[Jewelry making - Article 01074] - Re: [Orchid] CNC Wax Masters

[Kenneth Ferrell]

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    I have a question for those doing CADCAM wax master patterns, How
    much finishing do the patterns you send to your customers require,
    Reason I'm asking is I have been getting masters that still are
    showing tool marks on the back, some still have a significant degree
    of flash in inside cuts, and nearly all look as though the outside
    edges were filed with a checkering file!. The lines appear to be
    about 60 to 75 lines per inch and have a depth of around .010 to
    perhaps as much as .020 IN. These are most noticeable on rounded or
    areas that have a radius. Is this type of tool marking inherent to
    parts machined with a mill that uses steppers, or could this be
    solved by using a faster spindle speed and a slower rate of travel?
    Or would it take a different tool size accompanied by a difference in
    travel lineal travel, do to the size of the tool serrations on the
    edges, to me it seems as though a very small end mill is being used.
    Some straight edges are reasonably free from the edge serrations
    which lead me to believe that the X-Y steppers are not quite working
    to insure a smooth arc. Or that the Tool is being pushed too fast, I
    am doing quite a few castings for my client who is the one actually
    paying for the originals, and I have broken several trying to clean
    up flash and areas that were supposed to be cut all the way through
    but weren't. Fortunately until last Sunday all of the broken waxes
    were easy to repair and I was able to fix and clean them up. Sunday I
    broke one through a very detailed area and am not able to fix it, SO
    guess what I get to eat. The originals are done on Ferris Green which
    would seem to be a good material since it usually cuts and scrapes
    pretty clean, so I just want to find out whether these (rough waxes)
    are customary or is this just a case of operator error of trying to
    hurry, I realize that tool marks can be a problem because I used to
    work for Northrop aviation and spent many many shift hours in front
    of Bridgeport and Lagun Milling machines, but back then NC was just
    in it's infancy and I've had no real NC or CNC experience so I'm not
    really sure of the limitations of a table top system, I have been
    studying EMC and G code and have collected some great software but I
    don't know whether to start doing the CADCAM my own self or keep
    swearing at the person doing the waxes I'm having trouble with. I
    have managed to get MASTERCAM 9, JewelCad, and two other top shelf
    programs, I've been looking at Sherline mills, but they only work
    with Linux and EMC I'm used to Linux, but I really don't have the
    time to write the code, and keep up my production, I'd rather let the
    software do it. Does someone know if I can get a control card and box
    that operates on a Windows platform and is it possible to convert a
    Sherline to servos instead of steppers or are steppers even the root
    of the problem? I'm hoping that I can if necessary find an
    inexpensive milling machine that will work with the software that I
    have accumulated, that's why I'm really curious about a Sherline,
    that and the availability of a 4th axis not to mention the initial
    price.   Thanks 

Kenneth Ferrell
www.shadras.com


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