Mini Punch and Die SetET 449 LABORATORY 1
PURPOSE:
The purpose of this laboratory exercise is to review
the basics of SurfCAM, and use the software
to produce a small punch and die set.
A 3D parametric file will be created followed by a corresponding 2D dxf
file.
SurfCAM, will be used to make editorial changes, create
the appropriate tool paths for contouring and pocketing, create a CNC program,
simulate
the program execution, develop a set-up and operation
sheet, and produce a final part on the HAAS vertical milling machine.
One of the components (either the male punch or the
female die) will be produced. Your lab partner will produce the corresponding
mating component.
Each team member must use their lab partner's program
and set-up procedures to produce the part. Teams will be evaluated
on set-up, operations, precision, and appearance. A written lab report
is required. Illustration 1 shows a view of the project to be completed.
OBJECTIVES:Illustration 1: MINI DIE SET (PUNCH AND DIE)
After completing this laboratory exercise you should be able to do the following:
Manipulate a 3D model and generate a 2D dxf file.
Import the dxf file into SurfCam
Translate the axis for part zero
Select required geometry for drill cycles
Select required geometry for pocketing operations
Select required geometry for contouring
Select the appropriate tooling for machining operations
Set required feeds and speeds
Generate required tool paths
Run a simulation to verify part cut
Download a CNC program to the HAAS controller
Set a “Part zero” work plane
Set tool offsets
Operate the HAAS vertical mill to produce a final part.
TERMS:
Die setLaboratory Preparation and Procedure
Punch
Die
SurfCam
dxf
Dem file
NCC file
Part Zero (origin)
Tooling Set up
Transform
Pocking Operation
Contour Operation
Verify Operation
1. Study the drawing shown in Illustration
1, select the component, and identify the geometry to be machined.
The first step for this lab will include creating
a 3D parametric
model, then importing the required dxf file into SurfCAM. In SurfCam,
window around the part geometry and select
TRANSFORM/MOVE/LOCATION.
When prompted for MOVE FROM, select the left endpoint of the top
object line. When prompted to enter MOVE
TO, select KEYBOARD, and
make sure the coordinates are set to zero. Press enter and the origin
should then be located
at the top left corner
of the part.
ILLUSTRATION 2: MINI DIE SET ENGINEERING DRAWING
2. Determine the operations and steps in creating the required geometry. You should develop a set-up sheet as you produce the required CNC
3. After completing required
CNC operations, the final step will be creating required
CNC code for your
component. Double check all tool numbers, feeds, speeds, material
type and cutting tool specifications.
TOOL NUMBER
LENGTH OFFSET
DIAMETER OFFSET
WORK OFFSET
Select the COMMENTS tab and enter appropriate comment for each operation.
Next, select
the cut control tab. Specify "IN Z" depth of cut. For
roughing and finishing. If you are unsure, check references!
4. After you have completed the CNC operations, save your file, and run a verification.
5. After you have post processed the file, edit the program and provide the following comments.
Next, click on the OPERATIONS MANAGER icon.
SAVE YOUR WORK
At this point, you can run a graphical simulation; however you must set up the stock.
Right click on the BLUE HIGHLIGHTED NC PROJECT
Select EDIT SETUP INFORMATION
Select the STOCK tab
Select ADD then click OK
Next, click on the RED CHECK MARK icon
Change the VIEW to ISOMETRIC
RUN THE SIMULATIONClick on the RED CHECK MARK again to view tool paths.
Next Click on the OPERATIONS MANAGER icon.
Save Your work.
You are now ready to POST PROCESS.
Select HAAS for the controller
Make sure 2-axis is selected
Click POST
6. You can now save the file as LAB1.txt on a floppy disk and transfer to the HAAS CNC mill.
%
O1234
(PROGRAM/PART NAME: )
(PROGRAMMER: )
(DATE DEVELOPED: )
(DATE RAN: )
(CNC MACHINE PART RAN ON: )
(OPERATOR: )
(REFERENCE FILE NAME: )
(REFERENCED SET UP SHEET NAME: )
(REFERENCED OPERATIONS SHEET NAME: )
(G54 OR EQUIVALENT LOCATION )
(TOOL TYPE, NUMBER, TOOL CHANGER I.D. # )
(MAT'L TYPE: )
(SPECIAL SET-UP OR OTHER INSTRUCTIONS: )
7. SUBMIT A LAB REPORT USING THE FORMAT SHOWN BELOW:NOTE: MAKE A DRY RUN FIRST.
AFTER THE PROGRAM HAS BEEN CHECKED, RUN THE PART AND
RECORD THE TIME TO COMPLETE: ____________ MINUTES.
LABORATORY REPORT FORMAT
Title:
Your Name:
Lab Partner:Lab Section:
Date:
ABSTRACT: (One paragraph stating, what, when, where, how, and OUTCOMES).
Statement of Problem: (One paragraph concisely describing the problem under study).
Objectives: (One introductory complete sentence following by a listing of specific objectives.
Note: There should be one tangible outcome for each objective stated).Terms and definitions: (List and define any terms that are unique to the laboratory or terms that could
be used in another context that need clarification as to the use in this lab).Procedure: (One introductory complete sentence describing the overall procedure followed by
a description of steps taken).Results: (One paragraph describing the outcomes followed by appropriate tables, graphs, charts, etc.
Reference should be made to tangible deliverables that must include a minimum of the following:Conclusion/Discussion: (One to two paragraphs. Restate the problem, discuss the outcomes and descriptions of any difficulties encountered.1. Part drawing (dwg) showing G54 or equivalent location
2. Program Listing
3. Printed tool path simulation
4. Program Listing
5. Set-up Sheet
6. Operations Sheet
4. Actual Machined Part
Make recommendations any changes for improvements).References: Cite any references using APA format.
NOTE: YOU WILL BE GRADED ON CONTENT, FORMAT, GRAMMAR, AND SPELLING! MAKE SURE YOUR WRITE IN
COMPLETE SENTENCES AND CHECK SPELLING. WRITE IN THIRD PERSON, PAST TENSE, AND TREAT THE LAB REPORT
AS THOUGH IT WERE AN ON-THE-JOB TASK AND RESPONSIBILITY. LAB WRITE UP AND DELIVERABLES ARE DUE AT THE
BEGINNING OF THE NEXT SCHEDULED LABORATORY SESSION.