Eric U
Hot Rolled
- Joined
- Feb 26, 2003
- Location
- Eastern AL
Ok, here it is: http://youtu.be/RNgCNQqJPFw
Doosan Lynx 220 LYA with LNS barfeed and chip conveyor. "Installed" in early September. Got training on it more than a month later, but didn't know what questions to ask at the time. I did get my live tools ordered and delivered. Machining isn't my day job, so I've got a lot of other obligations that take up the majority of my time.
I just went ahead and tackled the hardest part I've got. Hopefully my other parts will come together quicker! I spent the better part of the last two months trying to a) crack the code on Fanuc, b) learn mill/turn, c) figure out how to get the barfeeder to do what I thought it should, and d) redesign my parts so they would be make-able on my Doosan. I also had to order some custom tooling that took ~5 weeks to arrive. During the 2nd week of January, both my slitting saws and step drills showed up. I needed custom slitting saws, because 2-3/4" diameter saws usually have a larger mounting hole than would fit in the 1/2" mandrels that fit in my live tools. I also needed custom carbide step drills because I've used up all the positions in my 12-tool turret. Carbide so no spot, step so I have a clearance hole (.199"), and the correct diameter (.175) for a 70% 10-32 form tap.
I have to give a huge "Thank You" to Tony and the other contributors to the Macro Programming Fundamentals sticky. It is no exaggeration to say that it changed my machining life. I ended up buying Peter Smid's book on Fanuc macro's and it helped fill in the blanks. For my part in the video above, back in the olden-days, it took me four operations to complete it. One on my Haas TL-1 lathe, and three on my Haas VF-2 mill. My part has a stepped bore...1" of it is 1.002" diameter, and the other 1-1/8" is anywhere between 0.805" and 1.030" dia. Previously I hand-jammed each size as required to do the bore on the TL-1. For each size I had to do on the TL, I had to post two different programs from my CAM to finish it up on the VF-2. What a pain! I probably have over 300 different programs for the different part sizes. Now at the top of my main program on the Doosan, I input part size and the number of parts I want made. That's it. Hit the "go" button. Macro variables, math, and 18 different sub-programs do the rest.
Programming my part is a bit more complicated than it seems on the surface, as there is a transition point where the stepped bore on both ends is equal. Since the larger opening needs to be toward the turret, having a part size LT or GE 1.002" affects: the side of the part the screw holes are on; how deep the bore and subsequently the cross slit are; alignment slots are different lengths; chamfer is different (back chamfer, chamfer between the steps of the bore, external chamfer), etc. I especially enjoyed working out how to strip out the numbers from the part size input at the beginning of the program so I could engrave it on the part! What an education working through this one! Total machining time on this part is probably only a couple minutes faster than before...but with no handling, no deburring, and no re-writing and re-posting programs for a new size, it's like a lifetime.
I love watching machine videos. Hopefully you like this one. You've earned it answering all my stupid questions (even if you didn't know it), and giving guidance. I'm all ears for any hints for making this part even better!
Thanks,
Eric U
Doosan Lynx 220 LYA with LNS barfeed and chip conveyor. "Installed" in early September. Got training on it more than a month later, but didn't know what questions to ask at the time. I did get my live tools ordered and delivered. Machining isn't my day job, so I've got a lot of other obligations that take up the majority of my time.
I just went ahead and tackled the hardest part I've got. Hopefully my other parts will come together quicker! I spent the better part of the last two months trying to a) crack the code on Fanuc, b) learn mill/turn, c) figure out how to get the barfeeder to do what I thought it should, and d) redesign my parts so they would be make-able on my Doosan. I also had to order some custom tooling that took ~5 weeks to arrive. During the 2nd week of January, both my slitting saws and step drills showed up. I needed custom slitting saws, because 2-3/4" diameter saws usually have a larger mounting hole than would fit in the 1/2" mandrels that fit in my live tools. I also needed custom carbide step drills because I've used up all the positions in my 12-tool turret. Carbide so no spot, step so I have a clearance hole (.199"), and the correct diameter (.175) for a 70% 10-32 form tap.
I have to give a huge "Thank You" to Tony and the other contributors to the Macro Programming Fundamentals sticky. It is no exaggeration to say that it changed my machining life. I ended up buying Peter Smid's book on Fanuc macro's and it helped fill in the blanks. For my part in the video above, back in the olden-days, it took me four operations to complete it. One on my Haas TL-1 lathe, and three on my Haas VF-2 mill. My part has a stepped bore...1" of it is 1.002" diameter, and the other 1-1/8" is anywhere between 0.805" and 1.030" dia. Previously I hand-jammed each size as required to do the bore on the TL-1. For each size I had to do on the TL, I had to post two different programs from my CAM to finish it up on the VF-2. What a pain! I probably have over 300 different programs for the different part sizes. Now at the top of my main program on the Doosan, I input part size and the number of parts I want made. That's it. Hit the "go" button. Macro variables, math, and 18 different sub-programs do the rest.
Programming my part is a bit more complicated than it seems on the surface, as there is a transition point where the stepped bore on both ends is equal. Since the larger opening needs to be toward the turret, having a part size LT or GE 1.002" affects: the side of the part the screw holes are on; how deep the bore and subsequently the cross slit are; alignment slots are different lengths; chamfer is different (back chamfer, chamfer between the steps of the bore, external chamfer), etc. I especially enjoyed working out how to strip out the numbers from the part size input at the beginning of the program so I could engrave it on the part! What an education working through this one! Total machining time on this part is probably only a couple minutes faster than before...but with no handling, no deburring, and no re-writing and re-posting programs for a new size, it's like a lifetime.
I love watching machine videos. Hopefully you like this one. You've earned it answering all my stupid questions (even if you didn't know it), and giving guidance. I'm all ears for any hints for making this part even better!
Thanks,
Eric U