Milling Machine

amazingly cool

having programed, the software today not only reconize tooling and fixtures (library) but material as well, to assist to avoid crashes. A lot of the roughing and finishing passes is an algorythm within the cam software, but it is still up to the programmer to select the correct routines, tooling and tooling sequence. But if I had to guess, and its a seasoned programmer.....40 hours. If you do not run into bugs in the software.........that would be a dream.

like to add one other thing, do not play the skill level down to program and operate this, that video was a dog and pony show. I am sure that buyers of machines like this are now wise to it. but there was a time when the pitch was....."All you have to do is.....Press a button"

And then after your company purchased it was left up to you to......."Press the button"....uuhhmm....I can't seem to find The Button!

p911

I don't know how long it takes to program the example in the video, but I know for sure that it would be impossible to mill it manually.

Imagine if you could program the machine to do dental work or medical procedures.

This will operate from a CAD program that drew the solid shape, with their software to instruct the machine to cut the shape.

The machine is instructed to cut everything outside of the solid, and the CAD operator would have to make it amenable to the limuts of the machine

Yep, it would be a nightmare to program that. It is taken from a CAD, you are right. I would not be using such cutting tool though. Have a look at the services that water jet and laser cutters can provide if any one is interested. They can even shape glass and other harder materials and not a tool change in sight. They can also handle very small parts and I mean very, very small.

http://spie.org/x8679.xml?ArticleID=x8679

That was a pleasure to look at so thanks to the OP for the link, Ky.

You really don't program the machine in the classic sense, you use a high-end MCAD program to model the object. That file is then used by the CAM software to create the tool paths and fixture movements that run the CNC mill.

The design time for the object was probably 40 hours or so if they started from scratch.

It is entirely possible they modeled the main part in a MCAD system and then moved the file over to something like Rhino for the finishing touches.

If you want to play around with MCAD software, go download the trial software from www.alibre.com. I use it all the time for drawings in my magazine. I can take the modeled parts, feed them into Alibre CAM or one of the higher end CAM products and end up with the G-Code to run one of the fancy mills or lathes.

speaking of programming, for a very long time they wanted and I am sure by now they may have to develop a new standard of programing syntax., other than G-Code. can not remember what ir was though......

For one thing that machining center is NOT your daddy's 3 axis Bridgeport! It's not even a "simple" 5 axis machine. The tilt and rotate capability of the fixture is an important ingredient and adds dramatically to the capability of the machine.

I don't care how good you are as a designer, you are NOT going to design that helmet in Alibre or any entry level solid modeling software that is limited to prismatic shapes. You need to be able to design using surfaces and export the surface information to a good G-code generator and it had damn well have a post processor that is machine specific and able to speak intelligently to the machine used in the movie.

Another thing. the tool paths for that demo were not programmed manually. They were generated in a high end CNC software package with a custom post. Even then, I'll bet a skilled machinist had to spend a long time debugging the result. That job was not simply a question of feeds and speeds.

The problem today is that many of the people designing parts often are inexperienced in fabrication and manufacturing methods. Movies like this will blow their minds.

After so many decades of selling high end CAD software, tool path generators like Mastercam and then designing in professional environments, I was certain I'd seen it all. Wrong! That movie was an eye opener. The Japanese have come a long way and are seriously outgunning us.

Thanks for bringing it to our attention.

L.J.

It's also worth noting that they are dry milling (no coolant) aluminum, which is a fairly recent development. 

It's also worth noting that they are dry milling (no coolant) aluminum, which is a fairly recent development.

No, its not that recent....when I was at the ship yard we were dry milling aluminium back in late 80's early 90's as well as other more exotic metals, letting the chipload carry away the heat some of the exotic metals reacted with the coolants.

Great post.

You do know that many people around the world design and build or build from bought plans their own 3, 4 or even 5 Axis milling machine? Its become a hobby for many, some even make a little cash from either selling the machines or the products.

The video was very top end, you are probably talking of a machine worth $500,000 or even more, the home one won't be quite as good, but will still be great fun.....

