[step-manufacturing] Minutes of September 7 conference call and results of third wet run

[David Loffredo]

Attendees
--------------
David Loffredo, STEP Tools, USA
Samson Bonfante, STEP Tools, USA
Bengt Olsson, Sandvik, Sweden
John Bijnens, KU Leuven, Belgium
Sid Venkatesh, Boeing, USA
Rich Morihara, Boeing, USA
David Odendahl, Boeing, USA
Chris Stedman, Boeing, USA
Dan Finke, Penn State University, USA
Caleb Severn, Penn State USA
Asa Trainer, ITI USA


A recording of the call is available at:

ftp://downloads/private/JWG15/Mukilteo/JWG_15_20160907.mp4

We discussed the results of the third wet run machining.  A set of
summary slides, detailed comments, and a video of the pocketing in
setup #2 are posted below.

ftp://downloads/private/JWG15/Mukilteo/Boxy 
2016-09-03%20cutter%20failure.mp4
ftp://downloads/private/JWG15/Mukilteo/Boxy%202016-09-03.pptx
ftp://downloads/private/JWG15/Mukilteo/Machining comments%202016-09-03.xlsx

Before the test, the stock was trimmed from a height of 92mm to 88.9mm

In setup #1, the asymmetry of the stock caused hard entries during the
profile operation.  The operation used climb cutting, which worked
better than conventional cutting in the prior test.  However, even
after the spring pass were noticeable ridges on the resulting surface.

The shank for the tool broke while performing the pocketing operation
in setup #2.  The tool completed the helix into the part, but broke
while spiraling outward.  The pocketing used the 10mm tool and the
depth of cut was 4mm.  The depth of cut was less than in the prior
test, and the feed was tripled.  The chip thickness was estimated at
140 thousandths / 0.6mm

After discussion, we will take the following actions to address these
issues.

- Trim the stock dimensions to 85x85x88.9 (Boeing)

- Setup #1 profiling will use the 16mm tool and include a more gradual
   entry move (Penn State)

- Setup #2 pocketing will use a 2mm depth of cut and reduce the feed
   by half (Penn State)

- For pocketing, the tool shank can be shortened.  Only doing 20mm
   deep pocket, not the 40mm pockets, so the shank does not need to be
   the full length.

- Sandvik has sent replacement equipment to Boeing, arriving today
   (Wed) and Friday.

- The Okuma codes should use M50 for through-tool coolant on all
   operations (STEP Tools)


We also viewed the initial capability for live material removal
display using the STEP-NC web interface.  Multiple participants were
connected to the server watching the machining state.

http://swim.steptools.com:8088/

Bengt discussed work being done with Mikael Hedlind to use AP242 with
cutting tool models.  The work uses the AP242 kinematics demonstrated
previously for machine tool models, but applies the kinematic linkages
to describe how the tool can move within a holder.  Simple movement
will be in and out of the holder along the spinning axis, but other
linkages can be described, such as radial or angular movement.


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 14.


Dave Loffredo