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Topics - agauger

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Hello fellow members,
I run a tiny company part time that makes small aluminum parts for a rather niche market. I have sold over 600 units of our first product and have since developed 2 additional products (this handle is one of them) that I expect to be even more popular- and profitable. I’ve created a video documenting my production process for a cam style quick release handle to show, in detail, the steps I take to make these parts.
I’ve made over 100 of these parts but it took me nearly 6 weeks to do it. Actually, it’s not as bad as it seems. I have Fridays off from my real job so that is my day to work in the shop. I also spent many additional hours working on them during the weekends when the kids will allow (two girls, ages 2 and 5).
My problem is this… it takes far too long to make these parts and there is far too much labor involved! I’m looking for advice on cutting these parts out in such a way that tooling marks are kept to a minimum and cutting speed is at its maximum. Obviously there is only so much that my little Taig CNC mill can handle and perhaps I am already getting all I can out of it. Hopefully those who are more experienced in the world of machining can make some suggestions to a young pup like me that will increase the efficiency of milling these parts.
I’m also not opposed to moving into a bigger machine. I’ve been researching a 3 axis full servo drive turnkey CNC Mill by IH CNC & Machinery (http://www.ihcnc.com/pages/cnc-mill.php) and it seems like an impressive machine. This is a huge step up from what I have and, if it’s necessary, I can justify the nearly $12k investment. In the meantime though, I’m looking for shortcuts, tricks, and improved techniques to make my life easier. Heaven forbid these new products take off once I begin advertising them and I’m unable to keep up with demand because I didn’t tool up correctly or was doing things the hard way because of my inexperience.
I’ve only been at this for about 6 months so don’t beat me up too badly, but everyone’s advice, as well as criticism, is welcome.
Thanks,
-Aaron  :D

View the video here:
http://gaugerfamily.com/cnc/milling_handle6.htm

...or if you're not using IE, try this instead:
http://gaugerfamily.com/cnc/milling_handle6.html

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This script centers my end mill on the part to set up for a perfectly centered slot to be cut along the X axis.
I
t does 4 things...
1) It probes down to the top (Z axis) of the part and records this position
2) It probes over to the front and back of the part (Y axis), records the position of each
3) It probes over to the left and right of the part (X axis), records the position of each
4) It moves the Z axis so it just touches the top of the part, the Y axis to the middle of the part, and the X axis to the middle of the part

Once the script completes, I manually reset the X, Y, and Z DROs and run my G-Code which cuts the slot in the parts.

I've never been able to successfully add a function to the script that will reset the X, Y, and Z DROs automatically upon completion. You can see my attempt below but it does not reset any of the DROs. Can someone suggest the appropriate command to accomplish this?
Thank you,
-Aaron

Code: [Select]
Rem VBScript To center mill On quick relase handle In preparation For slot cutting

If GetOemLed (825) <> 0 Then 'Check to see if the probe is already grounded or faulty
Code "(Probe plate is grounded, check connection and try again)"
Else
FeedCurrent = GetOemDRO(818) 'Get the current settings
XCurrent = GetDro(0)
YCurrent = GetDro(1)

Code "G4 P1" 'Pause 1 second to give time to position probe plate
Code "F2" 'slow feed rate to 2 ipm

Rem Probe Down

ZNew = Zcurrent - 1 'set scan to top edge of part - up to 1 inch of travel
Code "G31 Z" &ZNew 'move down to scan for top edge
While IsMoving() 'wait for the move to finish
Wend
ZTop = GetVar(2002) 'get the probe touch location

Code "G0 Z" &ZTop + .25 'rapid move .25 inches above part surface
Code "G0 Y" &YCurrent + .75 'Move to far end of part for next scan start point
Code "G0 Z" &ZTop - .1 'Move down to .1 inches below part top edge

Rem Probe foward

Code "G31 Y" &YCurrent 'Scan back edge
While IsMoving()
Wend
YPos1 = GetVar(2001) 'Record back edge position

Code "G0 Y" &YPos1 + .25 'Move .25 inches away from last scanned edge
Code "G0 Z" &ZTop +.25 'Move up to .25 above part surface
Code "G0 Y" &YPos1 - 1.25 'Move 1.25 inches to front edge of part
Code "G0 Z" &ZTop - .1 'Move down to .1 inches below part top edge

Rem Probe backward

Code "G31 Y" &YPos1 'Scan for front edge of part
While IsMoving()
Wend
YPos2 = GetVar(2001) 'record front edge of part

YCenter = (YPos1 + YPos2) / 2 'calculate Y axis center
Code "G0 Y" &YPos2 - .25 'Move .25 inches away from from edge of part
Code "G0 Z" &ZTop + .25 'Move .25 inches above part surface

Rem move To the center

Code "G0 Y" &YCenter 'Move to Y axis center location
Code "G0 X" &XCurrent + .825 'Move 1 inch to right for right edge of part probe
Code "G0 Z" &ZTop - .4 'Move down to .4 inches below part top edge

Rem Probe Left

Code "G31 X" &XCurrent - 1.5 'Move into left edge of part to determine right edge
While IsMoving() 'wait for the move to finish
Wend
XPos1 = GetVar(2000) 'record location of right edge of part
Code "G0 X" &XPos1 + .25 'Move .25 inches away from last scanned edge
Code "G0 Z" &ZTop +.25 'Move up to .25 invhrd sbovr part surface
Code "G0 X" &XPos1 - 1.25 'Move 1.5 inches left side of part
Code "G0 Z" &ZTop - .4 'Move down to .4 inches below part top edge

Rem Probe Right

Code "G31 X" &XPos1 + 1.5
While IsMoving()
Wend
XPos2 = GetVar(2000)

XCenter = (XPos1 + XPos2) / 2 'center is midway between XPos1 and XPos2
Code "G0 X" &XPos2 - .25 'Move .25 inches away from from edge of part
Code "G0 Z" &ZTop + .25 'Move .25 inches above part surface
Code "G0 X" &XCenter 'rapid move to the x center location
Code "G0 Z" &ZTop 'Place mill at 0 Z height

Code "F" &FeedCurrent  'restore starting feed rate

Rem Reset DROs

Call SetDro (0,0.00) 'reset X axis DRO
Call SetDro (1,0.00) 'reset Y axis DRO
Call SetDro (2,0.00) 'reset Z axis DRO

End If   
 
   

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