hi folks let's machine some Awards medals this is for the Zanesville survivor challenge and if you've ever heard anything about Zanesville it's probably either that we used to be the pottery capital of the world or that we have a wide bridge so Alex took the lead on this project some good examples of job-shop workflow in both fixturing and fusion 000 cam let's dive in we decided to make these out of half-inch plate for two reasons number one we had the material on hand and number two it lends itself to using the superglue method to make them six at a time starting off by ramping down the outside profile of our shape we have found when it comes to a slotting style tool path that a ramp technique can work quite well when you set the maximum step down of each ramp to ten percent of the tools diameter chip evacuation is critical and it's one of those examples where I found flood coolant to be superior to the fog buster because the fog buster nozzle just can't stay aimed at the curves as it rotates around all directions next up facing the part off so why are we using a quarter inch tool to face this part off shouldn't we just use a face mill or a fly cutter card here to the video on 00 different ways to face the part two benefits here number one we're gonna go sand these parts afterward using a smaller tool minimizes any tram air and the machine makes it much easier to sand your part to a really nice finish the second reason was minimizing the number of tools that we use Alex set this up while he was doing some other work is so fewer tools we need the better off we are next up sliding this 0/0 inch slot for the ribbon so this is tricky or rather this is an easy place to break a tool it's a 0/0 inch slot that's 0/0 of an inch thick so only 0 times diameter nevertheless we want to stack the deck in our favor so we're using the 0 D slot tool path that forces fusion to stay on the centerline of the cut works great seem step-down passes maximum roughing step-down we're doing 00% of the tool diameter you can type it in yourself or if you right-click and an expression you can see tool diameter times 0.0 fusion has a relatively new update that's great where you're not sure what formula to use just start typing tool and now you get a list underscore D I get diameter times 0.0 a really nice useful feature and we're slowing down our feed rate to one thousandth of an inch feet per tooth that does two things one less to pressure and number two smaller chips the smaller those chips are the easier it is for the flood coolant to flush them out so how do you program multiple parts when they're laid out on a sheet like this use a component pattern this is an awesome feature in fusion what it lets you do is we program one of these parts we then in the design side right click copy now I'll right-click you've got two options you can paste or paste new the difference is paste paste another instance of that component but it's still linked back so if we made a change on our original component like the engraving or the text that change would flow through that's the right way here because I want six identical components paste new would paste it as a new component with no link back to the original I'll do a paste I'll move it over here for the sake of this example click OK we've programmed the ramp tool path on our original part right click add a new pattern and what I love about this is it kind of breaks the mold of rigid parametric CAD where you have to have things in structured patterns and very much ordered switch it to component pattern the source our original the target already found it in this case it found all of them because we have automatic on let's say I want to just program it on this individual one just turn off automatic and under targets I can click this one or say this one and this one I love this very useful tool for thinking about manufacturing workflows in production and fixturing we then tried two different ways to finish these metals up one of them failed so Alex tried to use a hybrid fixture plus superglue to do the majority of the work on this interior pocket so superglue is all about the amount of surface area you have card here to our Vice torque video test where we start to talk about that the rule of thumb that I follow is if you have a an approximately six inch square part or 00 square inches or approximately 000 by 000 millimeters that's going to be sufficient surface area for the superglue technique to have a secure workholding especially on non ferrous parts smaller than that gets tricky and in this case if I click once on that face fusion tells me it's only 0.0 square inches or about one-fifth of my mental rule of thumb but Alex wasn't just relying on super glue he also had modeled in this fixture which did two things it located each part after he flipped it to hold the six in place and it would have given it some XY stability so this is a good lesson we've done some testing where if you have a super glue part and you put a single screw or strap clamp on there that extra tool works as a force multiplier that really compounds or holding power of the super glue here it wasn't enough it actually did work for the first six but Alex wanted something he could walk away from this didn't pass the test so on to soft jaws soft eyes are awesome and if you're a machinist that's heard about them but it's never made them I encourage you to give them a shot card here to a video where we walk through that workflow things to think about when you're making a set of soft jaws we buy them from Monster jaws in ten packs but we buy the reversible style so they instead of having a round Center slot it has an oval slot this lets us use both the top and the bottom so we usually get two setups out of the same set of soft jaws which haves the cost but seriously I remember years ago being intimidated by soft jaws that they are great but the problem with soft jaws is their one at a time not at the end of the world we only had to make 00 of these but I come in Alex because he was really trying to focus on how can I batch these up and run them six at a time and if we ever did these again I know we could make this work as a combined technique and what I would do is increase the physical clamping of this fixture plate by either resetting a pocket for this whole piece to sit inside of that's going to massively increase the XY stability of that part combined with superglue or do that along with something like the mighty bite fixture clamps that pivot on an eccentric screw this alone may mean you don't need a super glue I would probably still stack the deck in our favor at least on the first few of using they combined a super glue with the fixture clamp after they were done though Alyx did three different finishing techniques to differentiate first second and third place he did a great job on that and the local boy scout group and the event organizers were super happy to have a custom made metal for the event will have the CAD file up so you feel free to poke through it on your own over here on the NYC CNC web site otherwise folks hope you learn something take care see
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