broaching on an Okuma lathe

[cappy]

Good Evening,

 

I am researching methods to program a broaching application. I would like to mount a keyseat cutter to a boring bar and stroke it in and out on the Z axis on a lathe to broach a keyway in a bore. The operator I am working in the shop siad maybe a LAP cycle could be used for this code. I would like to position in front of the bore in X and Z and then broach in and out while moving up in X at a set increment. Does anyone know any tricks I could use with MasterCAM to generate this NC code??

 

Greg.

[YoDoug®]

Without having the broach guide you may get a lot of deflection in the broach. For the motion you are talking about doing in mastercam I would just do a lathe contour finish and make a bunch of small finish steps, just edit the code to lock the spindle.

[Greg Williams]

Greg,

 

I would use a custom Macro, Something like this

 

IDIA=25 (MINOR DIAMETER)

ODIA=32 (MAJOR DIAMETER)

LEGH=-15 (Z FINAL LENGHT)

INC=0.1 (INCREMENTAL VALUE FOR BROACHING SHIFT)

CANG=0 (C-AXIS ANGLE)

 

OBRCH

 

G0 X500 Z500

T010101

M110

G0 C=CANG

M147

V1=INC

NLOOP X=IDIA+V1 Z3

G94 G1 Z=LEGH F250

IF [V1 EQ [ODIA-IDIA][NEND

X=IDIA

G0 Z3

V1=V1+INC

GOTO NLOOP

NEND X=IDIA

G0 Z3

X500 Z500

M146

M109

RTS

[kazmir44]

I have never attempted to broach keyways on a lathe. But, I know PH Horn makes tooling specifically for this application.

You should check them out.

[cappy]

Hello,

 

Thanks for all of your replies. I have a tool made very similar to PH Horn style. My operator made up a lap Cycle to do this last night and cut a part in Aluminum. Surprisely it worked very well. I am going to try the Macro program posted too. If anyone would like see more of this let me know. Again thanks for your replies.

 

Greg.

[cappy]

All,

 

Here is the LAP cycle the operator wrote for the broaching.

 

G13

M110

G0X30Z50

T0909

G0C0

M147

G94G0X7.05Z.2

M8

G85N1D.001U.00W.000F200.

N1G81

G0X7.25Z.2

G1Z-3.41

X7.05Z-3.41

G80

M146

N10G0C90

M147

G94G0X7.05Z.2

G85N1D.001U.00W.000F200.

M146

N20G0C180

M147

G94G0X7.05Z.2

G85N1D.001U.00W.000F200.

M146

N30G0C270

M147

G94G0X7.05Z.2

G85N1D.001U.00W.000F200.

M146

M9

G0X30Z50

M109

M2

%

[Mick]

I used to do it all the time. We made speedway components at a place I used to work at, I particularly recall broaching an internal spline for wheel collars. It worked a treat.

 

The machine was a LB25II with a OSP7000L control.

[Curt B.]

These work great for that purpose:

 

http://www.razorformtools.com/websiteV2/html/home.html

 

It doesn't need to be more complicated than using a short sub with an L or K command.

[ATG]

I just program a cross countour with the c axis and use negative numbers to make sure the broach is heading in the right direction it is very fast and easy to do right in master cam no edits........ If you want a sample of the code i can post it.......works great...

[cappy]

Newchsmcam,

 

I would like to see that if you don't mind. The lap cycle works well, but some of our operators are not too familar with the Okuma Lap code.

 

Thanks,

Greg.

[ATG]

This is for a Haas

This is a 3/8 keyway in a 1.5 dia

If i coud figure out how to add a screen shot i would.........

%

O00000 (INSIDE KEY)

(DATE - 11-11-08-07:00)

 

(START TOOL LIST)

( T9 MILLING .375 keyway cutter from Horn )

(END TOOL LIST)

 

 

(T9)

()

G0 G40 G20

G00 G129 X0 Z0 T0

T0909

M8

M154 (C AXIS ENGAGE)

G00 G54 X1.2 Z.3

C0.

