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Colin Gilchrist

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Everything posted by Colin Gilchrist

  1. Are you using 'Reference Points'? What are your values for "Home Position", and do you have "Show Mill/Router Home Position" enabled in the Backplot Settings [!] menu?
  2. Money > Sandvik has it in spades Effort > Let's see if the Swedes kick things into high-gear. I would imagine it would be to their benefit to do some technology sharing between all of their code-bases, and just build "Sandvik CAM", with everything under the sun: UI, kinematics, machines, posts, simulators, etc. But that does come back to the Money & Effort argument, so hopefully something does change...
  3. Sure, and that's great. I get that completely. But it isn't here yet, and this new attempt at building the UI feels incomplete. More pages, but less functionality. That is going backwards to me. When CNC Software has rolled-out new functions like this in the past, there was typically a way to "disable it, and use the old way", so that the technology could mature before everyone was ready to migrate over to the new interface. Kinematic Awareness would be awesome, but that requires a whole system to be able to build kinematic models for both Programming Purposes (machine awareness at the toolpath level), and models for Simulation Purposes > showing what happens during when executing NC Code. This isn't just "tool removing material from stock". It requires being able to simulate the moves to/from a Tool Change, and all the other "motions" of the machine. At the higher levels (VERICUT, CAMplete, NC Simul), this includes things like simulating the motion of the tool changer arm when exchanging tools, or being able to model a tool carousel, where all of your loaded tools are available to interact with the stock/part/fixture models. It also requires the ability to simulate both "dynamic codes", and the correct interpretation of "how the rotary behaves on the machine". When you configure a Rotary Axis in VERICUT, guess how many "rotary behavior options" are available in the drop-down selection menu? You have the following Absolute Rotary Direction settings, which control how the rotary motion is interpreted: Positive -> CCW Positive -> CW Always CCW Always CW Shortest Distance Linear Shortest Distance - 180 CW Shortest Distance - 180 CCW Positive -> CW Absolute Positive -> CCW Absolute Shortest Distance 2 Shortest Distance 3 Shortest Distance - 180 Linear Shortest Distance 4 Question: why on earth would they have so many different configuration options, just for a Rotary Axis? Answer: because they have identified different machine behaviors during testing (all generally based on controller and parameter settings on the machine), where they had a need to create different internal routines for handling how the rotary moves, based on 1.) current position, and 2.) next commanded position. Since Sandvik owns VERICUT, ICAM, and Mastercam now (oh, and Gibbs for good measure), there would really need to be some type of integration inside Mastercam with the combination of ICAM & VERICUT. I'd be curious to see what the overall plan is for the next 2-years, 5-years, and 10-years. There CAD/CAM industry is going through quite a bit of upheaval, and I'm curious to see how that all plays out in the next decade...
  4. I really don't understand why CNC Software would release Machine Group Setup, in its current form. - You can "setup your machine simulation", but not really. Because the MGS selections, don't actually "do anything". You still have to use the "Machine Simulation Setup", so I just see a bunch of "extra stuff for the future", with no practical application in 2023. But even worse, things that "used to work in Machine Group Properties", now no longer work in Machine Group Setup. - You can select "material", but that doesn't actually select material for your Speed/Feed calculations. You must go to the "Material button" on the ribbon bar. You actually "set the material" under the Master Model menu, but it is only "displayed" under the Stock Setup. Why wouldn't they just use the same controls on each panel, so you could see & edit the material type and properties, in both places? - Stock Setup > they got rid of '2-points', and you now must go through the 'Bounding Box' button, to create rectangular or cylindrical stock. But the interface for Bounding Box doesn't really make it clear that you can just "type in stock values", as the first control you are presented with is "manual geometry selection" or "automatic". How is this not completely worse than the old method User Interface for Machine Group Properties? There is the "Machine Setup", which is the files you are programming with (MD/CD/PST), oh, and they stuck the Line (Sequence Numbering), Program Number, and Comment Output Checkboxes, with the MD, CD, PST Files? If it were me, I would make the following changes to the layout of the Machine Group Setup: Page 1 would be Machine Setup > MD/CD/PST, and Machine Simulation drop-downs/selection, and configuration options (move other settings below) Page 2 would be Model Setup > which would include 'Master Model' (Part) section, 'Stock' section, and 'Workholding' section. Material could be assigned/viewed/edited with a 'common control' on both Part and Stock pages. (Keep the 'Master Model' term if you like it, but I think Siemens may have a legitimate grip with using that term, although I don't know if they have it copyrighted, they've been using that term for a long time in their training materials...) Page 3 would be Program & Tool Settings > (Basically, take the "Tools" page, and add some controls, and move some settings from other pages. For example, move Tool & Operation Library selection to this page, also Program Comment Control, Sequence Numbers, and Program Number settings, I would eventually love to see "Control Settings" available on the "Program & Tool Settings" panel, because then all "program output and formatting controls" would be accessible through the MGS panels, rather than having to use the Machine Definition Manager, and Control Definition Manager functions, in a separate part of the software. It would also be cool if there was an option for "material", where we could have a "HUD" (Head's Up Display) checkbox, where that data would display overlayed on the screen, while manipulating the Bounding Box function. It would be cool if you could edit or push/pull the stock size, and based on the HUD being enabled, and material assigned, and see the results of those changes in the HUD data being overlaid on the screen. Vericut has the HUD function for displaying your NC Program, while running, and I love that feature. I think honestly, the only change I really like, is the ability to set a different 'Stock Color' on the Stock Setup page.
