I just installed X6

Your drwing says you are using X5.

The reasons I have seen are typically several.

 

There may be a change in software for several reasons, going from 1 to now 2

There is, as you mentioned, let's hire someone and then that want to program in the software they know.

 

There is your customer that says you "need" to be using the same software we use

 

I am sure there are several other reasons as well

It must be because the new hires wanted the software.

They kind of shoot themselves in the foot by doing this though. A good example, they get UG for the new engineer, but wont get the UG translator for Mastercam, so the engineer has to save the solid as a parasolid, then I bring it into Mastercam. now the model now has been converted twice which causes problems with the model.

The owner is very reluctant for different departments to learn the other softwares also. After seeing some of the features Tebis has, I asked to get another seat of it for hardmilling department, but he wont get another seat of it. Its not that I dont like Mastercam, I would just like to learn another software.

That was kind of a rant. Sorry

Here is what we have:

Engineering- UG and Solidworks

Hard turning- Gibbs

Hardmilling(me)- Mastercam

EDM (electrode production)- Tebis

Are there any other shops that do this? I think this is a big waste of money, having that many different softwares.

It seems when people get hired here, they buy the software that the new guy likes. I dont understand thier reason behind this.

Rick,

 

I agree for the most part with all the comments given.

However!

As far as 0.0002" being held day in day out everywhere???

 

The dimension first has to be defined as to what kind of a dimension.

A bore? Possibly.

Overall surface? Not likely.

I hear this all the time with people stating that they hold 0.0002" on everything they cut.

Then find out they are programming to the nominal tool size of a low end tool, from a low end tool manufacturer, in a 10 year old Cat 40 collet holder.

 

Temperature stability is of extreme importance to machining accurate parts.

Even though the machine has thermal compensation software it can not account for extreme variations.

In a 10 degree variance the part alone may see more thermal change than your tolerance.

This does not even include the tool holder and tool.

 

Keep in mind also that in 5 axis certain errors actually get doubled.

 

If machines could effectively comp for real world thermals then CMMs would not need to be placed in thermally controlled areas.

 

There are things that can be done to help but one must be realistic.

 

Call me.

508-474-1133

I could not aggree with you more Gerry. It is tough to get it through the owners mind that each axis has its own error, along with the tool and holder also. That doesn't even include the pallet changer. It can be very challenging to say the least.

Thanks for chiming in. You will be getting a call in the next few weeks for some more advanced training, which I dont believe I have had yet.

Rick

The 'Gap Size' is the distance between where one 'slice' of the surface(s) ends, and the start of the next slice begins. The two techniques I usually use to reduce any unwanted retract motion are:

 

1. Increase the 'Gap size' distance value (I almost always choose distance instead of % of tool diameter). I usually start with a 1" gap size, and increase if necessary.

 

2. Change the method that Mastercam uses for 'Motion less than gap size' to "follow surfaces", and remove any tangential extension.

A 1" gap size? I have been stopping at .100 and accepting what I get.I guess I just never knew better.

We have 2 Mikrons here. One 3 axis and a new 5 axis LP macihine. Max rpm of both machines is 42k.

We use the MST brand heat shrink holders. We have the heat gun type of machine. I think the machine was around $3500 and the holders are around 120-150 each. We also have the shunk tribos unit. Not many holders though (pricey). Shunk hyradulic holders also. they are pricey also, but they are balanced to 32k IIRC.

We have 2 Mikrons here. One 3 axis and a new 5 axis LP macihine. Max rpm of both machines is 42k.

We use the MST brand heat shrink holders. We have the heat gun type of machine. I think the machine was around $3500 and the holders are around 120-150 each. We also have the shunk tribos unit. Not many holders though (pricey). Shunk hyradulic holders also. they are pricey also, but they are balanced to 32k IIRC.

Tell the boss to sit down before the contractor hands him the quote!

Yeah I bet it aint pretty.

***update****

There has been 2 commercial A/C contractors in the shop in the last week. I just hope they get one installed before the hot weather hits.

Thank you all for the help.

