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Famous Quotes/ Deep thoughts

November 23, 2012, 11:21 pm by Eldar Gerfanov

Just decided to store here the quotes that i liked.

And those that made me think about purpouse of life and Univerce.


FSWizard:Stanadalone

October 26, 2012, 8:30 am by Eldar Gerfanov

The ONLY FREE CNC Speeds and Feeds Calcualtor

Confidently calculate cutting conditions for hundreds of work-piece materials and of combinations of tooling types and coatings.

  • Accurately Estimate cutting forces involved in machining process and prevent tool breakage.
  • Estimate machine power requirement and help choose best tool for the job.
  • Suggest safe and practical Axial and Radial engagement values.
  • Compensate for reduced-shank, long and extra-long tools.
  • Improve cycle times and tool life
  • UNIQUE feature that allows to set comfortable levels of cutter torque and deflection and prevent cutter breakage.
  • Ideal for use as your Dynamic / Thoroidal / Truemill calculator

Please visit the project page for download link, support and instructions.
http://zero-divide.net/index.php?page=FSWizard_SA

 


What to do when you can not clamp it

September 28, 2012, 12:51 am by Eldar Gerfanov

If you cant, then dont clamp it at all!.
Skin it!

In here i have to program and machine several sets of roundish aluminum pieces with +/-0.001" outside tolerance. and within 0.002" thickness repeatability.
Instead if fixturing it one by one i decided to skim cut a 33" x 23" x5/8" to within 0.0015 flat. And then machine each piece completely leaving .005" outside to holt everything together.

Worked out great. 

for pics...
...Read More


Shop-made indexing fixture

September 28, 2012, 12:32 am by Eldar Gerfanov

Needed to do alot of side drilling/milling/tapping on our moulds lately.

So I quickly designed and whipped up this custom indexing fixture that allows me to mount almost anything to it.

Face plate has several tooling dowel holes on front side to locate work piece.
On the back of face plate there are 36 3/8 dia reamed holes spaced 10 Degree apart.

Housing has a big 5.0"Dia pocket in the front into which the face plate's hub fits in with 0.001" clearance
Housing also has corresponding 3/8dia reamed holes spaced apart 9 degrees. This allows me to index the face plate with 1 degree increment.

Design time:2 hours, Machining time: 2 hours.

Pictures are here:

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FSWizard v0.01 Standalone Has been Released!!

September 10, 2012, 8:41 am by Eldar Gerfanov

Fow Windows XP and later.

It has just been released.

Please test it out and tell me what you think!!!!!

Download it HERE http://zero-divide.net/index.php?page=FSWizard_SA

 


Calculating Tool Engagement Angle, Radial Depth of Cut

August 18, 2012, 12:14 pm by Eldar Gerfanov

Here i will show you how to calculate Tool Engagement Angle using tool diameter and Width Of Cut (radial deopth of cut)

Lets first draw a pretty image that shows us everything we need.

Where:

  • r: Radius of the cutter = Diamater /2
  • a: TEA - Enagagement angle we are trying to find here
  • WOC: Width of cut or RADIAL Depth of Cut
  • r2: The difference between r and WOC, r=r2+WOC

 

Below we develop 2 formulas that allow us to find TEA and WOC

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Tired of printing out Operation lists and then wasting time adding setup information by hand?

There is a neat and easy way to replace standard Operations and Tooling lists with something very compact and usable.

Here are config files i use at my work to create Setup Sheets and tooling lists right from SurfCam.

  1. First make sure you backup you Operations.cfg and Tooling.cfg files in case you want to go back (VERY NOT likely)
    Those can be found inside your V5 or V6\Config directory.
  2. Unpack contents of the attached ZIP folder.
  3. Copy .CFG files found within into your V5 or V6\Config folder.
  4. Copy folder "images" into "C:\Surfcam\" directory, if you want also tool images to show with tooling list.
  5. Go to SurfCam Options and in section Setup Sheet select "Current" from several other choises.

Thats it!!

UPDATE!!!!!!

  • Operations list NOW highlights table rows when you move the mouse over them.
  • When you select ANY text on Operations List, the same text will be highlighted over the whole page!!!

Download current file below

Samples are below:

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Download file:Surfcam_custom_operations_cfg.zip Downloads:(3441)

Programming Efficient Peck Drilling Cycle

June 2, 2012, 9:18 am by Eldar Gerfanov

Using Peck Cycle is often needed when drilling deep holes.
When using proper feed and speed no peck is required at depths of up to 3xDia for regular or 5xDia for High-Performance Parabolic drills.
At depths up to 10x, up to 5 pecks are required for regular  drills and up to 3 for Parabolic.
Anything over 10x Dia requires constant pecking of 0.5-1x Dia for regular drills and 1.5-2 Dia for Parabolic.

Since for programming you need a peck amount. Here are the numbers:

Code:REGULAR JOBBER DRILLS
3x: No Peck
3x-10x: 1xDia Peck
over 10x:.75xDia Peck
over 15x:.5xDia Peck 
 

Code:HI-HELIX HP DRILLS
5x: No Peck
5x-10x: 2xDia Peck
over 10x: 1.5xDia Peck 

Of course our HSMAdvisor Speed and Feed Calculator suggests not only the Speeds and Feeds but also the proper peck depth for various drill types and depths of the hole.
It in fact was the first machinist calculator to do so. This feature was much later borrowed by our competition.

And here is a pretty image showing Peck VS Hole Depth for regular twist drill:

This not only means that peck amount should be different for different styles of drills and depths of holes.
But also that peck distance should be different for different stages of drilling the same hole.
Ideally we should start the hole with large pecks, that continually reduce as the hole gets deeper and deeper.

Let's find out how we can apply this knowledge when programming our toolpaths.
This is format for normal Pecking:

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okuma prog samples

April 27, 2012, 1:43 pm by Eldar Gerfanov

Here are some Okuma Captain 1200 program samples for work with live tooling.
Samples are quite big so READ full article

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Compound Cycle Tapping on Okuma Lathe

April 27, 2012, 12:56 pm by Eldar Gerfanov

Cycle Format:

G184 X Z C K (I) F Q E
OR
G184 X (Z) R C K (I) F Q E

G180 (Cancel)

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© 2009 Eldar Gerfanov. Materials on this site are presented as is and are mostly for educational use. You may freely reproduce information presented herein without any consent from me, provided you include link to this site.
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