ET 449 LABORATORY  1
                                                                 Mini Punch and Die Set
 
 

PURPOSE:

The purpose of this laboratory exercise is to review the basics of OneCNC, 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.
OneCNC, 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.
 

 
Illustration 1: MINI DIE SET (PUNCH AND DIE)
OBJECTIVES:

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 OneCNC
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 set
Punch
Die
OneCNC
dxf
XFA file
NC file
Part Zero (origin)
Tooling Set up
Transform
Pocking Operation
Contour Operation
Verify Operation
Laboratory Preparation and Procedure

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 OneCNC.  In OneCNC, window around the part geometry and select
      COPY/MOVE/.  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
       operations in OneCNC.  Note specifically the required tools, tool number, feeds, and speeds.  This information must be provided for the operator
       on the set-up and operation sheet.  NOTE:  While the ET 349 class focused on the basic steps for creating CNC programs,  this class will focus
       on the precision and efficiency of producing parts.  Pay particular attention to correct feeds, speeds, material, and tooling information.  Complete the required CNC operations to produce your part.
 
 

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.

        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.

 
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.
Select EDIT SETUP INFORMATION
Select the STOCK tab
Select ADD then click OK
Change the VIEW to ISOMETRIC
RUN THE SIMULATION
Save Your work.
You are now ready to POST PROCESS.
Select HAAS for the controller
Make sure 2-axis is selected
Click POST
5.     After you have post processed the file, edit the program and provide the following comments.
        NOTE: ALL CNC PROGRAMS SHOULD HAVE THIS INFORMATION IN THE FUTURE!
 
        %
       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:               )

Note:  These are default in OneCNC's setup sheet.  You may simply copy the information from the setup sheet when
          submitting your lab report

6.     You can now save the file as LAB1.txt on a floppy disk and transfer to the HAAS CNC mill.
        Check with your instructor for assistance, follow set-up and operation sheets, RUN THE PART.
NOTE:  MAKE A DRY RUN FIRST.
              AFTER THE PROGRAM HAS BEEN CHECKED, RUN THE PART AND
              RECORD THE TIME TO COMPLETE: ____________ MINUTES.
7.     SUBMIT A LAB REPORT USING THE FORMAT SHOWN BELOW:
 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:

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
Conclusion/Discussion:  (One to two paragraphs.  Restate the problem, discuss the outcomes and descriptions of any difficulties encountered.
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.