Or, if you want to make an STL from your model, you can Save > As STL, or just pick the solid from the verify options on the same verify popup

This will save it as the finished part sizee though. I need a "roughed" part for verifying. Your first answer will work. Thank you.

Rick

I created a simple toolpath with .005 stock to leave to roughly simulate the part that I will be cutting soon. How do I crate a STL file for verify to use. For the life of me, I cannot remember how to do this. Thanks in advance for the help.

Rick

First I want to thank you all for your resopnses. But most posts were on Sunday? I am also going to appologize for my spelling and my proper (or inproper) use of grammer. I am a toolmaker, not an english major.

Anyhow, to answer some of your questions. I dont know how to do the multi question quote like I have seen before so I have to go by memory...

There are multiple tools cutting this part. The finish cutter (that has to hold the .0002) is the 3rd of 7 cutters. The unfortunate part is that the part has been roughed to within only .01-.015/side. I am roughing then semi-finishing. Like I said before, it would be ideal to rough all the parts and then finish all of them, but in this case I am unable to.

I am not using the coolant. Just a mix of air and oil.

The machine does have thermal comp, but I dont know enough about it to give an educated answer.

The machine is in the same room with older( early 90's era) machines, also mixed into the bunch is a mori seiki millturn, that has a chip blaster unit attatched. That unit could heat the whole room in the winter by itself. With the chiller on the 5 axis, along with the millturn, it made it almost 75 this last winter.

The machine does have a probe, along with the probing inspection program installed. Unfortunately, up to this point, I have not had time to learn the 5 axis probing with it. I have a gage that I install over the part to measure "drop". That determines my size. I check it in the machine against gage blocks.

This job should be out of the machine late this week, so I think I will have some breathing room to get some more advanced training on the machine

I have, along with a few other workers, complained that it is not realistic to even come close to those tolerances consistantly without some sort of a/c upgrade.

Thanks,

Rick

My process is most likely part of it also. I am close to finishing the job, so I will have to work on that on the next one.

I am being pressured to get the job out the door (or at least out of the machine), so I am struggling through it.

here's the problem. It is leaving stock when it is hot in here, but when its cool I can hold size very well. Almost like the tool is too warme up and cools off during the cut. That tool is 2 hrs into the program, so it is difficult to adjust for it.

Have you tried warming the machine up before running parts?

 

On my Mori's back when, when running tight jobs I ran them through a half hour motion and spindle cycle, the head would grow several .0001's once it was up to running temp it would stay all day

This problem is AFTER its warmed up. I run the preheatup cycle, and laser check the tool lenght before cutting too. 2nd shift has an easier time with them. I contribute that to the temperature.

^^^^^ +1

 

Material matters as well, Aluminum is more more susceptible to ambient temperature changes than many other metals.

 

You may need temp controlled room & a coolant chiller

 

Not quite enough info to be exact but thse are things you can run into.

 

I have seen guys keep gage blocks in a buck of water to keep them fairly stable for gage setting.

Its a similar part that you helped me program during inhouse 5 axis training. Ivanhoe

Rick

regular old 420ss. Its a core for a suringe. Medical part. Injection mold part

It is contouring. Position is also critical obviously. The begining of the day is easy to hold that tolerance, but once the temperature is above 75 deg. its almost impossible to. Its a very detailed part, which takes 3hrs per part. I am pulling out my remainder of my hair on this job.

I would just do all the roughing in the afternoon, and finish the shutoffs in the morning, but the part is too irregular to do this, so the roughing and finishing need to happen in one setup.

We have a Mikron HSM 400U LP that was installed in early September of 2011. Everything went fine as far as accuracy goes, up until now. Come the erratic temperature changes of spring, I am having a tough time holding the tolerances (.0002). We get a temperature change of up to 15 degrees during the day so far. This is only the begining of whats to come as far as heat goes too!! We have 80's era air conditioners, which couldn't keep up with the cooling demands of the building.

I have tried to explain this to the owners before it was a problem. They are supposedly "looking into it". In the mean time, I still need to make good parts.

Has anyone else run into a problem with accuracy and heat? How have you overcome this problem?

Sorry about the first post, but I have not had internet at work in a few years( dont get me started on that on)

Thanks,

Rick