1. Modeling & Simulation National Center for Aerospace Leadership CCAT Engineer: Chris Pfeifer CCAT Presenter: Brian Kindilien STEP Tools, Inc. Machining of Mold Demonstration Part May 14, 2009

2. Machining Demonstration Mold – Aluminum-7075 CCAT Machining Applications Laboratory –DMG DMU 70 eVo Linear –Siemens 840D Control Cutting Tools –Helical Tools

3. 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 Tools

4. Machining Process ToolDescriptionOperationFlutesFeedRPM Time (mins) 43.750" Insert MillRoughing of Part322090003.22 18.750" End Mill w/.125" CornerFinishing of Sides34650931.65 4.500" Ball End MillSemi-Finishing Mold Surface2180100001.13 8.375" End MillFinishing of Pockets3120100004.33 4.500" Ball End MillFinishing Mold Surface2401000044.25 5.125" Ball End MillSemi-Finish Corners of Mold Surface2301000015.03 21.093 End MillFinish Corners of Mold Surface480100002.35 23.500" Spot DrillSpot Dowel Pin Holes2525000.12 22.242" DrillDrill Dowel Pin Hole21333610.17 24.249" ReamerReam Under Dowel Pin Hole21516000.10 25.251" ReamerReam Over Dowel Pin Hole21516000.10 Total72.45 10 Tools 6 End Mills/4 Hole Manufacturing Tools Helical Provided Tools 18, 4, 8, 5

5. Code Export Export Code for Siemens 840D –Siemens Traori Noted Absences –Drilling and Reaming Cycles –Home Commands –Stock Origin Coordinates

6. 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 Code

7. 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 Solutions

8. Machining Process Improvement ToolDescriptionOperationFlutesFeedRPM Time (mins) 43.750" Insert MillRoughing of Part322090003.22 18.750" End Mill w/.125" CornerFinishing of Sides3225100000.45 4.500" Ball End MillSemi-Finishing Mold Surface2320180000.67 8.375" End MillFinishing of Pockets3216180002.58 4.500" Ball End MillFinishing Mold Surface21501800011.83 5.125" Ball End MillSemi-Finish Corners of Mold Surface250180009.05 21.093 End MillFinish Corners of Mold Surface480100002.37 23.500" Spot DrillSpot Dowel Pin Holes2525000.12 22.242" DrillDrill Dowel Pin Hole21333610.17 24.249" ReamerReam Under Dowel Pin Hole21516000.10 25.251" ReamerReam Over Dowel Pin Hole21516000.10 Total30.65 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%

9. Overall, a very successful demonstration! Conclusions