MEC 2040 Electronic Notebook

By Stephen J. Bania

DAY 2 

Gathered information on CNC machines in lab.

EMCO PC MILL 55

Machinist Vise: max. Opening of 2.5”

Bed Travel:(x) 7.48”

(Y) 3.54”

Head Travel:(Z) 7.48”

Feed Speed:0 – 30 IPM

Step Resolution:.00004”

Collet Chuck: .059” - .629”

Max. Table Load:10 Kg

Speed Range: 100 – 3500 RPM

Drilling capacity: 10mm dia. (in aluminum)

Threading Capacity: m6 x 15 (in aluminum)

EMCO PC TURN 55 LATHE

Travel Range of Slides: (Z) 236mm

(X) 48mm

Tail Stock-

Sleeve Dia.:22mm

                   Inner Sleeve Taper: MT1

Stroke of center Sleeve: 35mm

Max. Stock for 3 Jaw Chuck: 80mm dia.

Tooling:

-PluginPivot

-Live Center

-Assorted Drill Bits

-6 Tool Torret

-Right and Left Handed Tool holders

DAY 3
Did some testing on CNC Lathe with aluminum. For testing

of the diameter the test piece was about 2.5” in diameter and

seemed not to be a problem for the machine. Next I tried different

speeds and feeds and found that a very fine finish was achievable.

Thought up a design of a USA key chain product and made

a sketch (see Fig. 1).

DAY 4
Made rough prototype of USA (3.000” x 1.250” x 0.125”)

with scaled penciled in letters (see Fig.2). This helped people visualize my idea.

Also made rough Mechanical Desktop drawing.

DAY 5
Scaled down the USA drawing to fit on 1” stock so that

when we cut the blanks we will only have to finish the short side

of the piece(ie; 1” instead of 3”) which will make the fixturing

design easier and save us production time.

DAY 6
Added key ring hole and letter radii to the USA key chain.

Also took on role of getting stock to work with.

DAY 7
Finished the last of the revisions on the key chain(see

Fig.3). Then Took the Mechanical Desktop file and made it into a DFX file In preparation for running the product in the Light Mill.

DAY 8
Designed and built a locating fixture out of aluminum so

that when we went into production with the key chain we could

quickly and accurately locate the stock (saving production time).

DAY 9
Jason and I got the USA DFX file into the Light Mill

and set up the tool paths. Next we trimmed the parameters of the 

key chain so that we were only cutting the radii and the short sides

of the outside of the part thus preventing us from cutting through

the jaws of Jason’s fixture.

Then we proceeded to cut the prototype. Besides a few

finish problems the product looked pretty good.

DAY 10
“Light Mill Dies” forcing us to change our production plan

(Namely the mill). Jason yourself and I spend all night trying to

USA into the EMCO mill.After having no luck trying to use the

EMCO software to write tool paths we down loaded our old DFX

file into the EMCO and after trying everything that we could think

of we still had no program.

Sketch

Prototype
3D Model