Crazy part

[alanu23]

Here is a part my company bid on for some strange reason. it is 13x16x3.75 approximatley. I have two months to make 3 of these. At 3 C-notes profit per part, I will most likely easily absorb any of that profit in programming and then some. Probably not hard for a bunch of you senior programmers, however it is to me. Does anyone have any ideas where to even start on this thing? I have a Haas VF8 and a Mori NH5000 4ax simultanious horizontal, and its 7075 thank god. I am thinking about roughing it to within .050 front and back on the VF8 and adding an inch excess material for tooling tabs, then putting it on a fixtured tplate in the mori, locating and bolting on my tooling tabs, finishing the grate pockets in the top shown in the 1st two illustrations and also the pockets on the ends, keeping it on that fixture or possibly even creating an identical fixture to rotate it 90 degrees to finish the pockets on the other two ends, then finally putting it on a fixtured tplate to finish the backside pocket.. Sound like a plan? Looking at the grate pockets though it looks like a good application to use either subprograms or tool path transform. Would that be easy? or would I be better off sillouete boundrying the whole thing normal to the pockets and translating each chain somewhat close to each individual pocket on the part then selecting all the chains to pocket then set my linking parameters to incremental? Any way I look at it this part is going to be some serious work. I really wish this part was just a little smaller, then I could put it on a Haas VF5 5ax... Three ops instead of 5 or 6. But sadly that is one variable I cannot change. Oh yeah.. Tolerances are +/-.008 on all wall thicknesses, +/-.030 everywhere else. Any Ideas?

 

 

 

[RandleXX]

Looks like a fun one.. Sometimes aerospace parts like this will have a mismatch spec callout on the print that will let you use a bull endmill on the closed walls.

 

I love these kind of parts.. w

[alanu23]

I just looked at the print and it does, surprisingly enough its allowed in all pocket walls! Definately the first time I have seen that. usually its just on the closed walls like you said. I originally thought I would have to use a 2"loc 1/4" ballnose to finish the radii. I have had to do it before on less complex parts. 1 hour to rough 2 hours to finish..

[Josh T™]

Man that looks like a good job! We used to machine parts very similar to that on my last job. Have fun with it!

[Hardmill]

I worked in a shop that had a simuliar windows

cut into it and they did it on a wire machine.

 

Good set up and good profit for them on it.

Ill try and dig up the file to show you.

 

 

PEACE

[alanu23]

awesome thanks

[SydwazShawn]

Oh man I wish I had to make that part! Good luck alanu!!

[Jayson Kramer]

The top surface looks radial and if so are the holes perpendicular to the outside OML. I also suggest cutting the hole project on the Horz.

When you rough you might want to leave a little more on and check for spring.Is there any stress re-leaf call out on the print?

[alanu23]

Jeez Jay you are right about those holes, they are perpindicular to the surface, they have a common vector in one direction and and are perpendicular to the surfaces in the other direction. It is hard to see in the rendered images but it is curved in both directions. So basically that is another fixture I am going to have to design to put some holes in. Maybe our Manual mill guy can put those in with a drill jig, that is what the boss would say anyways.. I didn't see stess releaf anywere on the print, I will have to check the info.

[TheePres]

Below is a part that I programmed, very similar to your design. It was roughed out on a home made trunnion fixture. Then an NCL guy was brought in to do the final walls on a 5-axis gantry. Bad picture here but every horizontal wall curves at diff angle, and each vertical wall is at also at diff angle to the radius, so no 2 corners are identical.

[alanu23]

That is really similar to the one I am doing. I wish that I had a 5 axis something or other to do mine.

[Jack_C]

Reminds me a little of this job......

Big fun.

 

 

Jack

[Guest CNC Apps Guy 1]

Looks like what you see on a plane when you land and the cowl(?) pulls back and the thrust diverts forward.

[Greg Williams]

Nice part Well done

[TheePres]

Jack,

Thats the exact same part. Ive seen it at several SoCal aerospace companys. Last I heard a place in fullerton was making it.

 

James, it goes on the C-17 plane and from what i understood, has to do with diverting air flow to cause plane to stop on shorter runways.

[Jack_C]

It's a little different.

You posted a picture of a 17P8D9362-1 which has a flange on three sides and meets the nacelle pylon.

Mine is a 17P8D9364-1, has only two flanges and mates with two other sections - 363-1 and 365-1.

 

I originally did this as a complete turn key and have subsequently implimented an optimized programming contract.

 

There are a bunch of people running these parts but the contractor is TSLA.

 

J

[alanu23]

Well here is what I have so far, I've been through ALOT to get this far... and still have .050" to take off all surfaces. Thank god for Vericut!!

 

[Dave.L]

Thats bitchin

[SydwazShawn]

Thats SWEET!

[Joe788]

GREAT WORK!

[BenK]

Cool part

[Mic6]

That's what machining is all about

[MACHINEMASTERG]

how many hours into that ????

[alanu23]

programming/tooling design/ vericut prove outs/ and countless post and control mods on a brand new post.. so far I would say about 80 to 100 hours. probably have about 50 more to go. Machine time so far is about 5 to 7 hours.

[Thee Rickster ™]

quote:

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and still have .050" to take off all surfaces

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So why teh hell is it off the machine then??

 

J/K, looks awesome!!