[step-manufacturing] Minutes of August 24th conference call and results of first wet run machining

[Martin Hardwick]

Attendees
--------------

Martin Hardwick, STEP Tools, USA
David Loffredo, STEP Tools, USA
Joe Fritz, STEP Tools, USA
Martin Hardwick, STEP Tools, USA
Bengt Olsson, Sandvik, Sweden
John Bijnens, KU Leuven, Belgium
Pierre Duchier, Airbus, France
Doron Cohen, Iscar, Israel
Sid Venkatesh, Boeing, USA
Rich Morihara, Boeing, USA
Chris Stedman, Boeing, USA
Leon Xu, Boeing, USA
Dan Finke, Penn State University, USA
Caleb Severn, Penn State USA
Larry Maggiano, Miututoyo, USA
Vincent Marchetti, Ameritech, USA
Thanh, Hyun, Okuma, USA
Ted Driggs, Okuma, USA

We discussed the results of the first wet run machining.

STEP-NC Machining data
http://swim.steptools.com:8085/
ftp://downloads.steptools.com/private/JWG15/Mukilteo/titanium_boxy_mukilteo_third_master_20160811.stpnc

Okuma Code files
ftp://downloads.steptools.com/private/JWG15/Mukilteo/titanium_boxy_mukilteo_third_master_setup_1.min
ftp://downloads.steptools.com/private/JWG15/Mukilteo/titanium_boxy_mukilteo_third_master_setup_2.min

MTConnect results
ftp://downloads.steptools.com/private/JWG15/Mukilteo/Boxy_Setup_XML%20Data.LOG

Video
ftp://downloads.steptools.com/private/JWG15/Mukilteo/IMG_0519_(1280x853).jpg
ftp://downloads.steptools.com/private/JWG15/Mukilteo/IMG_0525_(1280x853).jpg
ftp://downloads.steptools.com/private/JWG15/Mukilteo/IMG_0531_(1280x853).jpg
ftp://downloads.steptools.com/private/JWG15/Mukilteo/Boxy2016-08-20.mp4

The issue found and their suggested resolutions are listed in the 
spreadsheet below.  The next wet run will take place over the weekend 
and the results will be discussed in the next conference call to take 
place at the usual times on Wednesday August 31 (one week early).

Martin Hardwick
Convener ISO Digital Manufacturing


Category 	Item 	Description 	Date 	Party 	
	Resolution
Setup 	Stock specifications 	Need stock dimensions and tolerances 
8/20/2016 	Boeing 	
	New dimensions sent
Setup 	Workpiece location 	Need work offset location relative to stock 
features that we can measure 	8/20/2016 	STEP 	
	Rotate x and y (x should be along the slots)
Cutting tools 	Missing cutters 	We don't have two of the cutters 
8/20/2016 	Entry drill 	Change process to helical entry for pockets. Use 
3/16 inch (-.1mm - .3m)tool for drilled holes
Web interface 	Axis system display 	Helpful to have frame directions 
displayed on screen 	8/20/2016 	STEP 	
	Use axis system of the machine
Web interface 	Workpiece frame location 	Helpful to have workpiece frame 
system displayed on screen 	8/20/2016 	
	
	Chris to send an example
Web interface 	Identify datum features 	Nice to be able to be able to 
visually identify datum features.Like in STEP-NC Explorer. 	8/20/2016 
Done 	
	See tolerances tab
NC program 	No coolant commands 	Program does not turn coolant on/off 
8/20/2016 	PSU or STEP? 	Will try altering generation logic to trun 
coolant on after starting the workingstep
NC program 	Slow -Z feed during setup 1 	During facing, the down move 
after traverse across the part is very slow 	8/20/2016 	PSU 	
	Fixed in new version
Setup 	Interefence on Setup 2 	The support parallel on the bottom of the 
part in interfering with the un-cut surface of the part 	8/20/2016 	
STEP

	
	Fixed in new version
NC program 	Notes for operator 	Add notes in the program to let the 
operator know what is going on 	8/20/2016 	STEP 	
	Wrong export was used. Fixed in new version
NC program 	Conventional milling 	Is there a reason program does not use 
climb cutting? 	8/20/2016 	PSU 	
	Bug being fixed by PSU
Cutting tools 	Long 10mm tool 	Is long length required in later 
operations? 	8/20/2016 	Yes 	
	See deep pockets of setups 6 and 7
Cutting tools 	Short flute length 	Is there a reason a longer flute 
length was not used when cutting sides? 	8/20/2016 	Sandvik 	
	We think we are using 4.9mm of the 5mm
Video 	Camera position not optimal 	Camera needs to be higher to prevent 
coolant from blocking view 	8/20/2016 	Boeing 	
	See video
Setup 	Used Al 	Used aluminum 85x85x85mm block rather than Ti.We 
discovered Ti block dimensions were not very close to the 
specifications.Ti blocks were oversized by 2 to 3 mm. 	8/20/2016 	
	
	Will program feeds for full engagement and use optimizer to increase 
speed when engagement is smaller
Rough & Finish 	Strategies are mixed 	Roughing and finishing are mixed 
in same step and last pass did not cut metal 	8/20/2016 	PSU 	
	May not be ready for the demo
Project data 	UI needs to include basic info 	End user needs to know 
what file was used to make this data 	8/23/2016 	STEP 	
	Make file name explicit in the UI

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