Try the little used plunge mill path.

What type of Ti is it? S&F will depend on it I've found.  6Al4V vs 6Al6V for instance.

Turn and burn.

4-axis no-core.

I would also like to see an easier interface for anything other that basic 2d.  I have some parts that require a lot of model manipulation to get geometry to run 4-axis.

I still have to do a lot of customizing the g-code after posting for my Charmilles.

I asked about that years ago.  Charmilles played around with it and there was an add-on at one time that did just that.  I was told it didn't take off because of efficiency though.

I know that wire has always taken a backseat to mill and lathe.  After seeing what ***** can do, I was hoping that CNC Software might finally try to catch up. 

While ****** can do some pretty cool stuff, it is not very user friendly when transferring from MC.

17 hours ago, Newbeeee™ said:

Matt - I'm assuming you'd neck down the cutter - so it doesn't have much flute in contact to reduce sidewall rub?

Correct. 

We actually keep endmills on hand already relieved and can run over to the Monoset if not.

Any rumors on WEDM finally getting updated?  I know it's probably a long shot, but I thought I'd see if anyone has any info.

Thanks

I know this is a couple months old, but next time you might try using the old plunge milling method if you still can't us a WEDM.  With a small stepover you can get a good surface finish with little to no taper; similar to chop grinding on a jig grinder.

3 hours ago, machineimpossible said:

So the inspection is being done right from the solid model as nominal. I cannot speak to any import/conversion issues with the CMM software bringing the model in. The format we were supplied from the customer was .STP but I don't know if that went right into the CMM software with no issue, or if it needed to be converted to something else.

As to the method, they are using full scanning for everything, not just minimal points. so each of these internal arc features are scanned with dozens of points all along and across the feature. So I would say they are being checked as true partial cylinders, and the CMM is report deviations of Form, Position and Size to the solid model as nominal.  Which of course is required to truly evaluate a profile of surface tolerance.

I have had issues with inspection scanning profiles and giving bad data on small arcs. 

On one part they used a 1/2mm ruby to scan a profile with an .011 inch radius and a .0003 inch all around profile tol and said I was out at in two spots.  Well, the center of the probe tip was whipping a .001 inch arc and which has the same effect as with an endmill.  After chasing my tail for four weeks, they finally switch to a smaller (.2mm) tip, took measured points and voila, wouldn't you know the parts were good all along.

On 6/12/2020 at 8:16 AM, machineimpossible said:

The component I am working on has an overall profile tolerance of .005 to the entire model. There are dozens of small internal corners, all normal 90 deg arcs. Most of these arcs are falling out of tolerance on the .005 profile.

You should be able to hold .005 profile easily.  The little tricks mentioned are for when your splitting tenths.  Looks to me like the machine needs looked at. 

When was the last time it was checked (ballbar, laser,etc.)?  What were the specs?

On 1/29/2020 at 2:28 PM, Newbeeee™ said:

Now in my day, that hand sign meant something different to what it now does...

My kids were shocked to learn their generation didn't invent the circle game.

I seems that MC has gotten a little worse with each generation on its ability to handle splines.

You might try locking Y on hole B and x on hole C.

On 12/15/2018 at 8:43 AM, gcode said:

yes...  computer, wear and off.. I never never ever use Control

Wear on mill.

Off and CONTROL for wire.

My FARO arm quit on me and now has a "end stop/stress warning" during cal.  FARO tech support wants me to clear it Verisurf through the Hardware Device setup, but we can't find it.  Any Verisurf guru help would be greatly appreciated.

If you just use lines, it depends on which half of the line you pick on the direction of the vector.

double post...

Make sure and use this formula for your chipload and save yourself A LOT of headaches.

ipt (holedia - cutterdia) / holedia

When you have to put a 2 1/2-4 thread 2 inches deep in a solid block of unknown steel that is 68HRC, thread milling is a better than burning it. 

Do you have another 'puter available? Are you on a network or standalone. Swap out the keyboard and mouse.  Try using your config on another system. Need to isolate if it is a hardware or software issue.

Anyone here use it for molds? How much do you have to alter your gen settings to cut it and hold tenths?

When is Wire going to be updated?  It is WAY overdo...

I am a 5 axis cnc programmer and also a process engineer and only make 50k a year.  Does that seem right to anyone?  The other engineer makes way more than I do but only because he is about 20 years older.  It doesn't seem to matter if I do a better job than him or go above and beyond what I am asked, which he never does.  I am 30 years old and can't even afford a house!  I don't get it.  Why do all this work and put up with stress when I can't even live comfortably?

It all depends on what part of the country you're in.

When it comes to facing aluminum, I've found Mitsubishi to be the best.  Unfortunately the facemill that NEVER chattered for me is discontinued, but the AXD are fantastic too.

We recently got a 4" Sandvik Century RA590 facemill (not cheap) and that thing is amazing for surface finish if you ever need a part smooth as a baby's a$$. You can dial each insert in.

Thanks, for the info on the AXD. I'll look into the Sandviks as well.  I really like the idea of dialing in each insert.

Double stick tape, if it's practical in your situation.  Essentially free state, and should take care of the chatter since its "supported" over the entire part.  To get rid of chatter and get a better finish out of a facemill for stuff like this, I've also taken out all but one of the inserts... basically making it a flycutter.

The plates are to warped to use tape, plus it would be a PITA with the number of plates I have to do.

Old school fly cutter with HSS cutter.  Trust me...

I'm limited to a 2"Ø, or I would try a fly cutter.  I am going to try taking two inserts out of my current cutter today and see what happens.

The material is speced by the customer for reasons I can't discuss here. I requested it to come in ground but obviously I didn't get it. So like always, "just make it work...yesterday."

The first batch was .75 thick and I used Mitee Bite step clamps for holding with a 2 inch seco octomill and f15m inserts to cut, it's what is currently available in the shop. Some of the plates required flipping a few times, other didn't.  Vibration has really been the enemy I've been fighting and keeping it in a reasonable cycle time.  Only shaving what is needed to flatten one side in a free state before flipping and bolting down.

Kind of been looking at the Mitsubishi's AXD series.  Anyone use them or like it?  I'll look at the AB Tool shear hog.

Thanks for the input.

I have some 7075-T6 half inch sheets two foot square I am holding close to free state and need to flatten within .001in. Looking for the best facemill and inserts for cutting it.

Please opine.

Thanks