  5. Also, if you have a Hole in the model, you can use the "Hole Axis" command, to create a "Centerline" of the Hole. With a line (Vector) down the center, you can then use that to create a Plane. By viewing the part in different orientations (Top, Front, Right, Etc.), you can create wireframe geometry, and then "project the compound angled line, "flat" to one view. That way you can measure the angular distance for Tilt, and for Rotation.
  6. I realize this is an old thread, but wanted to mention something, which may help with the availability of moving tools from your 1st Machine Group, to the other machine groups. I will typically create a "Part File Tool Library" ("part_name" or "job number".tooldb). When programming the 1st Machine Group, I'm typically pulling tools from a large master tool library, and creating/editing the tools as needed for that 1st Setup. When finished with that 1st program, I will go into the Tool Manager (for lathe files, need to do this twice, once for mill tools, and again for lathe tools), and I will select "all used tools" from my "part tools", and use the 'down arrow button' on the dialog to copy all of those tools to the 'part_file.tooldb'. There is no "save button", but when you close the Tool Manager, you'll be asked if you want to save the changes to your tool library? (yes) Then, when I load the 2nd machine group, I can simply select this 'part_file.tooldb' as my Tool Library, and I've got all of those previously programmed tools from the 1st Setup, ready to bring into my next Machine Group. If I add new tools during the following setups (maybe I add a couple of tools on the 3rd Setup...), I can use the Tool Manager, to copy my "part tools" (from that setup), into the 'part_file.tooldb' file, and those tools are now available in my other Machine Groups, so long as I pick that library. Note: you can switch up libraries on-the-fly while programming. So, if you've got a tool in 'Mill_Inch.tooldb', you can simply open the Tool Manager, pick that other library, copy the tool into your 'Part Tools' section of the manager (up arrow button), and then switch back to your 'part_file.tooldb'. I typically ignore any warnings about creating duplicate tools. I probably have 200+ "T1's", in my Mill_Inch.tooldb. I just use the filtering functions to select the tools I'm after.
  7. First, this was an excellent video, thanks for posting it Aaron!!! As Freya rolled the credits, this link caught my eye: https://pomax.github.io/bezierinfo/index.html This particular site is like an extension of the mathematics, which underlie that video. There are a bunch of interactive applets, which allow you to "visually play" with the underlying math. Pretty cool.
  8. Post up a Zip-2-Go, that contains the Post, and a sample file. To be clear > are you talking about programming all the operations from the same WCS (top view), without using different Toolplanes? I'm with Ron > it could be as simple as having 'two axis combinations defined' in the Axis Combo list, and just picking the "3-Axis combination", but it would depend on who built your Post, and what they used as a "Base Post" to start with.
  9. The other possible solution would be to not use CSS, use RPM mode only, and then reduce the feed, starting at about 0.080" Diameter, down to about 0.0004 IPR, and then at 0.040" diameter, reducing to 0.0002 IPR. Also, possibly increase the SFM by 25-50, and see if that helps at all. What color were the chips coming off at your current programmed SFM? But I also like G-Code's advice to stop early, leaving the part connected, and breaking it off by hand. Either way, you will need to do some clean-up/finishing, unless that part of the pin is hidden in the fixture, and you can live with it. I'd also suggest reprogramming the part-off code, to "plunge in" about 0.060", pull-back for clearance, and then add a "chamfer" move, from out-to-in, to help push any burr formed towards the pin center. If you put a 0.01-0.02" chamfer, that would be plenty. Might want to program at 35-degrees, or 40-degrees, instead of 45-degrees, to help with pushing the pin into the hole, if the installation will be permanent. After cutting the chamfer, then proceed with the part-off cut, in stages, where you reduce the Feed-per-Revolution accordingly, or stop early, and hand-break the part.
