the right sequence of operations so that we could ultimately make a part that would comply with the Lockheed Martin specifi cations. That thought process took place over two months to get the CAM process right for just one part.” From having manufactured parts similar to these in the past, Bermudez understood what areas of the part would distort if manufactured incorrectly. These predictable problems were a function of the part’s slender geometry. He also knew that other problems would arise due to stresses that would be revealed in the part’s forged aluminum workpiece as it was being machined. These have to be detected as they occur by checking the fi rst article frequently, either on the machine or a nearby CMM.
Once these stresses and deforma- tions revealed themselves, Bermudez compensated for them by altering the machining strategy in Mastercam at a particular manufacturing stage. “A big mistake some manufacturers make in attempting to write a program for a part like this is creating the model and then using their CAM software to create a single program to make it. That would be easy, but it doesn’t work that way. What you actually have to do is write programs to make the part in six or seven stages. You are actually creating maybe six parts to fi nally get to the one you want that is largely stress free. Those intermediate parts may look very different from the one you fi nally end up with.”
Bermudez would not disclose what these intermediate parts looked like. ETJ considers those to be proprietary knowledge. However, he was willing to talk about the thought processes and CAM strategies he uses during various stages of manufacturing: How to Hold It: The fl ap track is a part with a lot of deep details and the
walls are all tapered on the outside. So the fi rst thing that has to be considered in making this is how it’s going to be held securely while allowing tools to reach critical areas. Bermudez
Continued on page 112
Jet Sleeve COOLANT SYSTEM
The patented Jet Sleeve TM system delivers coolant directly to the cutting edge and can be used with
coolant, air or oil. The system prevents build-up of chips and delivers coolant even in deep cavities or tight areas.
coolant tube sleeve with nozzles coolant
VIEW THE DEMO
FASTEST ROI:
Reduce Coolant Requirements up to 80% Improve Surface Finish up to 25% Increase Tool Life up to 100%
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BOOTH W-2275 IN TECHNOLOGY PARTNERS
www.bilzusa.com | 1140 N. Main Street, Lombard, IL 60148 | 847-734-9390 March 2014 |
ManufacturingEngineeringMedia.com 55
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