G98

M135 P0

X1.24

G01 X1.4444 F220.

Z-2.75

G00 X1.2

Z.3

X1.2444

G01 X1.4487

Z-2.75

G00 X1.2

Z.3

X1.2487

G01 X1.4531

Z-2.75

G00 X1.2

Z.3

X1.2531

G01 X1.4574

Z-2.75

G00 X1.2

Z.3

X1.2574

G01 X1.4618

Z-2.75

G00 X1.2

Z.3

X1.2618

G01 X1.4661

Z-2.75

G00 X1.2

Z.3

X1.2661

G01 X1.4705

Z-2.75

G00 X1.2

Z.3

X1.2705

G01 X1.4748

Z-2.75

G00 X1.2

Z.3

X1.2748

G01 X1.4792

Z-2.75

G00 X1.2

Z.3

X1.2792

G01 X1.4835

Z-2.75

G00 X1.2

Z.3

X1.2835

G01 X1.4879

Z-2.75

G00 X1.2

Z.3

X1.2879

G01 X1.4922

Z-2.75

G00 X1.2

Z.3

X1.2922

G01 X1.4966

Z-2.75

G00 X1.2

Z.3

X1.2966

G01 X1.5009

Z-2.75

G00 X1.2

Z.3

X1.3009

G01 X1.5053

Z-2.75

G00 X1.2

Z.3

X1.3053

G01 X1.5096

Z-2.75

G00 X1.2

Z.3

X1.3096

G01 X1.514

Z-2.75

G00 X1.2

Z.3

X1.314

G01 X1.5184

Z-2.75

G00 X1.2

Z.3

X1.3184

G01 X1.5227

Z-2.75

G00 X1.2

Z.3

X1.3227

G01 X1.5271

Z-2.75

G00 X1.2

Z.3

X1.3271

G01 X1.5314

Z-2.75

G00 X1.2

Z.3

X1.3314

G01 X1.5358

Z-2.75

G00 X1.2

Z.3

X1.3358

G01 X1.5401

Z-2.75

G00 X1.2

Z.3

X1.3401

G01 X1.5445

Z-2.75

G00 X1.2

Z.3

X1.3445

G01 X1.5488

Z-2.75

G00 X1.2

Z.3

X1.3488

G01 X1.5532

Z-2.75

G00 X1.2

Z.3

X1.3532

G01 X1.5575

Z-2.75

G00 X1.2

Z.3

X1.3575

G01 X1.5619

Z-2.75

G00 X1.2

Z.3

X1.3619

G01 X1.5662

Z-2.75

G00 X1.2

Z.3

X1.3662

G01 X1.5706

Z-2.75

G00 X1.2

Z.3

X1.3706

G01 X1.5749

Z-2.75

G00 X1.2

Z.3

X1.3749

G01 X1.5793

Z-2.75

G00 X1.2

Z.3

X1.3793

G01 X1.5836

Z-2.75

G00 X1.2

Z.3

X1.3836

G01 X1.588

Z-2.75

G00 X1.2

Z.3

X1.388

G01 X1.5923

Z-2.75

G00 X1.2

Z.3

X1.3923

G01 X1.5967

Z-2.75

G00 X1.2

Z.3

X1.3967

G01 X1.6011

Z-2.75

G00 X1.2

Z.3

X1.4011

G01 X1.6054

Z-2.75

G00 X1.2

Z.3

X1.4054

G01 X1.6098

Z-2.75

G00 X1.2

Z.3

X1.4098

G01 X1.6141

Z-2.75

G00 X1.2

Z.3

X1.4141

G01 X1.6185

Z-2.75

G00 X1.2

Z.3

X1.4185

G01 X1.6228

Z-2.75

G00 X1.2

Z.3

X1.4228

G01 X1.6272

Z-2.75

G00 X1.2

Z.3

X1.4272

G01 X1.6315

Z-2.75

G00 X1.2

Z.3

X1.4315

G01 X1.6359

Z-2.75

G00 X1.2

Z.3

X1.4359

G01 X1.6402

Z-2.75

G00 X1.2

Z.3

X1.4402

G01 X1.6446

