Actuator Frame Bearing Blank Creation
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.