[step-manufacturing] Minutes of August 30th conference call

[Martin Hardwick]

Attendees
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Martin Hardwick, STEP Tools, USA
David Loffredo, STEP Tools, USA
Joe Fritz, STEP Tools, USA
Martin Hardwick, STEP Tools, USA
Samson Bonfante, STEP Tools, USA
Bengt Olsson, Sandvik, Sweden
Mikael Hedlind, Scania, Sweden
John Bijnens, KU Leuven, Belgium
Pierre Duchier, Airbus, France
Alain Brail, Airbus (retired) France
Jean Brange, Boost-Conseil, France
JuMyung, POSTECH, Korea
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 second wet run machining.

http://swim.steptools.com:8085/
ftp://downloads.steptools.com/private/JWG15/Mukilteo/

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 September 7th.

Category 	Item 	Description 	Date 	Notes
Setup 	Stock specificaions 	Got stock height wrong.It is 95.9 not 
88.9.Added 7mm to Z location so bottom of block is -92mm. 	8/27/2016 
Boeing will reduce stock height to 88.9
Web interface 	Datum surfaces 	How do you see the datum surfaces B, D, 
E, G during setup 1?It will help to see how to rotate the part for setup 
2. 	8/27/2016 	STEP will add datum surfaces to result of setup 1
NC program 	Small cutter for sides 	Why do we use the 10mm cutter 
instead of the 16mm for surfacing the sides during setup 1? 	8/27/2016 
Corner radius on the 16mm cutter seems to be missing
NC program 	Climb cutting 	Still appears to be conventional milling on 
sides during setup 1. 	8/27/2016 	PSU will fix for the next run
NC program 	Aggressive cut top 	Seems like setup 1, pass 1 has a more 
aggressive cut when surfacing the top.Could be just our imagination. 
8/27/2016 	This was expected - feeds are programmed for full engagement
NC program 	Coolant 	Coolant on code was for flood.Would like to use 
thru-tool coolant. 	8/27/2016 	Need info to understand how this works. 
Maybe M50 or M51
NC program 	Aggressive cut sides 	First pass on the sides is heavy. 
8/27/2016 	This was expected - feeds are programmed for full engagement
NC program 	Additional passes 	Final passes on setup 1 sides has two 
passes separated by a very small amount. 	8/27/2016 	This was will be 
fixed in next version
NC program 	Aggressive first pass 	Setup 2:Heavy first pass on surface 
8/27/2016 	This was expected - feeds are programmed for full engagement
NC program 	Aggressive cut pocket 	Setup 2:Heavy cuts in pocket.Noisy in 
corners 	8/27/2016 	Will investigate and improve for next version
NC program 	Drill 	Drill used was high-speed-steel.Drill badly 
worn.Shaft was galled from rotating in collet.Holes were not fully 
drilled 	8/27/2016 	Will use carbide drill for next test
Video 	Different positions 	Tried different locations of video but still 
gets sprayed heavily. 	8/27/2016 	Will try again
NC program 	Varying step amount during surfacing 	Why is third pass step 
is greater than second step? 	8/27/2016 	See row 9
Relief on cutter 	How to manage the upper and lower reliefs 	Should we 
reduce the depth of cut? How much? 	8/30/2016 	Will discuss with Bengt, 
measure the position, and reduce flute length
Stock off center 	More material is being cut on two of the sides 
Consider moving the machining center to the part center 	8/31/2016 	Keep 
current offsets so that machining origin is at the corner. Delete rapids 
to part center to reduce operator stress/confusion



Martin Hardwick
Convener ISO Digital Manufacturing

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