Complex part · 3-axis milling

Fanuc · O0111 · CNMEC, small CNC workshop

The part

3D form Ø63 / Ø42 Ø10 Ø8 Ø6 rough sketch, worked out from the toolpaths
Machine
Fanuc 3-axis mill + B table (always at 0°)
Program
O0111 · 50,837 lines
Tools
9 · inch library (Ø12.7 = ½")

Work cycle

  1. Facing · T171 Ø50.8
  2. Adaptive roughing · T133
  3. 2D finishing: wall, Ø42, Ø63 · T135/T134
  4. Chamfer Ø63 · T131
  5. 3D finishing ×4 · T137 ball
  6. Holes Ø10, Ø8, Ø6 · T2/T3/T4

First remove a lot, fast; then bring to size; then refine.

Where the time goes

operationmin
Adaptive21.6
4 × 3D finish32.7
everything else3.2
total≈ 57

95 % of the time is roughing and 3D. Tool changes excluded.

Facing in 2.54 mm levels

Library: max 0.100" = 2.54 mm

Z-1.439 → Z-3.979 → Z-6.519 → Z-7.154 finish

Every level within the cutter's limit.

Drilling with coolant

Ø10, Ø8, Ø6: M08 in every hole.

Through holes 3.5 to 6 diameters deep in aluminium.

The coolant flushes the chips out of the flutes.

Production details

  • Holes drilled after the 3D finish, on the final surface.
  • Outer finish: descends in G01 through the area already cleared by the adaptive.
  • Library comments written in mm (MAX DEPTH OF CUT = 3.175 MM).

Inches ↔ mm

12.7 mm
½"
50.8 mm
2"
F1524
60"/min
F304.8
12"/min
0.100"
2.54 mm

1" = 25.4 mm. The program is in mm (G21), the library comments too.

Drilling peck by peck

G01 Z-12.969 drills
G00 Z-12.769 back 0.2 → breaks the chip
G01 Z-15.469 drills another 2.5

Halfway: G00 Z5.08, comes all the way out to clear chips.

Every operation starts like this

M01 → T M06 → T(next) → G90 G94 G17 G49 G40 G80 → S M03 → G54 → M11 → B0 → M10 → M08

And ends: Z15, M09, M05, G30 G91 Z0, G90, G49.

Before Cycle Start

  • 9 tools measured
  • Cutter stick-out ≥ 45 mm
  • Clearance under the holes (Z-49.3)
  • B axis at 0° and brake OK
  • G30 point = tool change
  • Coolant in every op
  • Optional Stop on

Adaptive: why?

The cutter always works at the same engagement: looping paths instead of straight passes.

Constant load → you can go deep (42 mm) with a Ø12.7 cutter without breaking it.

Setup sheet

at the machine
  • Stock top at Z0, part clamped clear of Z-49.3
  • Holes come last: drills after the ball end mill
  • G30 position = tool change
G-CODEblock-by-block explanation

Open the program on the control screen, with the reason for every line.