Mr. Bond, I know that timing is extremely important, so I will cut to the chase. Kill the lights, draw the curtains, disconnect your telephone, and immediately abandon your mailbox – unless you’re expecting a cheque. Andrew and I will see to it that you have a new identity, once you reach the 42nd parallel, please enter at the Detroit/Windsor crossing, preferably around the 2:00AM mark – call me on the red cell phone 45 minutes prior to crossing. (I am a Canadian citizen, I have been in the U.S. for 20 days, I have only these Krispy Cream donuts to claim ($21.00 worth), and would you like one? – Works every time. (Memorize this, and then eat the paper). Your new life shall entail an opportunity to earn a living (somewhere in southern Ontario), 100K in salary, the right to privacy, freedom of speech, and a pretty fair medical & benefits package. The show up and cut it moniker has finally made it’s mark – please do not despair for you will live a long & happy life up here along side the Eskimos, salmon, and polar bears. This message will self destruct within 20 seconds. Regards, Jack

Octhesax, The axis of all will sync to the slowest and adjust accordingly, Mastercam will not overcome the laws of physics nor will the Fadal, manually programming the multiple axis will prove this. The rotary axis probably revolves at about 20% of the feedrate that you were expecting, multiple processors will certainly do the math very quickly; however, this is a mechanical problem brought about by introducing one or more rotary axis to the mix. G94 vs G95 matters not; play around with the feeds and you will learn a little more. A scientific approach or explanation is required here, unfortunately - we are a hindered breed when it comes to explaining some things. Regards, Jack

TheePres, APT was a dead horse twelve years ago, and it’s still dead. Why are we even discussing this? Regards, Jack

As Scott stated, This is it! Regards, Jack

TheePres, No offence intended; but what the hell does Boeing know about machining? – absolutely nothing! Let me state this twice – absolutely nothing! Frame milling and pocketing routines are an individuals approach to an efficient machining procedure; this comes from experience only, hardly the defacto standard that some BS company purports to be their preferred method. If Boeing is addressing an issue about 7050 & 7075 thin walled machining, then I would certainly like to here about it. You have been slapped with another BS story from the experts on high – take the lecture with a grain of salt – everybody else does! Regards, Jack (only 20 years - but still a little rowdy and certainly able to prove it).

James, No offense, for I beg to differ, EDM costs are very much affordable as well as commonplace around the area slightly north of the 42nd parallel. If given the choice of milling your name into a fine tooth flat xxxx file (.01” below the tooth form) or burning this in via carbon and copper electrodes, would you still argue this point? My observation is based upon 66Rc, this is virtually impossible to machine when the tools recommended top out at about 50~58 Rc, there is an outside chance that CBN & diamond could effectively render a satisfactory result – economics would prevail if the cutting tool costs exceeded $1000.00 . Please don’t get me wrong, I am not challenging you or anyone else for that matter. From a shear economics viewpoint, I couldn’t expect a reasonable cost/result solution with this unusual application. Hard milling 48Rc, 55Rc, and even 58Rc is nothing new to many of us; 66Rc is not as common a hardness to deal with and quite honestly I have never personally machined anything at this hardness without a grinding wheel. Regards, Jack

Slick, I’m sorry, but this application is still haunting me. The economics of this task reeks of producing the male electrode and boiling it through the rough with graphite and finishing with copper perhaps. The time & effort spent on the electrode method will justify the cost; the opposing argument of hard milling is highly speculative and certainly cost prohibitive. ~ The gain is the education or personal satisfaction. Basically, this job may take 3 hours, may take 20 hours of fighting the laws of physics, or may never occur for all the time invested. Nobody here will judge or consider this a failure – please reconsider the attack, for nobody would argue that EDM is a solid solution given the 66Rc that you are presented. Basically, it all comes down to cost – what is the quickest, most efficient method to make this part, Etc! Regards, Jack

Slick, Give it your best shot. Do not entertain the feed hold button under any circumstances. If this is a solid, then ramp into the workpiece - the dull orange glow will warm your hands quite nicely (please avoid the touch as suggested). If your going with a .110" dia then order at least six cutting tools; do not forget to grind a .01" ~ .02" radius on these tools. Stay pumped, especially if the going gets tough. Regards, Jack

Dave, Just when I’m thinking (Dave is a stuffed shirt) you come out with “"Here comes the Metric System" and "Lead Paint: Delicious But Deadly" Keep it up please! Regards, Jack

Corey, The .013 depth of cut looks a little aggressive, but hey, who am I to question a professional? Slick, please heed the advice from Mold100 – he is an expert at EDM and a pretty good toolmaker besides. (Still owes me some beers, I might add). I still disagree with the depth of cut, yet, I am in total agreement with the avoidance of the sharp cutting edge. Slick, it’s really your call on this one – for we could all eat crow, theoretically that is. - You’re the one that’s going to perform this miracle (please do not disappoint your supervisor, or worse, the rest of us in this fun-time forum. As Emeril says, let’s kick it up a notch - BAM! Regards, Jack

