How To Machine A Complex Part 600% Faster Using Trick Techniques?

How To Machine A Complex Part 600% Faster Using Trick Techniques?

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In the fast-paced world of CNC machining, efficiency is paramount. The ability to machine complex parts quickly without sacrificing quality can set a shop apart from its competitors. Recently, we had the opportunity to work with a friend, Josh Quintero from Total Industries, who purchased a DVF 8000T machine. This article will explore the innovative techniques we employed to program, fixture, and prove out a complex part, achieving a remarkable 600% increase in machining speed. By leveraging advanced strategies and tools, we were able to streamline the process and maximize productivity.

1. The Importance of Proper Fixturing

When machining complex parts, proper fixturing is crucial. In our case, we faced a unique challenge with a part that had a massive dovetail on the bottom, which left it hanging in space. This design choice was intentional, as it allowed us to address two significant issues: clearance and accessibility. The large table of the DVF 8000T meant that the spindle had to descend far enough to avoid hitting the table, which could have resulted in catastrophic failure.

To resolve this, we opted to raise the material itself rather than using long tools or elevating the vise assembly. By holding only a small amount of material at the bottom, we could access 95% of the part, allowing us to finish nearly the entire component before leaving two tabs for final separation. This approach not only saved time but also ensured that the part remained securely in place during machining, preventing any risk of it flying out of the vise.

Precision Machining Example

2. Tool Selection and Stability

Choosing the right tool is essential for achieving optimal results. Initially, we encountered issues with a larger tool that led to instability and poor performance. However, through a process of trial and error, we identified a more stable setup that allowed us to remove a significant amount of material efficiently. This was particularly important as we prepared for full slotting operations, which can be demanding on both the tool and the machine.

As we progressed, we realized that while roughing passes are typically done first, this part required a different approach. The legs of the part needed support during machining, so we decided to finish the outer profile before returning to rough out the pocket. This strategy ensured that the part remained rigid and stable, preventing any unwanted flexing or chatter during the machining process.

3. Innovative Machining Techniques

One of the standout techniques we employed was the tabbing method. By leaving tabs on the part, we could significantly reduce the amount of excess material that needed to be machined away during the second operation. This not only saved time but also minimized tool wear and extended the life of our cutting tools. The ability to see the part move back and forth during the machining process was a satisfying reminder of the efficiency we had achieved.

After completing the first operation, we snapped the part off and prepared for the second operation. Instead of indicating each part individually, we designed a simple fixture with threaded holes that allowed for quick and accurate setup. This fixture utilized Mighty Bite extensions, which provided both secure holding and precise location for the parts. By using multiple holes, we ensured that the parts were held firmly in place, allowing for consistent machining across multiple components.

4. Streamlining the Second Operation

With the first operation complete, we turned our attention to the second operation. The cycle time for this phase was impressively short, taking only about ten minutes. This efficiency was largely due to the tabbing method we had implemented, which eliminated the need for extensive roughing of excess material. The result was a significant reduction in cycle time, allowing us to produce more parts in less time.

As we moved forward, we ensured that our process was well-documented and that all programs and tooling were ready to be sent to Josh at Total Industries. This collaboration not only showcased the capabilities of the DVF 8000T but also highlighted the importance of effective communication and planning in CNC machining.

Watch Our Machining Process in Action

5. The Role of Continuous Improvement

As with any machining process, continuous improvement is key to maintaining efficiency and quality. After completing the initial runs, we took the time to analyze our results and gather feedback. This included assessing the performance of our tools, the effectiveness of our fixturing, and the overall cycle times. By identifying areas for improvement, we could refine our processes and ensure that we were always operating at peak efficiency.

Additionally, we encouraged open communication among team members, fostering an environment where ideas and suggestions could be shared freely. This collaborative approach not only led to better outcomes but also helped to build a stronger team dynamic, ultimately benefiting the entire machining operation.

For those interested in further enhancing their machining techniques, consider exploring CNC milling strategies that can complement your existing skills and improve your overall workflow. Understanding advanced concepts such as peck drilling can also provide valuable insights into optimizing your machining processes. For more information on this topic, check out this resource on peck drilling.

In conclusion, machining complex parts efficiently requires a combination of innovative techniques, proper fixturing, and a commitment to continuous improvement. By implementing the strategies discussed in this article, you can achieve remarkable gains in productivity and quality, setting your shop apart in a competitive landscape. Thank you for joining us on this journey, and we look forward to sharing more insights in the future!