Project 11: Honeycomb

This project teaches the following skills:

Figure A.31: Honeycomb

1. Clamp Part In Vise

Clamp the sawed stock in vise as shown in the figure in table A.13. Set the G54 datum off the upper left corner of the stock. Be sure to leave enough stock so the face and outside perimeter tool paths remove material.

Honeycomb: Job-1 Setup

Datum: Upper-left corner of stock.

Op-1
Face 		Tool (inch)
0.25 End Mill 		Speed (rpm)
1800 		Feed XY (ipm)
18.0 		Feed Z (ipm)
9.0
  Rough XY (in)
1.0 		Rough Z (in)
.25 		Finish XY (in)
1.0 		Finish Z (in)
.005
  Stock to Leave XY (in)
0.0 		Stock to Leave Z (in)
0.0 		  
Op-2
Ctr Drill 		Tool (in)
0.25 Ctr Drill 		Speed (rpm)
1800 		Feed XY (ipm)
18.0 		Feed Z (ipm)
9.0
Op-3
Drill 		Tool (in)
0.25 Drill 		Speed (rpm)
1800 		Feed XY (ipm)
18.0 		Feed Z (ipm)
9.0
Op-4
Pocket 		Tool (inch)
0.25 End Mill 		Speed (rpm)
1800 		Feed XY (ipm)
18.0 		Feed Z (ipm)
9.0
  Rough XY (in)
1.0 		Rough Z (in)
.25 		Finish XY (in)
1.0 		Finish Z (in)
.005
  Stock to Leave XY (in)
0.0 		Stock to Leave Z (in)
0.0 		  
Op-5
Pocket 		Tool (in)
0.25 End Mill 		Speed (rpm)
1800 		Feed XY (ipm)
18.0 		Feed Z (ipm)
9.0
  Rough XY (in)
1.0 		Rough Z (in)
.25 		Finish XY (in)
1.0 		Finish Z (in)
.005
  Stock to Leave XY (in)
0.0 		Stock to Leave Z (in)
0.0 		  
Op-6
Remachine 		Tool (in)
0.25 End Mill 		Speed (rpm)
1800 		Feed XY (ipm)
18.0 		Feed Z (ipm)
9.0
  Rough XY (in)
1.0 		Rough Z (in)
.25 		Finish XY (in)
1.0 		Finish Z (in)
.005
  Stock to Leave XY (in)
0.0 		Stock to Leave Z (in)
0.0 		  

Table A.13: Honeycomb, Top Side Machining Parameters

2. Flip Part In Vise

Flip part about Y-axis, and set the datum as the upper-left corner of the finished bottom face. Use the method described in Project 5 (Steps 3-4) to set G55 for this part.

Honeycomb: Job-2 Setup

Datum: Upper-left corner of finished top face.

Op-1
Face 		Tool (inch)
0.25 End Mill 		Speed (rpm)
1800 		Feed XY (ipm)
18.0 		Feed Z (ipm)
9.0
  Rough XY (in)
1.0 		Rough Z (in)
.25 		Finish XY (in)
1.0 		Finish Z (in)
.005
  Stock to Leave XY (in)
0.0 		Stock to Leave Z (in)
0.0 		  
Op-2
Contour 		Tool (inch)
0.25 End Mill 		Speed (rpm)
1800 		Feed XY (ipm)
18.0 		Feed Z (ipm)
9.0
  Rough XY (in)
1.0 		Rough Z (in)
.25 		Finish XY (in)
1.0 		Finish Z (in)
.005
  Stock to Leave XY (in)
0.0 		Stock to Leave Z (in)
0.0 		  

Table A.14: Honeycomb Job 2