Actuator Frame Bearing Blank Creation: Difference between revisions

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Latest revision as of 15:44, 25 July 2024

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Instructions

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

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 == Instructions ==
-# Cut blanks that are 1.165 inch x 1.165 inch x .50 inch.
+# Cut Initial Blanks:
-#: The final blank will be 1.125 inch x 1.125 inch x .50 inch.
+#: Cut the acetal black sheet into rough blanks measuring 1.165 inch x 1.165 inch x 0.50 inch.
-#: The size of this part must be precise, use methods and tools that will achieve a clean cut.
+#: Note: The final dimensions will be 1.125 inch x 1.125 inch x 0.50 inch, so precision is essential.
-# Using the mill size the blanks:
+# Prepare for Milling:
-#: Place the blank in the vice on a 1 1/8 in spacer. Use a rubber mallet after clamping it down to make sure the piece is sitting evenly on the spacer.
+#: Place one blank in a vice on top of a 1 1/8 inch spacer.
-#: Use a 1 in endmill. Find the surface of the work by slowly raising the bed until the bottom of the endmill makes contact with the blank.
+#: Use a rubber mallet to ensure the blank is seated evenly on the spacer after clamping.
-#: The first cut will be 0.02 in below the surface of the work. Set this height on the bed as zero.
+# Mill the Blanks:
-#: The vice can hold 5 blanks at a time. Push them close together and use the rubber dead blow to fully seat them on the spacer.
+#: 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.
-#: Use the left/right automatic feed and run the mill at high speed.
+#: Set this contact point as zero on the bed height.
-#: Before un-clamping the vice, use a sharp de-burring tool to clean up the edges of the pieces and blow away any chips.
+#: Lower the bed by 0.02 inches for the first cut.
-#: Check that the dimensions of this cut part are now 1.165 x 1.145 x 0.5 in.
+#: 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.
-#: Cut one side of all the blanks in this way. Then, raise the bed by 0.02 in and cut the opposite side of all the pieces.
+# Perform the First Cut:
-#: The dimensions should now be 1.165 x 1.125 x 0.5 in, with two parallel machined sides.
+#: Use the automatic feed to move the mill left/right and operate it at high speed.
-#: Lower the bed back down to the zero mark and repeat the above steps with the other two sides.
+#: After the first cut, deburr the edges of the blanks and blow away any chips using compressed air.
-#: The final dimensions are 1.125 x 1.125 x 0.5 in.
+#: Verify the dimensions are now 1.165 x 1.145 x 0.5 inches.
-#: Place the pieces back in the vice to deburr the short edges.
+# 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.
+# 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.
+# Final Deburring:
+#: Place the pieces back in the vice to deburr the short edges and ensure all edges are clean and precise.