Slick, You are out there, in the grey area of Machinery’s handbook (ever notice how incredibly generalized feeds and speeds have become in the last six issues?) James – I’m really impressed! Greg – Ditto. This man is attacking the hardness approaching that of a file, the ones we use to deburr our parts! Some would say that experience is a good lesson or education. – Slick, you’re about to enter this realm. Greg has got an ultra valid point with CBN – your going to balk at the cost of these tools, you really need to ask your supervisor the following – do you want me to do this job or do you want me to dick around with it! – Drop the cash, lose your xxxx, and try to smile when you say – I just machined an impossible situation. James approach is quite valid. You’re going to consume some expensive tools here, no matter what the attack. (Sometimes we really don’t have any choice when it comes to machining a virtually impossible task) but hey, this builds character. I have deliberately consumed tooling (1/32 destroyed through light cut layered passes) – of course, the tools become reground after the abuse and live a happy and healthy life as stubby cutting tools (my personal fav, as these will soon become yours). Please let us know your attack, your result, and your general demeanor after completing the challenge. Hey Corey – just caught your reply the moment that I posted – looking good! Good luck and good grief, Regards, Jack

Wow! Regards, Jack

Assuming your using Mechanical Desktop ver6. Deleting surfaces still occupied the file, hence the file remains very large. Try save as, something else Ie: Jack1.dwg, Jack2.dwg, etc! Autodesk carries the baggage when using Mech6, the older versions of just plain 2D Autocad gave us the option that your looking for; you did say surfaces, therefore, my response. Regards, Jack

Climb mill all of it. Rough mill at .03" layered passes, Coromill 390/2040 grade. Semifinish leaving .01" one pass, coated Hss. Semifinish leaving .005" one pass, same tool. Finish in one pass, be a aggressive with the feed. The last tool is brand spanking new and ultra sharp or sharper. My spin on things is that you need three tools. Regards, Jack

Brent, Ultra impressive translation - I never would have thought of using babbelfish(sp). Regards, Jack

Slick, Appreciation, credibility, respect, etc! Have little to do with the accreditation of journeyman status. Paper is nothing more than paper; if a company wants to hire a professional, it has more to do with eye contact or perhaps the way you carry yourself. First impressions are everything to everybody; knowing Mastercam is certainly advantageous, yet it hardly makes or breaks a person’s ability to get the job at hand completed. I have two journeyman licenses – I don’t believe the papers prove or disprove my ability as a toolmaker or a machinist. We have all been through the same treatment or feelings that you are going through now. – Tough it out, we did, and were that much better for it. Opportunity comes when you least expect it, just be sure to shine when called upon. Your mention of being self taught in Mastercam carry’s a lot weight, you have learned to use the software the hard & honest way (making mistakes is always the best of teachers – I call this an honest education; a lesson learned the hard way seems to burn the brightest). My advice to you is to never, ever sell yourself short, to do your best, and to do this everyday. Sooner or later somebody will notice and they will just keeping giving you more work to do. I envision a letter to the forum in three months time from you that says (The boss keeps giving me the rush jobs or the difficult jobs, while the other guys are sitting around – dogging it). If you want to write the above mentioned letter in three months time – then tough it out. Best regards, Jack

Friends, As inferred, I was indeed born in Great Falls, Montana, 1955; it was part of an American/Canadian exchange program between my father, who was a Canadian air-force exchange employee with an American for a considerable period of time. My father is a born a Canadian citizen. I actually stood with my dad for five hours to see President Kennedy when he visited Montana; I believe this was in 1961/62. I had the birthright to choose which permanent status I would wish to have, perhaps this might account for my cowboy attitude- if I'm not punching out code, I have an overwhelming desire to light up a Marlboro and punch up some cows. Heehaw! When I became of age, I had to choose which country was to be my official status; although I will always have a dual citizenship, I actually chose Canada. This is the identical situation that Bret Hull (son of Bobby Hull) was faced with, Bret chose to be an American citizen, I chose to be a Canadian citizen; if Bret chose the Canadian, as I did, then chances are that he would be dangling an Olympic gold around his neck rather than the second place silver metal. - Yes, I will admit, he's probably 50 million richer for his decision. I have constantly questioned myself as to whether or not I chose the right citizenship since I turned eighteen; I did, my fine friends and American brothers, for I am still one of you, I am born in the USA, just like the rest of us. P.S. I tried the Marlboro’s – pehew, they tasted and smelled worse than a Turkish cigarette. Is it any wonder that Bush won’t sign on to the Kyoto Protocol concerning a cleaner and healthier environment? Regards, Jack

up to 404 Jack

BerTau, Not meaning to throw any negativity into this subject; please be aware that Chicago is both beautiful and very dangerous as well. I would strongly suggest that if you do make this move, that you immediately replace the California plates on your car with Illinois plates – any deviation from the norm will make you a target for the unscrupulous; two blocks off the beaten path is very dangerous, you will know this immediately. There are many places in Chicago that you will not frequent (Ever) – especially after dark; even the police know, respect, and avoid many areas – not meant to frighten or to cause alarm over the anticipated move, this is only meant to enlighten you and your spouse. – did you know that a team of professionals can strip an entire car within three minuets, right there in full public view - with you in it? quote: Let me know what you are looking for and I'll let you know where is the best place to live and where not to live. I live at Belmont and Lake Shore Dr. so I know the area really good. Beav700 has put this mildly, for your family’s safety, please follow his advice; I have been there twice and have left there twice – I will not be returning any time soon; traffic in Chicago is unimaginable, unimaginable – yes, I said this twice! Regards, Jack

