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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:(3619)

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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FS Wizard: Dormer Drill test on T6061 Aluminum

April 23, 2012, 8:22 pm by Eldar Gerfanov

As part of FS Wizard's development. 2 drills were tested today on T6061 Aluminum.

0.312 Dia and 0.390 Dia Dormer A002 Drill Jobber Drill with TiN coated tip.

Helix:30Deg

Point:Split, 118Deg.

Hole depth for both was 3.0"".

Peck equaled 1xDia

Speeds and Feeds for 0.312 Dia drill were

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Drilling Hardox 500 55RC: 0.281 dia .75 deep

April 20, 2012, 1:47 am by Eldar Gerfanov

Tool:0.281 dia 0 helix TIN coated carbide drill

Peck:0.125

Coolant: Air

RESULT
SFM: 49 f/min
RPM: 663
APT:  0.00070 in/rev
Feed: 0.93 in/min
MRR: 0.1 in^3/min
HP: 0.2
Torque: 19.4 in-lb
Max Torque: 22.9 in-lb

 


Test of NIAGARA 3FL HP End mill for Aluminum

February 27, 2012, 11:02 pm by Eldar Gerfanov

Recenty ordered a 3Flute High Performance End Mill From NIAGARA.
Was very glad and slightly surprised that when punched in all of the endmill's data into my Calculator nothing broke down.I had a rason: At 5000RPM and 3/8" Deep slot cut. The feed came to around 92.0IPM. Chips were making this nice ringing noise that sounds like money.

Setup:
HAAS VM-3
Hudrolic Tribos Holder
3/4" 45DegHelix 3Flute 1.625FluteLen, 2.375"Overhang TICN HP End mill

S:5000RPM
F:92.0IPM
DOC: 0.375" Slotting
Coolant:FLOOD

The calculation was pretty much dead on.


Tapping Hardox Rc 45-50

February 27, 2012, 10:43 pm by Eldar Gerfanov

A need arouse to drill and tap lots of blind 1/4-20 holes in 3/4" thick hardox 45-50RC hard plate.

So if you ever need to do this use:

1) DRILL
Tap hole: >0.202" or bigger.  5/8 deep.
Drill used: Tialn coated carbide drill.
S=1418 RPM
F=2.6 IPM
NO Peck, No Coolant

2)TAP
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Renishaw OTS tool probe cycle for HAAS can set both length and diameter offsets.

Too bad there is no choice: it only puts absolute measured diameter of the tool into D- diameter offset and makes wear offset=0

But if your programming is done with the center of the cutter, then you actually only need the difference between actual and programmed diameters of the tool.


I.E.: When probing 5/8Dia end mill, we get D=0.6248. You would normally have to subtract 5/8 from it and leave the -0.0002 difference.

But there is an easier way

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