Z-2.75

G00 X1.2

Z.3

X1.4446

G01 X1.6489

Z-2.75

G00 X1.2

Z.3

X1.4489

G01 X1.6533

Z-2.75

G00 X1.2

Z.3

X1.4533

G01 X1.6576

Z-2.75

G00 X1.2

Z.3

X1.4576

G01 X1.662

Z-2.75

G00 X1.2

Z.3

X1.462

G01 X1.6663

Z-2.75

G00 X1.2

Z.3

X1.4663

G01 X1.6707

Z-2.75

G00 X1.2

Z.3

X1.4707

G01 X1.6751

Z-2.75

G00 X1.2

Z.3

X1.4751

G01 X1.6794

Z-2.75

G00 X1.2

Z.3

X1.4794

G01 X1.6838

Z-2.75

G00 X1.2

Z.3

X1.4838

G01 X1.6881

Z-2.75

G00 X1.2

Z.3

X1.4881

G01 X1.6925

Z-2.75

G00 X1.2

Z.3

X1.4925

G01 X1.6968

Z-2.75

G00 X1.2

Z.3

X1.4968

G01 X1.7012

Z-2.75

G00 X1.2

Z.3

X1.5012

G01 X1.7055

Z-2.75

G00 X1.2

Z.3

X1.5055

G01 X1.7099

Z-2.75

G00 X1.2

Z.3

X1.5099

G01 X1.7142

Z-2.75

G00 X1.2

Z.3

X1.5142

G01 X1.7186

Z-2.75

G00 X1.2

Z.3

X1.5186

G01 X1.7229

Z-2.75

G00 X1.2

Z.3

X1.5229

G01 X1.7273

Z-2.75

G00 X1.2

Z.3

X1.5273

G01 X1.7316

Z-2.75

G00 X1.2

Z.3

X1.5316

G01 X1.736

Z-2.75

G00 X1.2

Z.3

X1.536

G01 X1.7403

Z-2.75

G00 X1.2

Z.3

X1.5403

G01 X1.7447

Z-2.75

G00 X1.2

Z.3

X1.5447

G01 X1.749

Z-2.75

G00 X1.2

Z.3

X1.549

G01 X1.7534

Z-2.75

G00 X1.2

Z.3

X1.5534

G01 X1.7578

Z-2.75

G00 X1.2

Z.3

X1.5578

G01 X1.7621

Z-2.75

G00 X1.2

Z.3

X1.5621

G01 X1.7665

Z-2.75

G00 X1.2

Z.3

X1.5665

G01 X1.7708

Z-2.75

G00 X1.2

Z.3

X1.5708

G01 X1.7752

Z-2.75

G00 X1.2

Z.3

X1.5752

G01 X1.7795

Z-2.75

G00 X1.2

Z.3

X1.5795

G01 X1.7839

Z-2.75

G00 X1.2

Z.3

X1.5839

G01 X1.7882

Z-2.75

G00 X1.2

Z.3

X1.5882

G01 X1.7926

Z-2.75

G00 X1.2

Z.3

X1.5926

G01 X1.7969

Z-2.75

G00 X1.2

Z.3

X1.5969

G01 X1.8013

Z-2.75

G00 X1.2

Z.3

X1.6013

G01 X1.8056

Z-2.75

G00 X1.2

Z.3

X1.6056

G01 X1.81

Z-2.75

G00 X1.2

Z.3

X1.61

G01 X1.8143

Z-2.75

G00 X1.2

Z.3

X1.6143

G01 X1.8187

Z-2.75

G00 X1.2

Z.3

X1.6187

G01 X1.823

Z-2.75

G00 X1.2

Z.3

X1.623

G01 X1.8274

Z-2.75

G00 X1.2

M9

M155 (C AXIS DISENGAGE)

G00 G129 X0 Z0 T0

M30

%

[ATG]

Now I'm taking very small steps .002 per pass. I'm using c-axis cross contour, using depth cuts. For the tool I'm just saying that its a end mill.