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  3. FYI While I am not the best at the machine, more statistical processing and fixture design, we have others that are very good. We have 2 other % axis machines. Even with the Haas techs setting MRZP we where seeing .006" error. Haas also sent in the equipment to remap the ball screws.
  4. I do, but I work for the Federal Division, however I know the Applications Manager for Phillips Commercial quite well. Please PM me your Serial Number, and I'll touch base with my counterpart in the Commercial Division, and we'll get you the Service/Support you need. To be fair, it sounds like there is also an opportunity for both Applications & Probing Training at your company, because "Probe Calibration" is a process you should know intimately. I would suggest that you'll want to calibrate weekly, until you really get the hang of the process. You may even want to spend a full day where you cut-and-test to get some data. Start by "calibrating at the low air temperature (after warming up the axes & spindle) first thing in the morning" (record all values), and then perform that same "full calibration process at Noon" - recording all data, and do a final calibration at 4-or-5 PM. What we are after here is "how much influence does the thermal cycle have on the process". As I mentioned, it takes process knowledge and Probing to really get the full capability of these machines, in addition to a properly formatted Post Processor. Things like using the High-Speed Codes, proper use of TCPC & DWO, and in-process Probing for those high-accuracy applications, are all critical to holding super tight tolerances. I have setup a process (funnily enough, on a Pallet Pool, just not a Haas Pallet Pool), that performed "full Calibration" before each part was cut. This allowed us to hold very tight tolerances, even as the machine warmed up from cold (cycle time was about 18-minutes). I don't believe you'll need to go to that extent, but it always depends on the part size, material, tools, fixturing, and thermal stability of the shop in question. In this case, performing the calibration (tool probe & spindle probe), then measuring the tools, and then probing the part which was freshly loaded into the machine, gave us the ability to hold some very critical in-line bore tolerances and true position locations, for some Port Features. I could not have done that using the static accuracy of the machine, throughout the thermal cycle of daily production. Without the Probe, I would have been chasing offset adjustments all day, and scrapping parts. By integrating the Probe into the process, not only did I hold tolerance, but setups became a lot less fussy. I could simply clamp parts in a fixture or vise, without stressing over trying to get those OP20 Parts precisely on location. I could measure each part "in the location it was at", without worrying if each pallet was built or setup precisely like the other pallets. This vastly simplifies your setup, because it just doesn't matter if you are slightly out of position, so long as you "probe that error", and correct the twist or positional error using your C-Axis Work Offset value. (NOTE: you must correct any C-Axis Error, and recall the work offset, and C-Axis (zero) position, before Probing for XYZ translation error). But you should also be aware of this limitation on the Haas > the DWO Function only compensates for single "rotary axis errors". So you can correct a C-Axis misalignment, but not a B-Axis error. So what I mean to say there, is that you shouldn't be sloppy with your fixture setup/building. If possible, machine soft jaws, or the mounting surfaces of your fixture "in place, on the machine", so the fixture is as precise as you can get it. But when you mount parts, if you incorporate the Probe into the mix, you don't have to be as careful in setting up the parts for XYZ location, but you should still be careful, as some rotary error cannot be corrected for using the DWO Function. (Fanuc WSEC Function allows 6-degrees of freedom correction for errors.)
