You should go into your preferences and check the option that always orients the stock the. right way up when you select that setup - that way you won't manually have to flip it over - it always puts Z up.
- Great vid. Thx. - 'Manufacturing Model' for each 'Setup' could come in handy. You can even 'Associate Named View' w/ each. - Maybe you are aware of this, but just chose not to use in this case. Or, maybe you've discovered it since making this vid. - And, thx for the 'Machining Calculator', clearly a bit of effort went into developing it. - Keep up the great content/work...
I'm hoping that the final version of that bellcrank-to-torque tube installation will have drilled bolts and safety wired castellated nuts? Pretty important for critical flight controls. I'd like to see thread locker on that jam nut, as well.
Scott, thanks for watching! I should have mentioned that the clip of it installed was just our initial fit trial for it. The hardware wasn’t final. We have a whole section on our knowledge base that covers proper hardware installation. www.darkaero.com/knowledge/hardware-specs/
Another fantastic video! Had a question about the CAD for the soft jaws. Did you simply extrude a rectangle to the Y-dimebsion of your jaw, then extrude a cut to remove the 1-inch space and then sketch and extrude a cut on the face of that rectangle for the op 1 side? Just trying to understand fully. Awesome work :)
I don’t understand how the locket to the left of the part where you set your xyz zero knows where the part is to perform the adaptive clearing or removal of the hat.
You can't do it in one pass inverted like that. There has to be something holding it in place so that you can machine it. If they did that, it would end up cutting the pieces free of the stock, and they would go flying. In the first pass, the base of the stock left unmachined holds them in place. Once the top surface is machined away, it's flipped, and the jig then holds the newly-machined parts in place while the remaining stock (that WAS holding them in place) is machined away.
Scott MacLean I think Nicholas means that they could have machined without using the soft jaws by flipping the 3d model in the cam software so that the flat side lays on the bottom and then using tabs to hold it in place while contouring, I would’ve done that too but i am not experienced in this stuff so take it with a grain of salt
Nicholas, thanks for watching! You could definitely machine these parts in a single operation with no flipping over or soft jaws required. We have used the tabbed approach for parts like this in the past. For these parts we wanted to be able to leave a nice facing finish on each side and also chamfer the edges on each side so doing a 2 operation setup made the most sense for us. To be honest, I'm not a big fan of tabbing because it requires post processing to remove the tabs, and I can never seem to get a good result in the end. I also haven't had much luck finding good information for tab spacing and tab size to ensure you consistently end up with final result you're happy with.
Seems like you’re leaving a lot on the table as far as speeds and feeds go. That step over looks realllllyyyy small. You’d be surprised how you can push a 1/4” carbide endmill. But maybe you’re using hss or something.
Thanks for watching! Agreed, there is always room for optimization with your tool paths! Since this is just a prototype part and given the power limitations of the CNC machine, we weren't focused on pushing it at this point.
That was very informative Keegan. Just curious - how long (hrs /days) does it take for you to design a CAM operation like you illustrated in the video? I’m sure it is many hours of programming in Fusion, was just curious.
When I was first figuring it all out, depending on the complexity of the part, it could take a day or two just to get everything setup in CAM. Now that I have a better idea of what I'm doing, this part for example, was completed in 2 hours or so. That was including cutting out a section of stock, completing the CAM and all the machining.
@@DarkAeroInc Yeah I figured there was a learning curve. But two hours seems really fast to do all that programming / visualization and the machining. You're a fast thinker!
DarkAero, Inc after reading my comment I can see how it might have came off rude. Not intended lol that being said it’s pretty amazing what you guys are doing.👍🏻
Liked the pocket for XYZ
You should go into your preferences and check the option that always orients the stock the. right way up when you select that setup - that way you won't manually have to flip it over - it always puts Z up.
I didn't know that was a thing. Thank you for the suggestion! :)
- Great vid. Thx.
- 'Manufacturing Model' for each 'Setup' could come in handy. You can even 'Associate Named View' w/ each.
- Maybe you are aware of this, but just chose not to use in this case. Or, maybe you've discovered it since making this vid.
- And, thx for the 'Machining Calculator', clearly a bit of effort went into developing it.
- Keep up the great content/work...
Thanks a lot for sharing knowledge with us
Vinoth, you're welcome!
We don't deserve all this info! Very informative, keep up the good work!
I'm hoping that the final version of that bellcrank-to-torque tube installation will have drilled bolts and safety wired castellated nuts? Pretty important for critical flight controls. I'd like to see thread locker on that jam nut, as well.
