Allen E. Paulson College of Engineering & Information Technology

Automation and CIMS

MENG 5331FINAL- Rear Bearing Housing

Team MembersIbrahim AhmedRoss Campbell

Bradley McDonaldIndigo Pinto

Casey SheppardSteve Soto

Submitted to : Submission Date:Mr.Spencer Harp 10/21/2014

Abstract:The purpose of this lab was to use the large CNC milling machine to create a rear bearing

housing for a formula one go cart.

Procedure:

Before the CNC milling

The first step of the process was to open the part file in SolidWorks. We then proceeded to make a sketch slightly bigger than the part which would represent our aluminum billet where the part would be machined from. After defining the stock material, we then set a coordinate system in order to give the CNC machine a reference point for all the coordinates in the G&M code. The first job we defined in HSM Works was a center drilling operation for all the holes on the part’s surface. This process was required so when the actual holes were drilled, the drill bit wouldn’t “walk” on the part surface. This is the same as a normal drilling operation, except the depth was set just enough to start the holes. The next job was the actual drilling of the holes, after the center drilling. Our bearing housing had 4 holes of a larger diameter, and 27 lightening holes around the actual bearing housing. These two jobs, while basically the same, needed to be separate due to the different drill bit size. So the 2 jobs were defined separately and the correct tools were selected. An adaptive clearing job was then created in order to start carving out the part from the solid aluminum billet. We set the cutting depth to be 0.4” in order to make it a faster process while still being within the capabilities of the CNC machine and the tool selected. For the center hole which houses the bearing, the entry for the flat mill bit was set to a helical entry. Also, since this was a rough cut and not a finishing cut, we left a small amount of stock material during this step in order to make the finishing cuts on a separate job which would provide a smoother finish. A horizontal clearing step was performed in order to remove the last small amount of stock material left during the rough cut in the adaptive clearing step, along with a vertical clearing for the vertical surfaces. These two jobs then provided a smooth finish for the part. A boring operation was performed in the center bearing hole in order to provide a smooth finish with no entry or exit tooling marks. This process removed the small amount of stock material left during the adaptive clearing and made the part to the specified final dimension. The last two jobs involve using a ball tipped bit in order to form the smooth fillets around the bearing housing hole. The 2D contour job was created in order for the tool to create the fillets and get rid of the stepping effect created during the adaptive clearing step. While it is basically the same job, this process had to be split into two jobs because the fillets were on two different planes, one higher than the other.

After SolidWorks

1. Turn on the system.2. Power up restart.3. Check tooling by jogging over to clear area on the table and bring the tool down 4” off the table.4. Switch to hand wheel jog mode and 0.001 increment mode.5. Use a 123 block to set the tool 1” above the table.6. Press tool offset measure.

7. Enter -1.0 and press enter.8. Repeat steps 3-7 for all new tools.9. Switch to new tool by pressing the MDI button on the CNC control box.10. Enter the desired tool number (eg.T-5) then press ATC FWD button on the control box.11. Press the offset key to switch between tool offset and fix offset.( machine must be in jog mode).12. Scroll over to the desire coordinate.13. Press the part-zero button to automatically insert the measure values.14. Jog and use the edge finder to locate x and z zeros on the mill and enter appropriate values

accounting for the diameter of the edge finder.15. Set the tool to zero by jogging 3” above the part.16. Switch to hand wheel jog and 0.001 increment mode.17. Use a 123 block to set the tool 1” above the part.18. In the correct cell, press part zero set in the highlighted Z cell.19. Enter -1.0 and press enter.20. Subtract the measure tool offset.21. A warning will appear just press enter.22. Upload the program to the CNC controller using a USB jump drive. Press select programs then

followed by the up arrow key followed by a right arrow key and select the program.23. Place the aluminum bar securely on the table.24. Make sure the coolant pump is pointed directly on the drills.25. Close the doors and press start.

Fig 1. Stock piece defined from a sketch.

Fig 2. Coordinate system set in order to orient the machine.

Fig 3. Center drilling the holes before deep drilling

Fig 4. Drilling holes

Fig 5. Adaptive clearing, creating the general shape of the part from the aluminum billet. Helical entry for the center hole

Fig 6. Horizontal clearing the surfaces to give it a smoother finish after the rough cutting.

Fig 7. Boring operation done to give the large diameter hole a cleaner finish after rough cutting

Fig 8. 2D contour operation to cut the fillets using a ball tipped tool.

Fig 9. Another 2D contour in order to do the same but on a different plane

Fig 10. showing tool selection

Fig 11. showing the aluminum stock on secured

Fig 12. showing holes being drilled into the part

Fig 13. showing the CNC controller

Fig 14. showing access material being milled off part

Fig 15. showing center hole being milled will coolant.

Fig 16. showing center hole being milled without coolant

Fig 17. showing part that is completed in the front

Fig 18. showing back pocket being milled

Fig 19. showing front completed part

Fig 20. showing back of completed part

Fig 21. showing top view

Fig 22. showing side view

Fig 23. showing part with rear bearing front view

Fig 24. showing part with rear bearing back view

Fig 25. showing two finish parts one with a sand blast finish