AT472 Fall 2020 3 + 2 axis exam Trailing edge plug

 Program machining operations for the part (plug for horizontal stablizer) shown above. The part
file (including stock) is attached. The part is relatively large and 3 + 2 axis operations are
required. Do not use full 5 axis tooling operations! You cannot use machining operations that
come from the top (Z axis) because the part is too tall. Tip: don’t use a roughing operation from
the top that machines the complete part because the tool and spindle will crash into the stock.
The most important part of this exam is to avoid crashing into the part. You can use any angle
between 0 and 118 degrees. (Don’t limit yourself to 0 or 90 degrees).
 Tooling material is epoxy tooling board.
 Use the DMS Tool catalog.
 Use the Whitney feed and speed calculator (all end mills are carbide) to calculate safe feed and
speeds (max SFM for roughing = 300, max SFM for finishing = 600, and Chip load per tooth = .
005.)
 Radial option = step over ratio, axial option = maximum depth of cut.
 Maximum radial step over = .5D, Maximum axial step down = .5D
 Pay attention to macros. It is really important to create planes so that the macros can guide the
spindle around the part without a collision. The DMS CNC can only rotate 360 degrees CW or
CCW. Your first operation should always start at the right side of the part (in viewing direction)
and after that move in a CCW motion to machine the remaining parts.
 Turn in the part files for the part and process and upload on blackboard. Save management is
important.
 You probably will have to create some sketches to limit tool paths.

GOOD LUCK.