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Author Topic: It's so easy a monkey could do it.  (Read 5312 times)

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Offline Acerocket

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It's so easy a monkey could do it.
« on: April 19, 2011, 07:27:16 PM »
So, a lot of people assume CNC machining is easy.  All I have to do is feed a Jpeg into my computer and a part pops out of the machine a few minutes later.  I wish it was that simple.  I have done this before on another forum, and thought it might be interesting to do here also.

Here is what I have to do to make a 'simple' box for a saber (you should all know which saber by now).

First, I need to create the 3D model in my modelling program and export it as an .iges file for the CAM program.



Then I import the 3D model into the CAM program and program the first operation.


Then I gather the tools I will need for this operation.


Before I can cut, I have to set up the part blank in the vice and set up my coordinate system of the blank.


After the first tool is done, this is what I have - the top is faced, the outside is profiled and the inner cavity is roughed out.


Then I use a 1/8" endmill to make the corner radii inside the box tighter.


Now I go back to the CAM program to program the second operation.


Gather tools again.


Reset the coordinate system after flipping the part over.


Face the bottom flat so the part height is correct.


Yup, back to the CAM to program the third operation.


Gather the tools for the third operation.


Set up the coordinate system from the finished profile of the box.


Mill the bottom features.


Back to the CAM again to program the fourth operation.


Gather tools for this operation.


Setup the coordinate system for this side of the box.


Mill slots and pocket.


Center drill the two holes.


Drill the two holes.


Tap the two holes (by hand with a tap handle held in the quill).


Did I mention those are .0469" diameter holes and a 0-80 tap?


Back to the CAM a final time to program the bottom radius.


Gather the tools for this operation.


Setup the coordinate system for the bottom of the box.


Mill the radius.


And there you have one box finished.




Just lather, rinse, repeat.

Bear in mind.  I do not redo every single step for each part.  I setup one operation and run all the parts before I advance to the next operation.

Oh, and for these keeping score, I did not break a single tap in doing all 118 holes.

Simple as pie, huh?

Offline Gil Gamesh

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Re: It's so easy a monkey could do it.
« Reply #1 on: April 19, 2011, 07:32:41 PM »

Bear in mind.  I do not redo every single step for each part.  I setup one operation and run all the parts before I advance to the next operation.


 :D  I would hope this is the case for anybody doing multiple copies of something!  Thanks for that write up Wat, definitely should give some an idea of what takes runs so long  ;D
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Offline Nightwing

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Re: It's so easy a monkey could do it.
« Reply #2 on: April 19, 2011, 07:33:10 PM »
Impressive, most impressive. But you are not a..... wait, scratch that, you are more of a jedi than I am.

Offline Big Boss

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Re: It's so easy a monkey could do it.
« Reply #3 on: April 19, 2011, 07:39:39 PM »
I could do that with my eyes closed  :P LOL JK yeah right i can hardly draw a straight line with a ruler ROFL :D ;D :D


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Offline Rafalema

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Re: It's so easy a monkey could do it.
« Reply #4 on: April 19, 2011, 08:34:33 PM »
Enlightening  ;)
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Offline Darth Inferis

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Re: It's so easy a monkey could do it.
« Reply #5 on: April 19, 2011, 09:11:03 PM »
I certainly never thought it was easy but I had no idea how complicated it was. :o
I'm going to go have a lie down, my head hurts.  ;)
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Offline Darth Brutalous

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Re: It's so easy a monkey could do it.
« Reply #6 on: April 20, 2011, 02:18:38 PM »
Wow... That is really all I can say.  :o I always knew it wasn't so easy you can do it with your eyes closed, but I had no idea that it was this sophisticated. I give you a lot of repect for doing stuff like this. Keep up this amazing work!  ;D

Offline EXAR KUN

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Re: It's so easy a monkey could do it.
« Reply #7 on: April 22, 2011, 10:38:46 AM »

Oh, and for these keeping score, I did not break a single tap in doing all 118 holes.

Simple as pie, huh?

That is very VERY impressive... all for just one saber part. Really makes any whole piece with multiple parts that much more sweet.

Yours seems like a very interesting profession with nearly endless possibilities.... like anything you can dream up you can make... and it's in 3D! Wow.



Offline Kalizon

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Re: It's so easy a monkey could do it.
« Reply #8 on: April 22, 2011, 11:37:32 AM »
A great look into the work behind the finished product.  Looks like you have a pretty sweet setup to Ace.
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Offline kamakazykid

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Re: It's so easy a monkey could do it.
« Reply #9 on: April 22, 2011, 01:22:20 PM »
I'm working on going to school for this! I've done some work but nothing ever that complicated yet. Great insight for all of us Wat!

Offline LoganV

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Re: It's so easy a monkey could do it.
« Reply #10 on: April 24, 2011, 10:27:33 PM »
My respect; you have it.
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Offline Mersenne

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Re: It's so easy a monkey could do it.
« Reply #11 on: August 01, 2011, 09:46:02 AM »
I'd watched some of RussRep's CNC work, but thank you for filling in the CAD side of things
Man you guys are talented and CLEARLY patient not breaking a tap that fine
and you machined your own LEDs too
hat off to you Erik
awesome :)
it's all Elemental

Offline rjgura

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Re: It's so easy a monkey could do it.
« Reply #12 on: August 26, 2011, 05:11:34 PM »
You're definitely setting the gold standard! :)

Offline Rhyen Skytracker

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Re: It's so easy a monkey could do it.
« Reply #13 on: August 26, 2011, 06:55:23 PM »
@wat - can you list how long it takes for each step to REALLY let people know how long it takes?  I am really liking that you are showing all the details and what it takes to make even simple parts.  Keep it up Bro.

Offline Acerocket

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Re: It's so easy a monkey could do it.
« Reply #14 on: August 26, 2011, 07:54:40 PM »
@wat - can you list how long it takes for each step to REALLY let people know how long it takes?  I am really liking that you are showing all the details and what it takes to make even simple parts.  Keep it up Bro.

I will try when I get back into town and can get to my notes.