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Shop Solutions Continued from page 55


uses the CAD features of Mastercam to design a workholding solution for the part in its fi nished form and its preceding itera- tions. He can work back and forth between the CAD and CAM views to assure that the holding solution he designs will afford appropriate clearances for tools at every stage. Knowing the Weaknesses: “The key is knowing how you are going to remove material without generating any more stresses than are already in there,” Bermudez said. Here is where experience comes into play as he determines what features of the part might be compromised if machined in the wrong sequence, too aggressively, or by removing supporting materials prematurely. Waterline Toolpath: ETJ relies heavily on Mastercam’s


Waterline toolpath that removes material at the same Z-axis height all the way around the part, with the tool dropping down in small increments after each trip around the part. The part takes shape from the top down as if it were sitting in a tub of water that is gradually lowering to reveal its dimensions.


Wing fl ap tracks are shaped like a hockey stick up to 130" (3302-mm) long and require special fi xtures on the four- axis Vision-Wide machining center. The longest fl ap tracks are fi xtured on the table diagonally.


This approach keeps stresses balanced because cutting is always at the same level.


Simulation: As Efren programs, he frequently uses Master-


cam’s simulation features, Backplot and Verify, to review tool motions and material removal in critical areas. Sometimes he


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112 ManufacturingEngineeringMedia.com | March 2014


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