Go onto YouTube and search using the words "DIY CNC machine" (you may see some Command 'n Conquer videos, just ignore them), if you like what you see and want to follow suite, I can give you enough tips to get you started.

It does not need to be expensive, especially if you have an old PC lying around to drive the thing. Even all the software can be freeware......to build a small reasonable CNC 3 axis should not cost more than $250 if you search well on ebay and the like......and make basically everything yourself except the PC (free or available), the router (2nd hand) and the stepper motors (2nd hand from ebay or similar).....

For example:- I got 9 x 1.8 amp Sanyo stepper motors for around €15, all were good except one.....I got a complete 3 axis stepper driver PCB for exactly €1.00 (about US$1.45)....it had never been used. There was a further 3 motors and sensors with it.....the router I bought defective for €7 on ebay (good German make) and sent it back for repair, another €30 including postage. I got a brand new one back (new model) as it was not repairable (older model), for that same price, a new one costs around €80.....etc etc

My single greatest cost was a SMPS (Switched Mode Power Supply) that I built myself, 10 amps at 24 volts using some clever chips.....and a circuit from Elektor......that cost €55 alone.....

I used plastic faced chipboard which is really cheap and very stable (the thickest I could find!!), normal 8mm threaded rod from a DIY shop, skateboard bearings (which just happen to be 8mm in the center and VERY cheap!)....All the metal bits came from DIY stores, a couple of bits I welded up myself (taught myself welding to do it!!)

Obviously the welder was NOT part of the deal in the price.......I needed one anyway and welding is also a FUN hobby!!!! I repair garden equipment for neighbours!!!

If you have Scottish blood and don't rush things, you can radically cut the costs of the build. Someone who is REALLY "Canny" (Scottish for clever!), will make one even cheaper.....especially if he is also an electronic/electric "Junky" anyway.....

I got a lot of my ideas from here:-

http://buildyourcnc.com/default.aspx

If you want any further help or infos or guidance, just ask, I am no expert, but:-

"a man with one eye is a king in the land of the blind!"

I'd say that in this case the programming time is irrelevant . The helmet is drawn by a talented artistic designer in some 3 d cad package . It could be drawn quick enough by a good operator , 4 or 5 hours maybe ?

Maybe the helmet doesn't even need to be drawn for this project because there must be heaps of existing drawings for helmets that are are mass produced the whole time .

Once the drawing is imported into the cam software i'd argue that there is very little programming to be done because a lot of the modern cam software is so functional that it nearly does the job itself .

And there is anti collision simulation software to run through the program checking for machine or tool collisions .

Might take a day to do the whole lot , including machining .

And number 2 helmet , 5 minutes !

here is some stuff

27 April 2010 — The full-face helmet from DAISHIN SEIKI CORPORATION won a gold medal at the Mori Seiki Cutting Dream Contest 2009. The complete NC program for this workpiece was created with hyperMILL CAM software from OPEN MIND Technologies AG.http://www.openmind-tech.com

and the Mori Seiki contests, years of them, fascinating

http://www.google.ca/#hl=en&source=hp&q=Mori+Seiki+Cutting+Dream+Contest+2009&btnG=Google+Search&aq=f&aqi=&aql=&oq=Mori+Seiki+Cutting+Dream+Contest+2009&gs_rfai=&fp=7767a3cd0aa0c10f

Well, some interesting posts here!!

I served my apprenticship back in 1970, in those days a horizontal Bridgeport 3 axis milling machine was one of the best.

CNC machines began to appear in the mid 70's using paper tape to program them!

As I'm an electronic engineer I haven't kept up to date with these advances, so to see one as in the video was quite an eye opener!!!

John.

I see the USA is right up there and a US company made the SW that did it.

Main Office North East (Boston)

OPEN MIND Technologies USA, Inc.

214 Garden Street, Unit 2

Needham MA 02492

Phone: +1 888 516 1232 begin_of_the_skype_highlighting +1 888 516 1232 end_of_the_skype_highlighting

Fax: +1 270 912-822

E-mail: Info.Americas(at)openmind-tech.com