@@ConourManufacturing We are using water soluble coolant, unlike you oil maniacs, and I think that doesn't hold onto the chips the same way the oil does. Along with not providing the same tool life and surface finishes, or course.
Interesting walk through Shawn! Please give us a call if you need help with a solution to this, but definitely giving us something to think about with respect to chip management!
why not press fit the nuts instead of using snap rings? you could build a two-part jig to press in the pins and nuts at the same time but use a real hydraulic press instead of the bridgeport. (change design to have pins and nuts in same part- either A or B) #lean $0.02
Are you saying I should use through spindle coolant right before the tool check starts? I guess I am not a huge fan of blasting the laser with 800 to 1000 PSI of cutting oil. If I was to use flood coolant I would have to have the table go to some specific location every time. Hit the laser setter with coolant then start the tool check. That would require it's own custom macro through my post processor. Running this air line/install took 30 min with no custom macros or post edits. To answer your question, the reason I used air is because it was simple and fast. It has been working incredibly well, the machine has not alarmed out since.
@@u_solutions_lv the problem with that is my coolant lines are not pointed straight down at my laser tool setter. So I would have to move to some predetermined position for the coolant to hit it. Then if I change my coolant line positions(based off tool length and specific parts) I would have to go edit the macro.
@@u_solutions_lv I use a variety of gauge length tools, so I try to keep coolant pointed in the general direct of what I am working. If I was to turn on coolant in the tool brake macro I would shoot coolant over the top of my tool laser and it would never wash it off. I would have to use TSC and not every tool is TSC. Hence rust adding an air line one time and never having to worry about it again.
How do you line up the tool setter with your coolant nozzles? At the end of every part I run the chip fan, which completely cleans the tool setter. This air blast is just to ensure I get through the part without a chip getting in the way.
@@ConourManufacturing I can make a video on Monday. Short answer, since mine is ts27r mechanical touch unit, If i align tool with probe i flush it. At tool break detect i turn on flood coolant, then I move to clearance height over the probe, M09, G04P500 for coolant to stop dripping, and then continue with the tool break detect. I only have plunge break detect.
Thanks for the plug on DSI Fusion Summit! On one hand we're so glad you're busy, but I sure wish you could make it to Chicago next month! Keep the videos coming!
And I thought my $1600 lease payment for the machine in my garage was a lot. Jesus As a new guy starting out what does it even look like to get the machine to a point where it's not only paying for itself but turning a profit at this level? Assuming it's running production? I'm so far away from doing that even where I'm at it's so hard for me to comprehend it.
A lot of work needs to move through the shop to justify it. It's all relative, having a single machine in your garage is just as difficult as a big shop with a bunch of machines.
Since this feature is for a nut, I would mill this hex and make my own nut to fit in there (or modify an existing one) . Way faster and cheaper. This just shows incompetence of design / construction.
This would be great for some other types of features when you have a part with impossible corners. I use a hand made sub program that’s only about 20-40 lines long. I wish I could post more of the stuff we have made. Also cncbroachingtools. Has some good samples
Your video is great and well edited. Thanks. For me, the missing part was the CAM cycle you used. You mentioned Fusion and CAMplete, but I don’t know what cycle you used. I’d love to know. Really awesome process.
Ya, my bad. I thought I was screen recording but the program was not recording the dialogue boxes. That mistake will not happen again. Thanks for watching!
How did you index the tool? Was it as simple as index it in the holder, square to the drive lugs. M19 a normal m code for robodrills.? My post is the one that Nyccnc made + I modded it so it to G53 x y at the end of program. Now I need it to shut spindle off during Z G53 at end of program. Right now it'll be spinning up by the tool change relying on M30 to shut down
So the broach had a ground flat on it, that aligned it to the tip of the tool. The tool holder had it's set screw in the perfect location. When I M19 the machine. It is at "0 degrees" so I used all nominal numbers for indexing. Had it been of X amount of degrees I would have just taken that into consideration.
