If you are currently using Fusion, I recommend giving DSI a call. Link in the video description to their website. They will get you going! Thanks for watching!
Very cool to see this! I am doing something similar to this on a Haas UMC750SS, but I do square through holes (usualy 40mm square, 100mm deep). I do it in plastics though (mostly UHMW but sometimes also in delrin) My solution was a hand written macro, but my needs are a little more simple as the square holes are for mounting a pulley on a square shaft, so its always on X Y 0. This solution is much nicer though!
That is a great point, thanks for pointing that out. At a certain point I have so much time and effort into it, that I forget to explain all the details. I am also working hard to keep the videos around 10 min long. Thanks for watching!
Your video is great and well edited. Thanks. For me, the missing part was the CAM cycle you used. You mentioned Fusion and CAMplete, but I don’t know what cycle you used. I’d love to know. Really awesome process.
All the rotary broach guys are not *exactly* wrong, but I think getting single point dialed-in for your shop is probably the more flexible option. Rotary broaching requires specialized tooling you would need to have for any job that comes across the bench - and all the delays and BS that bringing in tooling for a job entails. Being able to single point on-demand? Worth it. Having said that, Polygon has a rotary broach brake that lets you time the broach. You essentially engage the bottom face of the broach with the material, then turn the spindle on, do the broach, and retract to a point where the tool is still engaged. Turn the spindle off and the brake keeps it from losing position through the rest of the cycle. Wash, rinse, repeat. On a BT30, you will definitely want to get in with a small tool and pre-form as much of the broach feature as you can - not just plunge the broach into the book spec pre-drilled hole. This lowers the cutting pressure dramatically; you really just want to be biting out the minimal practical material in those corners. Remember- BT30 machines are happy with relatively high Z forces from all the drilling they do. I can't speak to the Fanuc 24k spindle (which is a bit higher strung than our Brother spindles), but I can't imagine a properly run rotary broach in 6061 would be a problem. We do this all day with 16k spindles in Speedios.
Thank you for all that info. That all makes sense. On this application I would have definitely needed custom made broaches to avoid hitting the top of my part. From pre drilled tangent hole to corner of broach is right at .035 of material, keeping in mind that is times six for each hole. I was a little apprehensive hitting that in one go on a rotary brooch. Had it been a spline with very little material being removed I might have given it a go. Thanks for all the input, it is greatly appreciated! Thanks for watching 🙏
I have never seen an angle oriented m19, going to have to try that. I have 2 robodrills as well, but im curious how many other platforms will take it. I have a c- axis single point macro from a lathe, all you told it was how many sides, start diameter, end diameter, depth and feed. Worked great, but we went to wobble broach for the speed.
As I’m new to CNC machining, can someone explain why you would choose to broach instead of using a small endmill? I understand there’s more of a radius in the corner, but the nut also has a radius. Or is it more of a tool length issue? So much to learn….
You are spot on man. Do to the Z hight location of these and the very small end mill required to create this feature. Broaching is the most reliable/repeatable process. Especially when you stat getting into high quantity/lights out production. The more robust your process, the better odds of long night time runs. This trade is a Marathon everyday you're going to learn something new. It takes a lifetime to become a well round Machinist. I myself have just scratched the surface of everything there is to know.
Awesome post editing but i think you would save loads of time by using a rotary broach. Single point is good for prototyping because you don't need specific tools, but if you're doing production, rotary broach all the way. Each hole would be like 5 seconds
The only thing I could not do with a rotary broach was "clock" the hex. I had also read that there is more cutting pressure with a rotary, but I could not find hard evidence of that. Thanks for the feedback and thanks for watching!
Nice video! Have you checked the load support on the table when pushing? It is certainly possible, but with B swiveled 90 degrees it is not optimal in the long run.
There is no load registering on the control. The 4th and 5th are locked. I am only taking .001 per step over at 250 surface feed. I don't think I am hurting the machine, you can't even hear it cut😅
Edge precision has the best broaching video on youtube, but he's doing it in a macro. Haas have VPS templates for broaching, and some good videos on them.
Horn make nice single point hex broaches. Loads more reliable than a wobble broach. Used them on Swiss for years with a little macro I got off the internet Write one line of code once in position and it will do what you need. 30 seconds work
They also make torx options as well I use the same macro with a y offset to make ratchet rings for bike hubs. The y axis means you can use standard slotting broaches to make the profile rather than needing expensive custom tips Loving the UberRobodrill.
I should have talked about rotary broaching in the video. I could not find one that would allow me to "clock" or orient the hexes the way they needed to be placed. I also read that there is a higher force on the BT30 over the single point cutting.
Ya, my bad. I thought I was screen recording but the program was not recording the dialogue boxes. That mistake will not happen again. Thanks for watching!
