Kir

Process and workholding

I prepared NC programs for two setups. In the first setup, I machined interrelated precision features from both sides without reclamping, and prepared the datums for the next operation.

For the second setup, I designed a dedicated fixture with locating pins and screw fastening. Mounted in the vise, it provides tool access to the remaining surfaces.

Machining and inspection

I used indexed 3+2 machining and five-axis Variable Contour toolpaths for the outer cylindrical surface and radius transitions. The work included a thin rib, holes and thread-milled internal threads.

I proved out the programs on the machine and carried out in-process checks using a Renishaw probe, a micrometer and plug gauges. The quality department performed final CMM inspection and accepted the parts.

Machining sequence

In the first setup, I machined the main envelope and the side with stepped cylindrical features. I used a chamfer mill and a Variable Contour operation for the annular groove.

The second setup covered the opposite side, including the internal cavity, shoulders and chamfers. I produced the M2 internal threads by thread milling.

Prove-out and inspection

I programmed the operations in Siemens NX and proved them out on the machine, working to the drawing's dimensional and surface-finish requirements.

I used calipers and plug gauges for in-process checks. The quality department carried out final inspection on a coordinate measuring machine.

Outer surfaces and side windows

I first prepared the stock for serrated-jaw gripping. In the first main setup, I machined the end face on the Ø30 mm recess side, the Ø90 mm outer surface and two 25 × 50 mm side windows with R12 corners.

I used Variable Contour to mill the outer cylinder, accounting for tool overhang and surface access. I also used it to break the edges of the side windows.

Internal cavity and inspection

For the second setup, I gripped the machined Ø90 mm surface in a chuck and machined the stepped internal cavity and opposite end face. In NX, I checked the toolholder-to-wall clearance and worked to the Ø78 H9 and Ø6.5 H9 bore requirements.

I used a Renishaw probe for preliminary measurements, followed by checks with calipers, micrometers and plug gauges. The quality department performed final CMM inspection.

Location

A locating boss on the plate centres the chuck using its mounting recess. Two cylindrical locating features position the vise. Locating keys position both bases on the rotary table.

Fastening and use

M10 bolts secure the chuck and vise to their bases, while T-slot nuts fasten the bases to the table. I also manufactured the keys and nuts. I use these fixtures in daily work to simplify mounting and changing the chuck and vise.