cutting round bar into hex on a 4th axis Fadal 4020

[Michael82]

Iam ruuning a Fadal 4020 mill and i need to cut a 1.7343" hex out of a 2" round bar stock and it is 25" long. I have a VH -65 model 4th axis with a 10" chuck. I need to get a program made using this equiment above and using Mastercam X3 I need to be able to show the boss how it will look on the computer before I run on the machine .Can anyone help with the mastercam part I need to know what function I use to cut a simple hex .I know there is a simple way to do this and its right under my nose can someone help????

[DareBee]

Forget MasterCAM
Takes 2 minutes to hand code.
This is single pass with Face mill
Disclaimer - XYZs & G58 may be different depending on YOUR setup

%
L200
G1Z0.8672 F42.
Y-3.5
G0Z1.2
Y3.5
G91 A-60.0
G90
M17
M30
G00G40G49G80G90G17
M08
T8M6
G0G90G58 X-12. Y3.5 A0. S1200.M3
Z1.2 H8
L206
G80
M05 M09
G91G28Z0.0
G00G90E0X5.0Y9.5A0.0
M19
M30
%

OOPS - I missed the 25" long part, need to change the feed to X direction with a back forth move at the shoulder.
If you want to side mill still almost exactly the same as above.

[Geof]

Originally Posted by Michael82 .....I know there is a simple way to do this and its right under my nose can someone help????

Quite correct there is a simple way.

1; Grip your part in the chuck with the other end supported in a center.

2; Zero the 4th axis and take one or more passes with a face mill to remove slightly less half the difference between your starting bar diameter and the finished size of your hex.

3; Index the 4th axis 60 degrees and repeat 2;

4; Repeat 3; until all six sides are done.

5; Measure the size accurately and run through the sequence again taking off whatever is needed to get the finished size.

Depending on what the starting material is don't be surprised if it warps like crazy.

If your boss really insists on seeing what a long piece of hex bar looks like give him an Allen Key and a big magnifying glass.

[Boots]

I would do the "END VIEW" Extruded to 25 in. long. to get your visual in mastercam.

[cadcam]

Here is a somewhat sample just make it " 25and the cut along the X if need be .also when creating the hex it is actully asking for the Radii not the dia. So mine is big.

http://www.mastercam-cadcam.com/vide...x/forthhex.wmv