Actuator Frame Bearing Blank Creation

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Instructions

1. Cut Initial Blanks:

   Cut the acetal black sheet into rough blanks measuring 1.165 inch x 1.165 inch x 0.50 inch.

   Note: The final dimensions will be 1.125 inch x 1.125 inch x 0.50 inch, so precision is essential.

2. Prepare for Milling:

   Place one blank in a vice on top of a 1 1/8 inch spacer.

   Use a rubber mallet to ensure the blank is seated evenly on the spacer after clamping.

3. Mill the Blanks:

   Use a 1 inch end mill and find the surface of the blank by slowly raising the bed until the end mill contacts the blank.

   Set this contact point as zero on the bed height.

   Lower the bed by 0.02 inches for the first cut.

   The vice can hold up to 5 blanks at a time. Position them closely together and ensure they are fully seated with the rubber mallet.

4. Perform the First Cut:

   Use the automatic feed to move the mill left/right and operate it at high speed.

   After the first cut, deburr the edges of the blanks and blow away any chips using compressed air.

   Verify the dimensions are now 1.165 x 1.145 x 0.5 inches.

5. Mill the Opposite Side:

   Raise the bed by 0.02 inches and mill the opposite side of all the blanks.

   Ensure the dimensions are now 1.165 x 1.125 x 0.5 inches, with two parallel machined sides.

6. Mill the Remaining Sides:

   Lower the bed back to the zero mark and repeat the milling steps on the other two sides.

   The final dimensions should be 1.125 x 1.125 x 0.5 inches.

7. Final Deburring:

   Place the pieces back in the vice to deburr the short edges and ensure all edges are clean and precise.