Fixturing a tapered part with compound angles on both ends

[JAW]

I am cutting a part that is round to rectangular with compound angles on both ends. The setup for this is no problem until I get to the final compound angle. If you have any ideas on the final setup I'd appreciate it.

I've attached a sample file of what I am doing with the multiple setups and final part.

[hub]

Leave some rest material for the last step maybe and fix it to an angle plate?

** EDIT**
The taper would be the other way around, bigger towards the rest material..

[job_it]

Leave some rest material for the last step maybe and fix it to an angle plate?

You will have to cut the last part with a ball end mill or a tapered mill.

[JAW]

Leave some rest material for the last step maybe and fix it to an angle plate?

In this pic the green parts are extra material where I will clamp on to it with machinable jaws. The big square end will be milled down to remove the excess stock, then I can easily mill the compound angle for that end. Once that is done the small rectangular end will be milled down and that end will receive a compound angle too.

The second pic shows the final part straight on at front, right and back view.

[hub]

In this pic the green parts are extra material where I will clamp on to it with machinable jaws. The big square end will be milled down to remove the excess stock, then I can easily mill the compound angle for that end. Once that is done the small rectangular end will be milled down and that end will receive a compound angle too.

The second pic shows the final part straight on at front, right and back view.

Yes, that would work I think

[JAW]

What I am trying to figure out, is how to hold it, so I can mill the small end and cut the compound angle because this will be all that is left

[hub]

What I am trying to figure out, is how to hold it, so I can mill the small end and cut the compound angle because this will be all that is left

I'm assuming you are doing this with a 5+ axis?
So, I would leave enough stock to fix it for the last operation. And the last would be to cut the part off the rest material. Maybe I'm not understanding correctly.. What machine are you using?

[job_it]

What I am trying to figure out, is how to hold it, so I can mill the small end and cut the compound angle because this will be all that is left

if the whole part is tapered then mill the small end of the cone first. Cut a mold the small end will fit in. Put some side setscrews or clamps. then mill the large side.

[JAW]

I'm assuming you are doing this with a 5+ axis?
So, I would leave enough stock to fix it for the last operation. And the last would be to cut the part off the rest material. Maybe I'm not understanding correctly.. What machine are you using?

I would prefer to keep this 3 axis if possible. I may have to look at doing this in 5. I am working with a Haas ES-5-4T, horizontal mill.

[JAW]

if the whole part is tapered then mill the small end of the cone first. Cut a mold the small end will fit in. Put some side setscrews or clamps. then mill the large side.

I think that may work!

[hub]

I would prefer to keep this 3 axis if possible. I may have to look at doing this in 5. I am working with a Haas ES-5-4T, horizontal mill.

OK..
In my opinion that part would be difficult to make on a 3 axis. Because there are internal & external tapers.
But MAYBE, do the internal taper first (through the rest material). Then, flip the part and do the external taper & facing. Then fix the part 90deg & cut off the part from the rest material..

[job_it]

I would prefer to keep this 3 axis if possible. I may have to look at doing this in 5. I am working with a Haas ES-5-4T, horizontal mill.

You just have to make sure the part doesn't rotate. your mill will provide the down pressure. I would use a .75 or 1" plate and mill a segment up the part a straight cut will be fine. . If you are milling alu. then place wood or plastic on edges where it makes contact on the walls of your cone shape