3d printing is an good alternative. The company to go to is Z-Corp.

Hello, The big decision is in your tooling,tool holders, and inspection tools. Programming in metric does not make sense unless you use metric tooling and measuring equipment. You can use inch tooling and measuring equipment but a conversion is still being used. When I run into an ignorant boss, I like to base my argument on dollars and cents. Let him know the cost to tool up and train the machinists for all metric processing. I don't want to add fuel to your bosses argument (even though it sounds like he doesn't have one) but some machines/controllers have a better resolution in metric mode and will hold tighter tolerances. Even knowing this, we use inches since all of our tooling, inspection, and training is based on inches.

Hello Tony, I opened the SW file into mcam9 without any trouble. I am current through MR0105 also. It does not appear to be a file problem.

Hello Frank, Nobody likes to make mistakes but everyone does. I think your boss is making a big mistake by restricting you to 20 year old methods. CAD models pay for themselves in time (a little learning curve). I'll bet your ratio of errors to good cuts is very low. Consider all the operations on all the parts machined. Anyway, hang in there and keep focused on your job and don't get gun shy. If your boss doesn't appreciate your efforts I'm sure there are many others that would.

Hello, the db.ovf is a temporary file and usually resides int the mcampcommontemp folder. The file is usually emmpty (0 bytes). You may want to make sure this folder exists or that your configuration file is pointing to that folder for temporary files.

Hello Mike. As a minimum the graduate must understand blueprint reading, trigonometry, speeds and feeds (as well as how to calculate from the material and cutter size), toolholders, absolute and incremental positioning, and safety.

ez3putt, All of the above questions are good to ask job applicants. I would also suggest a simple math test. We implemented a basic math test to screen candidates. During an interview I let the candidate do most of the talking during a walk through the shop. It is interesting and sometimes surprising what the candidate will say when not sitting in an office.

Yes you will, but you can stabilize the vibration with a couple of supports (screw jacks). Also, try and rough out all you can in the first operation.

itsme, I would machine the entire bottom side of the steering wheel including the holes while you have the entire bblock to grab onto. You could then flip the block around onto the flat surface that you just machined and use the screws through the holes to hole the wheel onto a fixture plate. This would allow for total machining in only 2 setu ups.

Travis, that is an interesting problem. I don't know why they will not project. I was able to connect the point with a line and then project the line onto the surface using the create->curve->project function. You can then creat points at the end of the projected curve, but the point project function should work. Not much help, I know.

I agree with Murlin, I keep two copies of my mc9 files. I save one and then immediately open it to verify it is a good save. After working a bit longer, I save the file with a "-1" in the name. I then immediately open that file to veirfy it is a good save. I then switch back and forth between the two files on my next saves. It doesn't make the problem go away, but the lost work is minimized.

Ernie, the order in which you apply the fillets makes a big difference. In general, you want to apply fillets with the largest radius first and work down to the smaller ones. Sometimes it is best to delete an earlier fillet and get back to it after other fillets are applied. As Greg mentioned, put it on the FTP and We can provide better direction.

RandleXX, I only backup what can not be easily recovered. Config files, tool libraries, posts and similar do not need routine backups since they do not change often. I include that stuff with a more comprehensive system backup. I do not backup the nc programs since they can be reposted from the mc9 file.

Rob, I do a weekly backup of all my "active" jobs. I try to keep the active folder down to 1 backup CD. When I approach the limit of a single CD, I move older stuff into an archive folder. I try to move enough jobs to fill a CD into the archive folder. I then burn a CD for that archive. This keeps my weekly backup to one CD. If I need to work on a job that has been archived, it gets moved into the active folder until I need more space there. This is a manual backup system but it works for me.

I have always found the HP-GL/2 driver to work the best reguardless of plotter model. However, I do not have XP.

I find standard level naming and use is necessary when files are used by more than one person. A good description will save the next guy from searching the levels for the geometry he needs. Even better is standardization the put different geometry types on different levels. For instance, levels 21-40 for 2D geometry, 41-50 for construction surfaces, etc. It even helps me when I call up a project I worked on several months ago.

Another approach would be to creat 2D rectangles for the size pieces you want, extrude those into a solid and perform a boolean common operation. The result would be a solid section of your originall that fits into the rectangle you created.

Filleting can be a complicated task. I do not know the design intent or the construction history for this part. A full fillet can not be applied to the small edge so the error message gets displayed. The part needs to be modeled differently. I was able to get a fillet, but only after the verticle corner was filleted with a very small radius (R.001). This caused the R.55 to wrap around the corner and also fillet the other edge at the base of the verticle wall. another operation couls remove that fillet if it is not desired, however, I think you need got back a few operations and use a different modelling approach.

I have had this happen since V8. I also save different versions; part1,part2 to avoid having to manually regenerate the solid. I can fully explain this file saving process if needed. There is no warning when saving the file; "some solids in need of generation" and the solid manager impliews that all is well. I design molds which usually require converting a part file from another CAD system and I also like to merge in 2D geometry for standard mounting hole patterne etc. I experience the trouble when I translate the 2D geometry to match the origin of the current design. I do not use the merged 2D geometry in the mold solid and have this geometry on its own level but it still corrupts the solid. This can be a real problem.