ET 449 LABORATORY 5
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
will be used to create required 2D dxf files. 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.
Shaft from Lab 3
Hub from Lab 4
Lab 5: 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:TERMS:
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
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 hexagonal hub to specifications.
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
shaft created in LAB 3
will be mounted in a 3-jaw chuck, the circular
hub created in LAB 4 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.
3. Save your part file ! Next export an iges file (make sure that you change from mm to inches.
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 operation sheets.
HAAS PROCEDURE CHECK
After you have created the required CNC code, complete the following:
1. Touch off and set tool work off-sets for the 1/2 inch
end mill.
2. Download your program(s) to the VF1 CNC machine.
3. Graphically simulate your program for verification.
4. Have your instructor approve the program and set-up.
5. Run the CNC program(s) to produce the hex part.
6. Have your instructor sign the lab completion form.
7. Write a lab report using the standard lab format, and
turn in
deliverables as indicated.
NOTE: LAB WRITE UP AND DELIVERABLES ARE DUE AT THE BEGINNING OF
THE NEXT
SCHEDULED LABORATORY SESSION.
Created by Aaron Ball February 8, 2007