[URGENT] 3-axis machining of small, angled surface

[robmadms]

Hello everyone,

I am having trouble getting the toolpath for some geometry in one of my soft jaws I need to machine. The files are attached below with an image that points to what I have been having trouble with. I was thinking of first a 3d adaptive move with a smaller tool, then a parallel finishing move. This hasn't worked, nor has any other method, even when the tool will clearly fit within the boundary and my heights encompass the geometry. Other parallel finishing strategies have worked in the past, so I'm not sure what is different about this one.

One caveat about this design is that I designed the two soft jaws in tandem and used a single piece of stock to model the manufacturing. I think this might be the cause of some issues, but I have machined soft jaws before this way, and it has been fine. 

I currently have my toolpath set to a 2d adaptive that machines through it and ignores it, but I would really like to rest my part (the caliper mount) on as much surface as possible. Is this contour really even necessary from a machining standpoint? 

For context, I will be using a 3-axis HAAS VF2SS to make this part. 

Thank you everyone and have a great day.

Rob

[seth.madore]

We can get you a toolpath on that surface, but some advice from someone who has done more than a few parts shaped like that; it's going to be easier, quicker, and more accurate if you just flip the fixed softjaw on its side and attack it like this:

 

The question is, I'm sure; "how do I get them aligned. I want to machine it all in one go to guarantee accuracy". When assembling, lightly tighten the bolts, place the part in the jaws and lightly close the vise. Use some shim stock/feeler gauge and check for clearance all around, tapping jaws left/right as needed. Once satisfied, lock the bolts down

[programming2C78B]

Side mill it as shown above, or surface it with a ballnose and under-cut the corner for clearence. 

if side milling, have the machine mill both sides of the jaw that you use to pickup when you put it back in the proper orientation for "op2", so everything is centered. I've done it many times.

Ive also never had to use shim stock or check, the part should force both jaws to go (with fixed jaw tight, movable finger snug) to where it needs to, then finish tightening the bolts. 

[robmadms]

Hey guys,

Thanks for the help! 

So I machined these on a manual, basically squaring to size and doing the counterbores. The jaw in the image above is going to be with the back jaw of the vise. I can't side mill it like that because of the shape of the part unless I drill a hole to account for the tool radius.

How do I undercut the corner with a ballnose? And then how do I machine both sides of the jaw so it's centered?

This is more of a programming question too because I have been trying to get the toolpath for the angled surface, but it hasn't been generating and I don't know what to do about it because I ran out of ideas

[engineguy]

@robmadms 

FWITW on the alignment I have always used quality vises that are ground accurately (Kurt in examlpe image) and machine my soft jaws to fit as in the image below, for what I do/have done over the years the system works well for me, I can go back to a job weeks/months later and if my vise is correctly setup all i have to do is drop the jaws in and tighten the bolts, works for me 🙂 🙂