Modeling & SimulationNational Center for Aerospace LeadershipCCAT Engineer: Chris PfeiferCCAT Presenter: Brian Kindilien

STEP Tools, Inc. Machining of Mold Demonstration Part

May 14, 2009

Machining DemonstrationMachining Demonstration

• Mold – Aluminum-7075• CCAT Machining

Applications Laboratory– DMG DMU 70 eVo Linear– Siemens 840D Control

• Cutting Tools– Helical Tools

• DMG DMU 70 eVo Linear

• 3-Axis Linear

• 2-Axis Rotary

• 18,000 RPM Spindle

• Special thanks to Helical tools involvement with the process

Machining Demonstration-Machine and ToolsMachining Demonstration-Machine and Tools

Machining ProcessMachining Process

Tool Description Operation Flutes Feed RPMTime

(mins)

43 .750" Insert Mill Roughing of Part 3 220 9000 3.22

18 .750" End Mill w/ .125" Corner Finishing of Sides 3 46 5093 1.65

4 .500" Ball End Mill Semi-Finishing Mold Surface 2 180 10000 1.13

8 .375" End Mill Finishing of Pockets 3 120 10000 4.33

4 .500" Ball End Mill Finishing Mold Surface 2 40 10000 44.25

5 .125" Ball End Mill Semi-Finish Corners of Mold Surface 2 30 10000 15.03

21 .093 End Mill Finish Corners of Mold Surface 4 80 10000 2.35

23 .500" Spot Drill Spot Dowel Pin Holes 2 5 2500 0.12

22 .242" Drill Drill Dowel Pin Hole 2 13 3361 0.17

24 .249" Reamer Ream Under Dowel Pin Hole 2 15 1600 0.10

25 .251" Reamer Ream Over Dowel Pin Hole 2 15 1600 0.10

Total 72.45

10 Tools6 End Mills/4 Hole Manufacturing ToolsHelical Provided Tools 18, 4, 8, 5

Code ExportCode Export

• Export Code for Siemens 840D– Siemens Traori

• Noted Absences– Drilling and Reaming Cycles– Home Commands– Stock Origin Coordinates

• Export Siemens *.MPF code and loaded onto DMG to simulate

• Without alterations, the simulation ran• Dry ran the part, where some limitations noted:• No Home Commands between operations

– This causes a problem after the 5-axis moves, as there is no command to return the table to B0 C0

– CCAT would like to see home commands to make sure tool and table are reset each time

• No Drilling Cycles– This eliminates the possibility of clear Peck Drilling

Cycles• Ream Cycle is not available either

Steps to Running CodeSteps to Running Code

• Added Home commands at Tool changes by utilizing the Insert NC Function within Step Explorer– “G0 SUPA Z0

SUPA X-28 Y-14 SUPA B0 C0”

• If selecting Return Home, only G0 Z0 is inserted• Ignored Peck Cycles due to small depth• Added Spindle Stop at bottom of Ream for a cleaner cycle• With these additions, then set up the work offsets and ran the part• Work offsets were found by

– Z – Touch Probe the Top Surface– X,Y – Touch Probe Cycle to find center of Bolt Hole– The latter would be made easier with the ability to determine position inside

STEP Explorer• Resorted to exporting the Stock Model to SolidWorks and using the

Measure Function• The Workpiece model did not export correctly

SolutionsSolutions

Machining Process ImprovementMachining Process Improvement

Tool Description Operation Flutes Feed RPMTime

(mins)

43 .750" Insert Mill Roughing of Part 3 220 9000 3.22

18 .750" End Mill w/ .125" Corner Finishing of Sides 3 225 10000 0.45

4 .500" Ball End Mill Semi-Finishing Mold Surface 2 320 18000 0.67

8 .375" End Mill Finishing of Pockets 3 216 18000 2.58

4 .500" Ball End Mill Finishing Mold Surface 2 150 18000 11.83

5 .125" Ball End Mill Semi-Finish Corners of Mold Surface 2 50 18000 9.05

21 .093 End Mill Finish Corners of Mold Surface 4 80 10000 2.37

23 .500" Spot Drill Spot Dowel Pin Holes 2 5 2500 0.12

22 .242" Drill Drill Dowel Pin Hole 2 13 3361 0.17

24 .249" Reamer Ream Under Dowel Pin Hole 2 15 1600 0.10

25 .251" Reamer Ream Over Dowel Pin Hole 2 15 1600 0.10

Total 30.65

Through Helical’s James Graham’s recommendations, we were able to increase feeds and speeds of the highlighted tools. By doing this, we

cut the cycle time by over 50%

• Overall, a very successful demonstration!

ConclusionsConclusions