Scott, thanks for watching! I should have mentioned that the clip of it installed was just our initial fit trial for it. The hardware wasn’t final. We have a whole section on our knowledge base that covers proper hardware installation. www.darkaero.com/knowledge/hardware-specs/
@@DarkAeroInc Thanks guys, I figured as much! :)
LOVE THIS! THANKS FOR THE BREAKDOWN!
Great video. Thanks. I was curious on 2nd operation (6.50) why u change xyz to loc at circular pocket instead of fix at previous loc.
Gratefulness
When you guys complete the plane, you should totally contact Steve at Flight Chops!
Another fantastic video! Had a question about the CAD for the soft jaws. Did you simply extrude a rectangle to the Y-dimebsion of your jaw, then extrude a cut to remove the 1-inch space and then sketch and extrude a cut on the face of that rectangle for the op 1 side? Just trying to understand fully. Awesome work :)
why not just use the edges of the jaws to set X Y?
I don’t understand how the locket to the left of the part where you set your xyz zero knows where the part is to perform the adaptive clearing or removal of the hat.
6:52 Why didnt you use the same zero point as when you machined jaws?
Curious why you chose that starting part orientation which requires the part to be flipped rather than just machine the full part in one pass
You can't do it in one pass inverted like that. There has to be something holding it in place so that you can machine it. If they did that, it would end up cutting the pieces free of the stock, and they would go flying.
In the first pass, the base of the stock left unmachined holds them in place. Once the top surface is machined away, it's flipped, and the jig then holds the newly-machined parts in place while the remaining stock (that WAS holding them in place) is machined away.
Scott MacLean I think Nicholas means that they could have machined without using the soft jaws by flipping the 3d model in the cam software so that the flat side lays on the bottom and then using tabs to hold it in place while contouring, I would’ve done that too but i am not experienced in this stuff so take it with a grain of salt
But the goal of this video is how you could setup a soft jaw operation and he explained it in a fantastic way
Nicholas, thanks for watching! You could definitely machine these parts in a single operation with no flipping over or soft jaws required. We have used the tabbed approach for parts like this in the past. For these parts we wanted to be able to leave a nice facing finish on each side and also chamfer the edges on each side so doing a 2 operation setup made the most sense for us. To be honest, I'm not a big fan of tabbing because it requires post processing to remove the tabs, and I can never seem to get a good result in the end. I also haven't had much luck finding good information for tab spacing and tab size to ensure you consistently end up with final result you're happy with.
@@DarkAeroInc Thanks for the reply, I figure its just a matter of personal preference. Always great to here of other's thought process
Great stuff. What tool do you use to radius the corner between the arm and the torque tube holder?
Thanks Ed! The inner radius was .03" so we simply used a .03" bull nose end mill to come and finish cut that radius.
Seems like you’re leaving a lot on the table as far as speeds and feeds go. That step over looks realllllyyyy small. You’d be surprised how you can push a 1/4” carbide endmill. But maybe you’re using hss or something.
Thanks for watching! Agreed, there is always room for optimization with your tool paths! Since this is just a prototype part and given the power limitations of the CNC machine, we weren't focused on pushing it at this point.
That was very informative Keegan. Just curious - how long (hrs /days) does it take for you to design a CAM operation like you illustrated in the video? I’m sure it is many hours of programming in Fusion, was just curious.
When I was first figuring it all out, depending on the complexity of the part, it could take a day or two just to get everything setup in CAM. Now that I have a better idea of what I'm doing, this part for example, was completed in 2 hours or so. That was including cutting out a section of stock, completing the CAM and all the machining.
@@DarkAeroInc Yeah I figured there was a learning curve. But two hours seems really fast to do all that programming / visualization and the machining. You're a fast thinker!
how did you setup the transparent color for stock remaining in fusion ?
We didn’t have time to get into the CAD setup much but we modeled both the op 1 and op 2 stock and applied a transparency to both.
DarkAero, Inc ah ok so they are new body’s that are transparent, thanks
Hello, What happened to the use of OnShape?
Hey, thanks for watching. We still use Onshape for all our design work. Fusion for all our CAM.
@@DarkAeroInc Thanks for the explanation.
Wasted time ramping the larger hole in op 1. You could have just plunged inside the hole you pre drilled.
Thanks for watching! That’s a fair point! Better for tool life too. Not sure why I didn’t. Good suggestion.
DarkAero, Inc after reading my comment I can see how it might have came off rude. Not intended lol that being said it’s pretty amazing what you guys are doing.👍🏻
This is a project executed in just 1 op😄😄😄 this is not for 3X...you just spend time and ..finally money and nerves.
Hello, please what type of aluminium is that?