CNC programming questions

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  1. CNC programming questions

    MasterCAM tapered bores

    What toolpath would you guys recommend for machining a tapered wall bore (MasterCAM 2022 43/4 axis)? I have a bore roughly 5in dia at the large end on the mill and 1 in deep. the taper is 30 degrees. I know it can be done as simply as clicking "tapered walls" for a 2D path, but am looking to see if there is a better method using one of the 3D paths. Thanks.
  2. CNC programming questions

    Mastercam 2013 display glitch when drawing wireframe

    I also have the same problem. We use MasterCAM 2022 and my computer is under 2 years old, with high end GPU that was on the recommended lists for both SolidWorks and MasterCAM (I forget which GPU we chose because I am not at work, but it was one of the top ones for CAD/CAM). The weird thing is, I have only had it happen on a couple of parts, not all of them. It is incredibly frustrating when it happens. I also get a MasterCAM crash on almost every part after I import the model and choose "Machine" (doesn't matter if it mill or lathe). I have learned to save before I do this for every part.
  3. CNC programming questions

    Deep drilling/boring aluminum

    I have a part with a 1.850" dia bore approximately 6" deep (flat bottom) in 6061 Al. I am trying to figure out the best method to machine this. My initial thoughts are to drill it with a large diameter (probably carbide insert) dill and then finish it to size with a boring bar (it's a round part so I will likely do this on the lathe). The issue I am having is finding a drill that can go that deep. Also, I will need a large diameter boring bar that is "stiff" enough to avoid taper/chatter. We are trying to do this as economical as possible; however, there are some surface finish requirements (not too deep so I can switch to a second, short setout tool projection, boring bar for those). Any thoughts or tool ideas? Thanks guys!
  4. CNC programming questions

    deep pocket in aluminum (continued)

    We do not have air blast. I am going to look into setting one up though.
  5. CNC programming questions

    deep pocket in aluminum (continued)

    Collin- can you shoot me a part number? Dont want to ask too much, but I am not good at navigating these sites.
  6. CNC programming questions

    deep pocket in aluminum (continued)

    I tried running it with a shear hog and it did okay but the MRR was not good enough (plus the noise was an issue). I will look into the Dapra tool. The method I am using is holding up and works for 60+ parts per run but I just cringe when I hear the sound because I can hear it recutting chips. I can try to hookup an air blast and see if it improves. I programmed a stop in between the axial cuts to blow out chips but didnt help much. Unfortunately, we do not have TSC or air blast on the machine. Thanks again for the help guys!
  7. CNC programming questions

    deep pocket in aluminum (continued)

    12k. I will see about a ceiling mount. I think that makes the most sense.
  8. CNC programming questions

    deep pocket in aluminum (continued)

    I should add that I add M00 to get clear-out chips, but at quantity we are running it is inefficient to do it this way .
  9. I made a post about this before and it seemed like the general consensus is that I was doing it right, but it is still one of my least favorite jobs to run. It is a 4x5x3in deep cavity (in Al 6061) that I need to machine. The way we have been doing it is, " 3/4 x 3.5" solid carbide rougher (with chip breakers) from Helical tool and finished the walls with a 1/2 reduced neck EM. With the rougher, I did a helical plunge with a dynamic toolpath and 2 passes axially (1.5" depths of cut). " The main issue I am having is recutting of chips. We are running flood coolant and the coolant and chips are stuck in the cavity. Any ideas on how I can Improve this process (tools, methods, whatever..?) I appreciate any help.
  10. CNC programming questions

    Deep pocket in aluminum

    I agree with both of you. I do tend to probe parts and use macro variables to make sure the height measured is within a certain value of what it is supposed to be. I just didn’t think wasting the cycle time or manual entry programming time for this part was worth it (need to learn how to add drill cycles for probing still) . I’m not faulting the operator as mistakes can happen and he is usually pretty on point. I was more getting at if there is a better option to solid carbide cost wise.
  11. CNC programming questions

    Deep pocket in aluminum

    I am machining a 4x5x3" deep (0.78 corner rad) pocket in 6061 Aluminum. My previous method used a 3/4 x 3.5" solid carbide rougher (with chip breakers) from Helical tool and finished the walls with a 1/2 reduced neck EM. With the rougher, I did a helical plunge with a dynamic toolpath and 2 passes axially (1.5" depths of cut). Although it cut great and we got high MRR, an operator recently broke the tool (due to the incorrect orientation of the workpiece) and now I am considering switching to an inserted tool of some sort to save money in the long run. Anyone have a tool recommendation to keep the MRR high? I used a single flute shearhog from AB tools to finish the run, but the MRR was not nearly as good and I got significant squealing during some of the cut that annoyed the entire office (we have electronic engineers and computer programmers throughout the building that couldn't stand the noise from the shop.) I've considered the Sandvik CoroMill 790, but had trouble on their website finding one for the application so I thought I would see what you guys are doing before taking the risk of spending a good amount of money on something that, for a large part, would only be used in a couple of jobs in our shop. I am fine with a larger dia tool and coming back in to clean up the corners with a smaller diameter reduced neck endmill. BTW, the stock is held in a vise and I am using a HAAS VF2SS.
  12. CNC programming questions

    Kennametal KOR-5 worth it?

    How are you calculating the tool deflection?
  13. CNC programming questions

    Kennametal KOR-5 worth it?

    That is interesting. We have used them for roughing and finishing operations for a couple of years now with no issues. We do moderate amounts of stainless steel and titanium but primarily aluminum and plastics. My current alternatives are ER collets or Weldon shank holders. I have seen tools pulled out of our ER collets on multiple occasions.
  14. CNC programming questions

    Kennametal KOR-5 worth it?

    I agree. I am thinking it will only be useful in larger parts where the machine can get up to full feed rate through the cut. I often use G187p1 to help with ACC/DEC when roughing with a dynamic.
  15. CNC programming questions

    Kennametal KOR-5 worth it?

    Thanks for the feedback. I am using 6061 Aluminum and plan on holding it in a Shunk hydraulic holder. I generally use dynamic tool paths with a 15% stepover as a starting point for roughing operations in aluminum. The Haas has 500IPM maximum. I am excited to see how hard I can push it.

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