  5. FYI: HFO Phillips is our dealer. Do you have anything to do with that diversion?
  6. The other thing to understand, is the difference between alignment of the machine geometry and machine leveling, and setting > Center of Rotation Parameters. That isn't leveling, and it doesn't twist your machine. When you mention "Probe and Inspection Balls", you are talking about the MRZP Process. This sets the Machine Rotary Zero Point. Depending on your software, and which Macro Programs you are running, this either sets Settings 254-257, or Settings 300-305. These values are used with a combination of the following: Accurately measured TLO values (positive Tool Length Offset values) Accurately measured Work Offset Location. Do not use "Centerline of Rotation" for your Work Offset. The number of people I have seen, who insist it must be done this way, is staggering. Make the location for your Work Offset, a feature on the part or fixture which is easy to PROBE. Preferably, a location on the Part itself. Accurately set MRZP Values. The 'Renishaw Axiset Macros' do the best job here. Talk with your HFO about getting these macros loaded. From what I've been told by Renishaw, we are allowed to install and run them on a UMC where the customer has not purchased the Axiset package, however we are not allowed to supply the Excel Spreadsheet which comes with the package, and is used to track geometric values over time. (To help you track the dynamic performance of the machine.) These Axiset Macros are especially good at finding the "offset" for the C-Axis Platter. This is Setting 254. Settings 255-257 describe the "centerline of the B-Axis" from Machine Zero. Setting 254 is the offset (+-) from this centerline position (along the X-Axis), for the center of platter (C-Axis) rotation. The note on the screen says "should be no more than +- 0.005", but I have seen that value up to 0.0087" > and the machine cut very accurately on a full 5-Axis Part, because we accurately measured "the true state of the machine". You MUST, MUST have a Post Processor which invokes both DWO (G254) and TCPC (G234) codes, in the proper way. This means you must be sure DWO & TCPC are properly canceled, between Ops, especially if you are changing modes. You must call the Active Work Offset (G54 typically, but could be any of them), Position the Rotaries (B & C move), and then call either DWO or TCPC Codes. TCPC must start with a G0 move, and you typically need to "recall the current position on the G234 line". For TCPC, I prefer to have a "prepositioning move" done using DWO, so the tool can approach "from the correct direction", cancel DWO, and then invoke TCPC. None of those Machine MRZP Values are used, if you aren't invoking DWO or TCPC. Let me state that again > none of those Machine MRZP Values are used, if you aren't invoking DWO or TCPC and calling it properly!!! If you are just using Work Offsets (G54, G55, G56, Etc.), and programming from COR of the machine, then you're not utilizing the power of the machine. If you aren't integrating Probing into your processes, you're not utilizing the power of the machine, and you're going to have difficulty using that Pallet Pool, because you need to be able to account for the variations of each pallet/part. You do this with a Probe, not with "a perfect setup". There is no such thing as a "perfect setup", unless you're in a Laboratory. When I worked at Methods Machine Tool, we had a lab for our Yasda machines, where the temperature did not vary more than 0.5 degrees C (1-degree F), over a 24 hour period, and the entire volume of air was replaced every 3 minutes in a 3000 Sq.Ft. room. We still used a Probe, but we were able to hold +- 1 micron on the PX30i (production machine), and we were able to split a Micron (+- 20 millionths), on a YMC650. Each machine was also placed on a 40" thick isolated and reinforced slab, with 5000 PSI concrete. That said, when a Haas machine is calibrated properly, and you're using the Probing System for critical features, along with Probing your Tool Length, and Probing Parts for Work Offset Location, you should get incredible performance from your UMC-750SS with Pallet Pool. Are you using High Speed Machining? Are you adjusting your G187 P values (P1-P3) to switch between Roughing and Finishing Mode? Are you setting the Corner Rounding value with the E parameter? Rough = G187 P1 E0.04 Semi-finish = G187 P2 E0.004 Finish = G187 P3 E0.0004 (sometimes I drop it to E0.0001). Are you using "Exact Stop" for Drilling, Reaming, Boring? (G61 > Exact Stop Mode, G64 > Normal Machining Mode, or place an individual "G9" on each line of your Canned Cycle. You can use G9 to enable "Exact Stop" for individual holes. So if you were spot drilling 10 holes, and 2 are dowel holes, you could place a "G9" on those two holes only. NOTE: you will get a slowdown when using Exact Stop, but the locations are more accurate.)
  7. Thanks for this different approach, I like it. That's what I was looking for a different insight. Much appreciated.
  8. https://www.kennametal.com/us/en/products/p.xdpw12-d-precision-pressed-with-reinforced-geometry-first-choice-for-hardened-materials-and-cast-iron.6033257.html#tad With that EDP# for the insert, and based on the insert geometry, I found the following Feed Table (in metric values), at the bottom of the post. With the recommendations you posted, the recommended Feed per Tooth you gave (at 0.01186" per tooth), is only 0.3mm per tooth. More importantly, look at the range of feed values. On the low end, we have 0.22mm per tooth, on the high end, 0.82mm per tooth. I think with those numbers you listed (173 ipm), that is running on the very conservative side of the tool. (low end of the feed values). Nothing "wrong" with that per se, but you're leaving some performance on the table for sure. You could easily do between 250-350 IPM, using those inserts and that mill body, in Cast Iron, with 40-100% stepover. Something to note about the drawing you posted: the calculations are being made based on the "diameter of the flat", not the diameter at the periphery of the tool. I'm not sure how that plays into their calculations of feed-per-tooth, but I thought it worth mentioning...
