Anyone here use Mastercam?

[finley31]

I got a project I'm trying to wrap up at work that has some 78 degree countersinks machined parallel to the face a plate that is bent on a 12 degree angle. I would just lay the part over to compensate for the angle, but the through hole I have to drill in it is drilled in the same plane as the rest of the assembly. I know there are several machinists and cnc guys around here and If anyone could give me some pointers I would really appreciate it. I have already completed the rest of the countersinks that are flat using a wireframe tool path. I attached some photos of my setup and the drawing to get a better idea. Please note the countersink in question is not shown on the drawing but is located in the bent section of the plate.

If I can't make a program, I will probably end up putting our large angle plate on the boring mill, standing the part up vertically then rotating the table to make it a flat situation.

 

[macgyver37]

I am not quite understanding where you want to put the holes and countersinks, is it in the bent section of the plate? The way you worded it confused me.

Assuming you just need to drill/ctr sink in the bent section, make a custom work plane for that bent section. Once you make a new work plane when you do your toolpath in MC you can just use any normal 2d operations and it makes it very simple. You will have to pick the correct work plane in the tool path manager, make sure all 3 sections in the toolpath are set to your new work plane and also that they are all 3 axis at zero, it will default to seemingly random numbers, needs to be zero.

Also when you pick your geometry for the work plane, it will show the Z in or out from the plane, this of course will determine which direction it comes from when you do the toolpath.

I would have to open it up and take screen shots to show exact steps, there should be some good help in the help menu to get you going.

Let me know if you need more info

Jason

 

[bullnerd]

I think I get it.

You want to contour a countersink(chamfer) on a surface not true to your horizontal spindle axis? And the hole is on the same "plane" as the other holes not on the 12 deg angle?

 

[wingnut_1]

On the drawing that you show, could you pencil in the detail and post the picture again for us?

 

[finley31]

I think I get it.

You want to contour a countersink(chamfer) on a surface not true to your horizontal spindle axis? And the hole is on the same "plane" as the other holes not on the 12 deg angle?

exactly.


I think I got it worked out now, I rotated my entities 12 degrees then created a surface and it looks like it is going to work out. The reason for the difference in the hole and the countersink is that this part has to be riveted together and the rivet head has to be flush or slightly below the surface. Once it's riveted, each rivet has to be welded over water tight, then a water-chamber is installed over the plates.



I attached a sketch of what I was trying to achieve.


I appreciate the responses.

 

[macgyver37]

Is there any reason you can't use a counter sink tool? Why do you need to ball mill it? I know 78 deg isn't the most popular...

 

[bullnerd]

Wow, that's weird. The rivets for these holes will have to have the heads canted to match the angle? If the head is square to the shaft, it wont work.

Unless you just rivet it and let the force pull the head to the side? Seems like it would cause a huge stress problem if it even worked without popping the head off. Unless its done hot? OK, I'm just talking to myself now. LOL>

 

[finley31]

Yeah, they are put in white hot. It's a pretty interesting piece, It's held together with 32 1" dia. rivets, and then cover with water passages to keep it from melting down while it's operating.

 

[finley31]

Is there any reason you can't use a counter sink tool? Why do you need to ball mill it? I know 78 deg isn't the most popular...

If I used a counter sink tool I would have had to rotate my work piece perpendicular to the machine spindle. I was trying to get both the drill op. and the countersink op. completed from the same setup is the reason I used the ball mill.

 

[bullnerd]

Sounds cool. Can you take a pic of the countersink when your done?

 

[Kevin54]

You are going straight in to the 12 degree part. All you need is support underneath it and you shouldn't have to rotate anything. Use a large 78 degree countersink. One side of your hole, the rivet will be flush. The other side of the hole, your rivet will be seriously beneath the surface of the part.

Just a question though.....are you sure the rivet goes into the 12 degree angle the way you show, or should it be in perpendicular to the 12 degrees? Depending on the particular situation, you are going to lose a lot of strength with the way you have the rivet going in. If you put it in relative to the 12 degree surface, you would have your most strength.

 

[macgyver37]

I assumed you would countersink with the same setup as the drill operation, it would be the same in my mind, just different tool.

 

[jimgood]

You are going straight in to the 12 degree part. All you need is support underneath it and you shouldn't have to rotate anything. Use a large 78 degree countersink. One side of your hole, the rivet will be flush. The other side of the hole, your rivet will be seriously beneath the surface of the part.

Is this what you're talking about?

View media item 52982

 

[finley31]

Here is what they ended up looking like. They took about two minutes per hole. I also attached a cutaway view from the original print showing the skew between the through hole and countersink. I guess whoever designed it was more concerned with clearance in the passage than the strength of the rivet head.

 

[bullnerd]

Very cool, nice job Finley.

 

[A_Pmech]

That's a lot of Copper.