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John Arey
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The purpose of this project is to practice CAM and CNC machining skills (to hone my skills in design for manufacturing). For this practice part, I completed a CNC project as part of DSGN 345, a class focused on this matter at Northwestern University.
My part, which consists of an embossed logo of the popular video game DOTA 2 constructed on a smooth complex surface, was designed to demonstrate several milling methods on a single part. Feature sizes directly in line with tool sizes were chosen to simplify manufacturing through design.
This part was modeled in SolidWorks and then imported into NX to use its subsequent CAM package to construct the milling operations.
The toolpath used as many types of milling as was reasonable to use on the part, including cavity, floor, and contour milling to create a the desired look. Finishing operations were created but limited in scope to reduce cycle time, affecting the final surface finish.
Setup and machining was completed in a Haas Mini Mill, with the appropriate tooling loaded in and part zero planes measured. The entire process lasted about 2 hours, with changes in feed rate postCAM being made during operation to reduce vibrations in the part.
The stock was clamped in the vice with 1’’ parallels for maximum clamping area while still allowing the part to be cut without any crashing occurring.
Machine time was about an hour and a half, with feeds and speed overridden to 200%, as conservative numbers were set during toolpath setup.
The part turned out well, though a smoother finish given more time would have improved its look. The part was meant to mate with an inverse model (done by another student), but differences in toolpaths and poor tolerances meant the two did not line up as intended.