  9. I'm sorry you are correct. Feed mill : 6025583 Insert: 6033257
  10. What insert grade are you using?
  11. We had a similar issue on a UMC-1000 recently, and while I can't reveal any customer specifics, here is how we addressed the issue: Testing revealed that Thermal Compensation was continuing to add growth over time, even though the growth had stabilized. We worked with the Haas Factory to generate a "Patch File", which disabled the Thermal Compensation feature. (I'm not 100% sure if it disabled all thermal compensation, or just disabled the sensors on the Spindle Cartridge.) Due to turning off the Thermal Comp, it was necessary for the customer to run a modified Spindle Warm-Up program. We extended the length of the warm-up from 20-minutes, to 30-minutes, and added code to "stroke the XYZ and B/C Axes", as we ramped up the spindle to full RPM over 20 minutes, and then ran at Max. RPM for 10 minutes. Once the warm-up cycle was complete, we then performed a full calibration of the Tool Probe, and then touched off all tools for a given job. (Must measure the tools with the spindle in the "warm state".) With the machine warm, we then calibrated the "Spindle Probe Length" (Z calibration). Then we calibrated the Spindle Probe Diameter, using a Ring Gauge. Finally, we ran the Axiset Macros for the B-Axis, and then ran the Axiset Macros for the C-Axis. (There are two sets of macros when using the Renishaw product. This is not the same macro package as "MRZP Calibration", that come installed with the machine.) When running parts, we use the Spindle Probe to pick up the Work Offset (Program Zero), G54 (or G55, or G56, Etc.) For critical location features, it is beneficial to use Spindle Probing, to pickup a local work offset for adjusting critical features. So even though we use DWO/TCPC for most features, if you have a critical "True Position Tolerance", your most reliable solution is to perform "in-process Probing", using a local Work Offset for that feature. To do this, we typically use G55, or G56, etc., and have code at the top of the program which simply assigns those values to equal "G54 Offsets", after we have finished probing to pick up the current location of G54 on the individual part being run. By disabling the Thermal Compensation with the Patch File, it then becomes necessary for the customer to use "process techniques" to manage the Thermal Growth, and it becomes critical for the customer to "not cut parts until the machine is fully warm". I would also suggest checking with your HFO & the Haas Factory, to ask if these Thermal Compensation issues are being addressed in current or future software release. And please do me a favor, and don't start the conversation with "Well Colin Said...", as you may be experiencing a different Thermal Growth issue, but this sure sounds a bit similar to the issue we dealt with recently. However, I don't speak officially for Haas on this issue (as I don't think you're one of our customers, and unless Phillips is your HFO, I don't have authority to speak on this officially), so please just treat this information as anecdotal, and see if you can get your HFO to request a Patch File, to disable the Thermal Comp. That will at least stop the control from applying a "growing comp value" to your machine. But you will see a difference in cutting, between a warm machine, and a cold machine, by disabling the Thermal Comp. However, if you know how the machine is going to behave in certain environmental conditions, and you manage that thermal cycling of the machine properly, then you will be able to achieve consistent performance. But I would strongly recommend integrating Spindle Probing into your machining processes, both for locating each part prior to machining, and also for hitting any critical tolerance features, by performing in-process probing, and adjusting the individual coordinate system values for "each critical feature or face". You mentioned "Haas advertises 0.0002" accuracy, and 0.0001" repeatability". Do you have a document or web link that shows this? https://www.haascnc.com/service/online-manuals/umc-series/umc---geometry.html#:~:text=It%20is%20important%20to%20remember,accuracy%20is%20%2B%2F%2D%2015%20arc. According to Tab 7.3 GEOMETRY - TROUBLESHOOTING: It is important to remember the Linear accuracy of the machine is 0.0004/10" and the angular accuracy is +/- 15 arc. sec. These tolerances can add up quickly. The 5-Axis machines are never listed as a overall static accuracy across the entire linear stroke. As you can see above, the specification is 0.0004" over 10 inches, not over the entire travel range. And, you have +- 15 Arc Seconds of Rotary Positioning accuracy. Like a "wedge of pie", the farther you are cutting away from the rotary centerline, the more those angular errors are magnified as a linear distance. Also, the "table weight" becomes a concern for large part/fixture combinations. If you are cutting a 20" diameter part, that linear accuracy is more like 0.0008" over that distance. Now, that is the specification, and we can often achieve much better tolerances. I've personally seen most of the UMC-750 machines hold more like 0.0002-0.0006", over a 25" long part. But, that is also the 'dynamic accuracy', so with adjusting cutter compensation, using probing, and other "process techniques", we can get down closer to the lower end of that tolerance range, when it comes to repeatability.