Andrew and friends, While the closing of the Ford “F150” plant is certainly a shame; the F150 is actually an American Icon, right up there with mom’s apple pie, Harley Davidson, the Ford Mustang, Coke classic, and Mr. Bond! even if James won't own up to it- I will! Look at the larger picture; NuTech (Milton, Ontario) manufactured a tremendous amount of tooling for this plant – now this tooling will be shipped to some American city where all can admire the craftsmanship and sheer design brilliance of one of Canada finest engineering firms. – Watch for the up and coming projects, it would not surprise me to see 100 million worth of automation tool design and manufacture return to Canada via NuTech’s extraordinary ability to outperform when it comes to engineering; of course, myself and many other toolmakers have done a lot of work for this and many other fine Canadian companies. Only in Canada, can a Cnc toolmaker actually earn a six figure income. Only in Canada, can the above be raped for 50% by the government. Only in Canada, do we also get the hidden 20% taxes in everything we purchase. The bottom line is that if I am lucky I will manage a meager $30K once is all said and done. A far as the question of work and the general economics of our trade – Ontario bounces around quite a bit, gone forever are the predictable highs and lows of the late 80s and early ninety’s; personally, the availability of work is directly proportionate to the ability of the shop to diversify within its own customer base; Danny Devito said it best when he talked about making the finest damn buggy whip (can’t remember the film, but, it was a great one). If the business is slow then move along or be prepared to out-produce the other shops. I’m not talking about pulling down your pants to do a job just to break even; I’m talking about earning your paycheck rather than whining about how hard everybody else is working. Personally speaking, I have done very well in this trade and will continue to do so as long as there is a challenge with something to learn; if I am well paid along the way then life is good and yet, I still enjoy this trade immensely, as do I this forum. My family is what matters to me most and, of course fine sausages. Andrew, I also take offence to the Fat American manager comment - please read the new thread called "Born in the USA" This might turn into an interesting thread to say the very least. Regards, Jack

Jeff, In order to beat Andrew to the punch! What exactly is it that you don't like about this particular key? Insert, Delete, End, etc! are all healthy keys, these keys are here to help us, these keys are our only friends in our time of need. Regards, Jack

Eric, 600~240~120 is a common step down voltage for the transformer you are looking for. 600~208~120 is also common and exactly what your looking for. Be extremely careful: it’s acceptable to voltage drop about ten percent, it is not acceptable to increase the same on a very old system – odds are you will fry an almost irreplaceable component.; Those that deal with these older machines have the market locked up with leg irons. - pay me now or pay me later, you're gonna pay me through the nose! and you can take that one to the bank! The Bridgeport/Boss controller is not a gift for your father – it's a nightmare! I am no stranger to this machine or the controller – I am probably one of the few that will actually admit to the extremely bad taste left upon my taste buds after briefly working this machine tool; I actually typed the code on a flexowriter. (Those that are familiar with what I am talking about also have the ability to read Eia/Iso code upside down & backwards, since this was the only way to edit the paper tape), and yes, this was before computers existed, in the common sense of the term. Switch the controller for one the cheaper upgrade models (Centurion) sp, (Ahha), Etc!– you will actually begin to enjoy this machine once the Boss series is gone forever. If a machine has a ball screw and an axis, you can slap a servo or the more inexpensive stepper motors to the machine. A Cnc machine tool is nothing more than a calculator with a spindle on it; trouble is; the Boss controller actually precluded calculators. Sorry for the rant ~ and even sorrier for the father. Deepest Regards, Jack

Corey, Were still awaiting your choice for an Avatar. TheePres is climbing all over his choices, and yet, you are about 50 posts past due. I am considering Eric Cartman in full dress when he did the German sausage episode ~ but alas, I have another 50 or 60 posts to go. Regards, Jack

James, Since animated Gif's are allowed, what do you think about putting a little spin on that beanie? Regards, Jack

Jayson, So often we tend not to appreciate something until it becomes briefly unavailable, or worse, completely unavailable. Please email me your complete address - I will send a token amount of money towards the purchase of a new hard drive; I would also suggest to the other members to please consider the same; I'm sure that any amount would likely be appreciated and put to good use. Consider this a token act of gratitude for the privelage of using your server to help the thousands that have visited your FTP site. Regards, Jack