Small Parts Need High Accuracy

[OneCNC]

The gear below was designed and programmed in OneCNC.

After so many postings of "normal" sized parts this gear is a nice change of pace. Here are images of a .006 diameter gear after being sonically polished. Thanks to Dave at Albright for the photos.

The gear and tool specs are as follows:

Gear dia .006"/175 microns
Center hole .001"/ 25 microns
Endmill dia .001
Depth of cut .002"/50 microns
Material 7075 Aluminum
Machine resolution .00002" .5 microns





The image below was added later to give a better idea of relative dimensions.



OneCNC-USA
http://www.onecnc.com

[Cold Fusion]

That's amazing. What sort of feedrates are used with such small bits?

[nervis1]

Looks like you got a little gouge over there on the left... better cut it again.

[Ken_Shea]

Spectacular, I just cranked down my calipers to .006 to get some visual feedback for just how small that is.

I bet that spindle was a crankin.

[nervis1]

Yea Ken it's even smaller than my tax return last year.


So do tell, what kind of machine can do work like that, with what bit, how fast, what you have there is pretty much science fiction...amazing stuff. Really.

[Ken_Shea]

what kind of machine can do work like that?

Not sure, possibly a Haas tool room mill

All kidding aside, that is absolutely amazing, I saved the link for when some of my loitering acquaintances seems unimpressed with CNC.

[nervis1]

So not to thread jack but...how do you like that tool room mill? I almost bought one of those but ended up getting a used machine. The TM-1 is a really cool looking piece of gear I think.

Post up some pics on the onecnc site, I'd love to see it.

[Ken_Shea]

I am totally (read perfectly) pleased with it except for several points:
1) It is built for 600IPM but limited to 200IPM because it is a open machine.

2) 4000RPM, I dis-like this the most although this may be more of a psychological issue then a problem, at least as I use it.

I like the added X distance but never use it.

I may post some pics of it on the OneCNC forum, but if you have seen one then you have seen them all.

I hope we read more on the micro-micro gear !, very interesting.

[OneCNC]

The machine originally started out as an "old bridgeport" but I am unable to disclose the customers replacement hardware and electronics or feeds and speeds. (Don't you just love trade secrets) .

But to put the gear's size in perspective the image below is of the gear photographed next to a grain of salt. Even more amazing when you look at it comparatively.

OneCNC-USA

[rickyt]

probly a Datron HSM speed and feeds blazing fast.

[lerman]

Do you have a photo of the endmill? What type of machine was it made on?

Ken

[diarmaid]

Seriously...what on earth would you use a gear that small for?? Dont give away any secrets, but an example of its use would be good. Thanks & wow!