  12. I'm sorry, Ductile Iron.
  13. Sorry Ryan, I have answered your email now. The eMastercam-mails are thrown in my spambox for some reason. Should for the thread say that after the v22.4.11.362-update from Cimco I havn't had any issues yet. First update in 70 updates over the two past years that works for me :-) Hope it will continue with that!
  14. With these parameters, and custom built wireframe geometry (and modified based on backplot/verify results), I'm showing 43 seconds with this 2.5" (63mm) High-Feed Face Mill. I'm using 0.095" Step Down, and 250 IPM. I don't know the material, but at the programmed 2,089 RPM, we're showing 1375 SFM.
  15. It will be more stable if you keep it running nonstop, and if you can manage your HVAC situation. Probing each tool as you pick it up will also help. Don't rely on the Z of the spindle probe; that will move with your thermal growth. Here's another idea, kind of similar to Ron's. When I'm picking up the Z of the center of rotation of a trunnion, after getting it close, I'll tilt over 90°, cut a face, spin 180°, and cut the opposite face. Then I can mic between the faces to gauge my error, and adjust that out. You could automate that at the start of your part, and instead of micing, tilt back to 0° and probe in X. Then a simple macro can fine adjust your Z for every part.
  16. I just turn it on and leave it on. What it does, is if you're doing a raster type path zigzagging back and forth, it will start the filtering from the same end of the path regardless of the direction of tool travel. That way entity endpoints line up better, and depending on your tolerance settings, high feed codes, and machine dynamics, it can produce a better surface finish. I've never seen any reason to have it turned off.
  17. How to use one way filtering Tried a lot of images but don't know how to use thanks
  18. Last week
  19. i got a 3fl em to do it in 1:30 dynamic milling. If its alum and that holder is that long it may vibrate. Stub it all up and you could bump the SFM a lot.
  20. Here is my take on it. Seemed to be just a bit of recutting, by tracing the whole contour. So I just built my own wireframe, after measuring the width across those faces. I did some digging on that tool definition, and couldn't find those part numbers on Kennametal's website. Are they perhaps old part numbers? Closest I found (based on 7-flutes, and 2.5" diameter) was this: SAP Material Number 6025275 ANSI Catalog Number 7792VXD12-A063Z7R [D1MAX] Maximum Cutting Diameter 2.480 [D] Adapter / Shank / Bore Diameter .8666 [D1] Effective Cutting Diameter 1.764 [D6] Hub Diameter 1.771 [L] Overall Length 1.574 [AP1MAX] 1st Maximum Cutting Depth .0984 [Z] Number of Flutes 7 Based on their recommended starting feeds, at 40-100% Stepover, and .098" stepdown (2.5mm per pass), they are recommending between 0.44mm and 0.49mm per tooth. That would be about 0.017"-0.020" per tooth, so about 250 IPM for that 7-flute feed mill. Check out the path, and results... Feed mill_custom-contour.mcam
  21. That is not a bad way to do it. Another way that is better in Mastercam using that tool I cannot think of one. I would try dynamic with a solid tool full flute and see if it is faster thought I doubt it would be. At 1 minute 30 seconds of a backplot time that is impressive. Anyone who say they can do it faster are more than welcome to step up and teach us both. Using the same SFM as the High Feed with Dynamic and 25% step over I can get 1 minute 35 seconds with the .004 per tooth feed rate defined on the 1" Endmill. I kick it up to .006 per tooth I get 1 minute 4 seconds time again with 25% step over. The High Feed cutter process you are using without seeing the setup, rigidity of the machine and other things it would seem is probably still the best way.
  22. Here you go, thank you. Feed mill.mcam
  23. To be fair I interpolate holes to =/- .0001- .0002, so they are just being a bit economical with the truth. Re-probing and re-touching critical tools, might help, but I might be tempted to run Productivity+. Then you can probe for stock. This might also require re-calibrating the probe. Contact Renishaw for the straight skinny on this, I have always found them to be very straight forward. Monitoring your spindle growth through the process might just do the trick as well. Once the spindle grows, does it stay there for the rest of the shift? As long as you don't shut it down too long before starting the unattended work you might get away with it.
  24. +/-.005 Aerospace maybe, but tight tolerance parts expect problems. Need to use probing and a standard monument feature on each part to use to gauging. It could be a tooling ball or a gauge block that will allow you to check something that should never change in size to gauge deviations and then program in a way that compensates when the measurement of them changes.
  25. Without a shape and size of tool to see what your doing sorry I can't say.
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