  10. You might consider: Yes, Center-height of the tool, could play a role. Should be as close to perfect as possible. Try using RPM, instead of CSS. The "ramping" can have a big effect as you get close to "zero", and will be limited by your G50/Max. RPM line anyway. Might consider starting at 0.0008 IPR, but only going down to about 0.080" Diameter, and then dropping down to 0.0002-0.0004" per revolution If you continue to chip the inserts, consider dropping SFM by 50-75. (Try 250, or 275 SFM)
  11. "3mm High-Feed" > excellent choice. What brand if I may ask?
  12. I'm with Matt. Carbide is roughly 70-80 HRc. Take light depths of cut, maybe 0.005-0.010 per pass, and just do a "zig-zag in depth, to move through the material. No need to grind with a grinding bit, unless you're requirement is for the ground finish on the cut-end of the gauge pin. Cutting with carbide should be much quicker, and you could likely "gang" these parts together, if you have a group of pins with the same length, using pockets in soft-jaws. (Cut in X or Y, drop down your depth-of-cut in Z, and reverse the cutting direction to go the opposite way, then repeat.) If you hold the pins "on the side of the jaws" (as opposed to sticking "straight up"), you could slot-through the side of the pin. So, instead of machining away the entire material, you could just have to cut through the diameter, making slotting passes. 200-400 SFM, and 1-2% of the Tool Diameter, "per tooth".
  13. 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.)
  14. 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.)
  15. 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...
  16. What insert grade are you using?
  17. 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.
  18. 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.
  19. 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
  20. result = force (feed) #This will force a single variable result = force (xout, zout) #This will force a 'range' of variables That will force the output of the "variable range", between the start and end "index variables". In this case, we're only giving it a single variable in the range, so only the 'feed' variable gets forced. Now, this is assuming that your Post is setup to use 'feed' as the Feedrate Output variable. Otherwise, you'd need to use a different 'variable name' as the start/end index variable in the 'force' function.
  21. For what it's worth > Haas now sells a MRZP Test Cut Kit, which includes everything needed to make a test cut (besides the block of aluminum). https://www.haascnc.com/service/troubleshooting-and-how-to/how-to/umc---mrzp-test-cut-kit---ad05450.html PN: 93-3347 UMC - MRZP TEST CUT KIT This kit comes with a self-centering vise, and 3 tools (complete tool assemblies), needed to cut a test block, to find and correct MRZP Errors, using their 'standard test program' (which you can find in that Haas Link above).
  22. I was looking at the Shrink Holders on the Haas website. They are roughly $120-160 each. If you got 20 holders, with an average of $150 each, that's a savings of around $3K on the holders. That is a pretty great deal, for having that capability. I also love the idea of a Capto reduction, to give you the reach, and a replaceable-tip cutting tool. For replaceable tips, I've use the Ingersoll 47D RQ 90-degree Variable Pitch Tips in Titanium, and loved them. I would bet they handle Cast Iron great, but that grade doesn't come in a Sharp Corner version. The Series 48 & 49 Tips do come in sharp corner, and they are also available in multiple flute lengths (1.5xD!) if needed. Series: 47D_RQ - 90° Variable Pitch Tip for SS & Hi-Temps Series: 48_ & 49_ - 90° End Mill Tip Sandvik, Kennametal, and Iscar also make replaceable tip tools, so I'd look for a vendor with the best local service and support.
  23. https://www.helicaltool.com/products/4-flute---corner-radius---chipbreaker-rougher---variable-pitch---reduced-neck-aplus https://www.helicaltool.com/products/multi-flute-corner-radius---knuckle-rougher-variable-pitch https://www.helicaltool.com/products/multi-flute-corner-radius---knuckle-rougher-variable-pitch-reduced-neck Any of their 4-Flute or 5-Flute tools would work well. I'm with Ron > get yourself one of these. The prices have really come down... https://www.haascnc.com/haas-tooling/tool_management/shrink_fit_machines.html Plus, Haas is running a great deal right now > buy a Shrink Fit Machine, and get 20 Shrink Fit Holders included!
  24. 3D > Optirough, for roughing basically any 3D Shape.
  25. Also, with Backplot, you've got the "quick verify feature", where you can see a "2D area plot", of where the tool tip has traveled. The other thing with Backplot, you can "expand the floating box, with the double down arrow button, and see the XYZ Positions, of each "move in the NC Code", plus Feed/Speed info, and "toolpath time", under the info tab. I use the "estimated time", in order to judge "did my improvements to the path make it more or less efficient from the initial baseline"? I'm with Gcode & Jparis, I typically use Backplot the majority of the time I'm programming paths, as a "quick check", and I don't actually run Verify/Simulation, until the process is much more mature. (Until I've got most of the part programmed.)

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