How To Make Aluminum Part with Desktop MicroMill and SuperCam
How to Make Aluminum Part with MicroMill & SuperCam

In this example we are going to make a show how to make an aluminum part. Our example result is an adapter plate that will fit on the face of a standard brushed servo motor. This will enable the servo motor to be used on the same mounting holes as a stepper motor.

1. Clamp Material and Home the machine.
1.1. Most parts involve cutting through so it is almost always a good idea to put a sacrificial plate under the raw stock that the part is to be made of. In this instance we are using scrap medium density fiber board, cut to size on a band saw.
1.2. Home the mill with the HOME command. This makes sure that the mill can be returned to the same position after the machining has begun.
1.3. Put the Cutting tool in the spindle. For this part and tool path a 0.125 inch center cutting end mill is all that is required.
2. Line up Drawing to Material.
2.1. Bring the spindle down by using the PgDn key or the Z command. The object is to be able to tell where the tool tip is in relation ship to the stock material.
2.2. Move the spindle to the place on the raw stock that will be the bottom left of the part that is going to be created. The Arrow keys can be used or the MOVETO command with the mouse to position the mill spindle.
3. Set surface.
3.1. Use the MOVETO command to move the spindle to the center of the part to be made.
3.2. Use the SETMSURF command to bring the spindle down to where it just barely touches the surface of the material.
3.3. Execute the UP command to bring the tip of the end mill to the travel height.
4. Move to Limits of part drawing.
4.1 Use the MOVETO command to move the spindle to the edges of the tool path boundary.
4.1.1.The objective is to make sure the part will be contained on the raw stock provided.
4.1.2.The objective is to make sure spindle will not hit any material holding clamps.
5. Set Cutting Paramenters for first outline.
5.1 Use the pull down menu SETUP, command SETZDPTH to set the depth of cut to be 0.02 inch.
5.2 Set the cutting speed to be 0.100 inch per second.
5.3 Set the Cutting Slew Speed to be 0.200 per second.
5.4 Set the Cutting Ramp to be 0.01 rate.
6. Make single outline shallow cut pass.
6.1. Use PLOTITEM to select the outline tool path line.
6.2. Make single pass cut to the preset depth of 0.020 inches. This is a test cut that will verify that spindle speed and motion speeds are correct.
7. Drill the holes in the part.
7.1 Use PLOTITEM command to select the points that correspond to the holes that have to be drilled.
7.2 Answer NO to the first question and make a progressively deeper cut.
7.3. Set the Final Cut Depth to 0.260 inches.
7.4. Set the Increment of Cut to be 0.031 inches.
7.5. Select the Pecking Cycle method of executing the tool path.
7.6. Execute the tool path, Light cutting oil should be used to increase end mill life.
8. Cut Pilot holes.
8.1. Use PLOTITEM command to select the circles that are around the inner four drill points. These correspond to the Pilot holes that submerge the head of the screws that pass through the inner holes.
8.2. Make a progressively deeper cut.
8.3. Set Final Cut Depth to 0.188 inches.
8.4. Set Incremental Cut to 0.021 inches.
8.5. Select Pecking Cycle method of executing the tool path.
9. Cut Face Plate depression. This cut is 0.062 inches deep. The objective is to leave a protrusion that will correspond to the face plate configuration of a NEMA 23 stepper motor.
9.1. Use PLOTITEM to select the lines that correspond to the tool path for cutting the face plate.
9.2. Make a progressively deeper cut.
9.3. Set Final Cut Depth to 0.062 inches.
9.4. Use the default value of 0.021 inches for the Incremental cut. That is the previous cuts setting.
9.5. Select Pecking Cycle method of executing the tool path.

10. Make Bore Cut the Center Hole. This hole goes completely through the raw stock, care must be taken when the final pass is made that frees the center waste part. A standard flat screwdriver is a good tool to hold down the loose part until the milling cycle can be interrupted by hitting the space bare on the keyboard.
10.1. Use the PLOTITEM command to select the line corresponding to the center hole.
10.2. Select the NO option to make a progressively deeper cut.
10.3. Set the Final Cut Depth to 0.260 inches.
10.4. Use the default value of 0.021 inches for the Incremental cut. That is the previous cuts setting. Right click on the mouse to use the default value.
10.5. Select Pecking Cycle method of executing the tool path.
11. Cut out the completed part. This cut will completely free the part. Care must be taken on the pass cut the goes through the stock. A standard flat screwdriver is a good tool to hold down the loose part until the milling cycle can be interrupted by hitting the space bare on the keyboard.
11.1. Use the PLOTITEM command to select the line corresponding to the outside tool.
11.2. Select the NO option to make a progressively deeper cut.
11.3. Set the Final Cut Depth to 0.260 inches.
11.4. Use the default value of 0.021 inches for the Incremental cut. That is the previous cuts setting. Right click on the mouse to use the default value.
11.5. Select Pecking Cycle method of executing the tool path.




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Published 2/10/2017 8:10:51 AM
Copyright 2016 Dennis Bohlke