Wade C
Stainless
- Joined
- Jul 21, 2004
- Location
- Wiggins CO. USA
Im new to VMCs, and finally getting done with various maintenance and cleaning on the new to me Fadal 4020HT (88HS, Rigid Tap, 10k Spindle, 28" Z - for reference)
Im starting the learning process on fixturing, setting up, accuracy, etc. Im not well versed in multiple part fixtures because until now, its all been turning center work, or running singles on the manual mill. But now with the magical "tool changer" contraption on the new to me VMC... and increased demand for some of my products, its time to start thinking more about efficiency and output and get this critter humming. Not to mention learning more about everything in general in the process.
Im starting my learning with a fixture for holding an ≈8" long by .625" round, water hardening drill rod (from enco), and I need to cut three "flats" or "slots" across it - all on the same "side" - like a flat for a set screw on a shaft.
I wanted to pick some brains about fixturing ideas if anyone is feeling generous with their time.
I would like to be able to hold maybe 10-20 of these at a time. I have to cut one slot 1.040" wide (+/-.025") that is .124" deep (-0/+.002") in the middle of the 8" long rod, and one end (within 2" of the one end), there will be two slots each .500" wide (+/-.025") and .070" deep (+/-.025"). Positioning accuracy is +/-.025". Basically one slot is important to functionality (slot depth is the major factor), the other two just need to be there, location of the slots does not have tight tolerances.
Im probably over thinking this... and worried about nothing, but thought best to get good advise before I plop down a chunk of change for a block of material to cut the fixture into. To complicate things (maybe) I will be later doing very similar parts in different diameters up to .875" dia.
Here are some of my initial questions: (main concern is keeping the -0/+.002 tolerance on the one slot across all the parts)
Material Choice for Fixture:
Steel? Aluminum? cheap Chinese mill vise body (I have a couple laying around and two Kurt 675s on the way to replace them)?
Type of cuts in the fixture for best hold and locating of part and clamping: -Fixture face milled flat on bottom portion, and a top clamp the parts down with a "U" flange of some sort?
-Cut sort of a "V" into the bottom portion, and a flat clamping bar across the top
-5/8" holes drilled through a couple blocks, and then set screws into each bore (drill/ream blocks and mount so holes are parallel to the table) - I suspect this to be the lease accurate way to do it
-Some other methodology I am obviously missing because I didnt mention it?
I can see some potential head aches for all of these methods, and I know it will be a learning process - teaching my self to make the fixture, and then how to remove it from the table and accurately reinstall it at a later time. But I dont have the experience to know which headaches will be a big deal, and which ones are easy to overcome. Id like to think Im not stupid, but KNOW Im VERY inexperienced.
I hope I havent wasted everyones time (and made you regret reading this post)... Im just getting my feet wet on the VMC side of things, and trying to avoid some of the usual stumbling stones... er I mean learning stones that i tend to easily trip on.
Thanks for reading and thanks in advance for your patience and help.
Wade
Im starting the learning process on fixturing, setting up, accuracy, etc. Im not well versed in multiple part fixtures because until now, its all been turning center work, or running singles on the manual mill. But now with the magical "tool changer" contraption on the new to me VMC... and increased demand for some of my products, its time to start thinking more about efficiency and output and get this critter humming. Not to mention learning more about everything in general in the process.
Im starting my learning with a fixture for holding an ≈8" long by .625" round, water hardening drill rod (from enco), and I need to cut three "flats" or "slots" across it - all on the same "side" - like a flat for a set screw on a shaft.
I wanted to pick some brains about fixturing ideas if anyone is feeling generous with their time.
I would like to be able to hold maybe 10-20 of these at a time. I have to cut one slot 1.040" wide (+/-.025") that is .124" deep (-0/+.002") in the middle of the 8" long rod, and one end (within 2" of the one end), there will be two slots each .500" wide (+/-.025") and .070" deep (+/-.025"). Positioning accuracy is +/-.025". Basically one slot is important to functionality (slot depth is the major factor), the other two just need to be there, location of the slots does not have tight tolerances.
Im probably over thinking this... and worried about nothing, but thought best to get good advise before I plop down a chunk of change for a block of material to cut the fixture into. To complicate things (maybe) I will be later doing very similar parts in different diameters up to .875" dia.
Here are some of my initial questions: (main concern is keeping the -0/+.002 tolerance on the one slot across all the parts)
Material Choice for Fixture:
Steel? Aluminum? cheap Chinese mill vise body (I have a couple laying around and two Kurt 675s on the way to replace them)?
Type of cuts in the fixture for best hold and locating of part and clamping: -Fixture face milled flat on bottom portion, and a top clamp the parts down with a "U" flange of some sort?
-Cut sort of a "V" into the bottom portion, and a flat clamping bar across the top
-5/8" holes drilled through a couple blocks, and then set screws into each bore (drill/ream blocks and mount so holes are parallel to the table) - I suspect this to be the lease accurate way to do it
-Some other methodology I am obviously missing because I didnt mention it?
I can see some potential head aches for all of these methods, and I know it will be a learning process - teaching my self to make the fixture, and then how to remove it from the table and accurately reinstall it at a later time. But I dont have the experience to know which headaches will be a big deal, and which ones are easy to overcome. Id like to think Im not stupid, but KNOW Im VERY inexperienced.
I hope I havent wasted everyones time (and made you regret reading this post)... Im just getting my feet wet on the VMC side of things, and trying to avoid some of the usual stumbling stones... er I mean learning stones that i tend to easily trip on.
Thanks for reading and thanks in advance for your patience and help.
Wade