is is similar to the following:

You are now ready to post process and for exectution on the VF-1 HAAS Machine.

Make sure you provide a detailed setup sheet for this laboratory exercise.

Make sure you have your lab instructor verify your setup before proceeding.

When the actual CNC code is produced, verify that A axis begins at zero and is indexed by 60 degrees at the beginning of each cut.

Save your CNC program as a plain text file, check with your instructor and proceed to download to the VF-1.

Set G54 on the VF-1 appropriately, verify your tool path, and machine the part.

Submit a written laboratory report using the standard format.  Make sure to include set-up and job sheets along with other deliverables.
 

NOTE:  LAB WRITE UP AND DELIVERABLES ARE DUE AT THE BEGINNING OF THE NEXT
             SCHEDULED LECTURE SESSION.