As I’m new to CNC machining, can someone explain why you would choose to broach instead of using a small endmill? I understand there’s more of a radius in the corner, but the nut also has a radius. Or is it more of a tool length issue? So much to learn….
You are spot on man. Do to the Z hight location of these and the very small end mill required to create this feature. Broaching is the most reliable/repeatable process. Especially when you stat getting into high quantity/lights out production. The more robust your process, the better odds of long night time runs. This trade is a Marathon everyday you're going to learn something new. It takes a lifetime to become a well round Machinist. I myself have just scratched the surface of everything there is to know.
That is a great point, thanks for pointing that out. At a certain point I have so much time and effort into it, that I forget to explain all the details. I am also working hard to keep the videos around 10 min long. Thanks for watching!
I have never seen an angle oriented m19, going to have to try that. I have 2 robodrills as well, but im curious how many other platforms will take it. I have a c- axis single point macro from a lathe, all you told it was how many sides, start diameter, end diameter, depth and feed. Worked great, but we went to wobble broach for the speed.
Edge precision has the best broaching video on youtube, but he's doing it in a macro. Haas have VPS templates for broaching, and some good videos on them.
All the rotary broach guys are not *exactly* wrong, but I think getting single point dialed-in for your shop is probably the more flexible option. Rotary broaching requires specialized tooling you would need to have for any job that comes across the bench - and all the delays and BS that bringing in tooling for a job entails. Being able to single point on-demand? Worth it. Having said that, Polygon has a rotary broach brake that lets you time the broach. You essentially engage the bottom face of the broach with the material, then turn the spindle on, do the broach, and retract to a point where the tool is still engaged. Turn the spindle off and the brake keeps it from losing position through the rest of the cycle. Wash, rinse, repeat. On a BT30, you will definitely want to get in with a small tool and pre-form as much of the broach feature as you can - not just plunge the broach into the book spec pre-drilled hole. This lowers the cutting pressure dramatically; you really just want to be biting out the minimal practical material in those corners. Remember- BT30 machines are happy with relatively high Z forces from all the drilling they do. I can't speak to the Fanuc 24k spindle (which is a bit higher strung than our Brother spindles), but I can't imagine a properly run rotary broach in 6061 would be a problem. We do this all day with 16k spindles in Speedios.
Thank you for all that info. That all makes sense. On this application I would have definitely needed custom made broaches to avoid hitting the top of my part. From pre drilled tangent hole to corner of broach is right at .035 of material, keeping in mind that is times six for each hole. I was a little apprehensive hitting that in one go on a rotary brooch. Had it been a spline with very little material being removed I might have given it a go. Thanks for all the input, it is greatly appreciated! Thanks for watching 🙏
If you are currently using Fusion, I recommend giving DSI a call. Link in the video description to their website. They will get you going! Thanks for watching!
It looks to me like design for manufacturing has not found it's way yet. A lot of complicated procedures for simple feature. Can't you just press in nuts, or use serated inserts/cling nuts. Or could potentially just use normal nuts some simpler punch feature to deform once nut is in.
My client wanted to specifically be able to remove the nuts from the part, quickly and easily. I agree it's a tricky design that is definitely not a common feature. Thanks for watching!
Very cool to see this! I am doing something similar to this on a Haas UMC750SS, but I do square through holes (usualy 40mm square, 100mm deep). I do it in plastics though (mostly UHMW but sometimes also in delrin) My solution was a hand written macro, but my needs are a little more simple as the square holes are for mounting a pulley on a square shaft, so its always on X Y 0. This solution is much nicer though!
Horn make nice single point hex broaches. Loads more reliable than a wobble broach. Used them on Swiss for years with a little macro I got off the internet Write one line of code once in position and it will do what you need. 30 seconds work
They also make torx options as well I use the same macro with a y offset to make ratchet rings for bike hubs. The y axis means you can use standard slotting broaches to make the profile rather than needing expensive custom tips Loving the UberRobodrill.
I should have talked about rotary broaching in the video. I could not find one that would allow me to "clock" or orient the hexes the way they needed to be placed. I also read that there is a higher force on the BT30 over the single point cutting.