It looks to me like design for manufacturing has not found it's way yet. A lot of complicated procedures for simple feature. Can't you just press in nuts, or use serated inserts/cling nuts. Or could potentially just use normal nuts some simpler punch feature to deform once nut is in.
My client wanted to specifically be able to remove the nuts from the part, quickly and easily. I agree it's a tricky design that is definitely not a common feature. Thanks for watching!
Since this feature is for a nut, I would mill this hex and make my own nut to fit in there (or modify an existing one) . Way faster and cheaper. This just shows incompetence of design / construction.
How did you index the tool? Was it as simple as index it in the holder, square to the drive lugs. M19 a normal m code for robodrills.? My post is the one that Nyccnc made + I modded it so it to G53 x y at the end of program. Now I need it to shut spindle off during Z G53 at end of program. Right now it'll be spinning up by the tool change relying on M30 to shut down
So the broach had a ground flat on it, that aligned it to the tip of the tool. The tool holder had it's set screw in the perfect location. When I M19 the machine. It is at "0 degrees" so I used all nominal numbers for indexing. Had it been of X amount of degrees I would have just taken that into consideration.
@@ConourManufacturing hey, got a potential job that requires broaching a hex with orientation like you are doing! Would you be willing to sell me your post?
@@RoboDriller you can purchase this post with something like 12 months of additional changes/modifications to it from DSI. I think it's $500 from them, it's well worth the money! Their link is in the video description. Let them know Conour Mfg sent you. If you then have any questions or want to see an example program, just shoot me an email and I will help out!
@@RoboDriller I don't believe so. If you click on the video description there is a link that will take you to the DSI website. You are using Fusion correct?
Imagine that a guy who is willing to share his job shop journey for the internet to enjoy , aspirational! 👍🏽
Thank you 🙏
Devon Dupuis is such an inspiration to me.
He is the goat!
Awesome stuff Shawn! Keep up the great work!
Thank you so much 🙏
Great video showing your process, Shawn.
Thanks for all the help Angelo!
I’m single point broaching in our robodrill but it’s all hand written. Would love to see more on the fusion post!
If you are currently using Fusion, I recommend giving DSI a call. Link in the video description to their website. They will get you going!
Thanks for watching!
I use broaching inside fusion on a haas umc750. I also use trace and draw in a small arc at the bottom for my back off.
Very cool to see this!
I am doing something similar to this on a Haas UMC750SS, but I do square through holes (usualy 40mm square, 100mm deep).
I do it in plastics though (mostly UHMW but sometimes also in delrin)
My solution was a hand written macro, but my needs are a little more simple as the square holes are for mounting a pulley on a square shaft, so its always on X Y 0.
This solution is much nicer though!
That sounds cool! Thanks for the kind words 🙏
Thank you for the video, very cool. It was a little confusing, showing us the tool close up before jumping into the CAM might have helped!
That is a great point, thanks for pointing that out. At a certain point I have so much time and effort into it, that I forget to explain all the details. I am also working hard to keep the videos around 10 min long. Thanks for watching!
Your video is great and well edited. Thanks.
For me, the missing part was the CAM cycle you used. You mentioned Fusion and CAMplete, but I don’t know what cycle you used. I’d love to know. Really awesome process.
We just shot a follow up video yesterday and included all that in the video. It should post in about two weeks. Thanks for following along!
All the rotary broach guys are not *exactly* wrong, but I think getting single point dialed-in for your shop is probably the more flexible option. Rotary broaching requires specialized tooling you would need to have for any job that comes across the bench - and all the delays and BS that bringing in tooling for a job entails. Being able to single point on-demand? Worth it.
Having said that, Polygon has a rotary broach brake that lets you time the broach. You essentially engage the bottom face of the broach with the material, then turn the spindle on, do the broach, and retract to a point where the tool is still engaged. Turn the spindle off and the brake keeps it from losing position through the rest of the cycle. Wash, rinse, repeat.
On a BT30, you will definitely want to get in with a small tool and pre-form as much of the broach feature as you can - not just plunge the broach into the book spec pre-drilled hole. This lowers the cutting pressure dramatically; you really just want to be biting out the minimal practical material in those corners. Remember- BT30 machines are happy with relatively high Z forces from all the drilling they do. I can't speak to the Fanuc 24k spindle (which is a bit higher strung than our Brother spindles), but I can't imagine a properly run rotary broach in 6061 would be a problem. We do this all day with 16k spindles in Speedios.
Thank you for all that info. That all makes sense. On this application I would have definitely needed custom made broaches to avoid hitting the top of my part. From pre drilled tangent hole to corner of broach is right at .035 of material, keeping in mind that is times six for each hole. I was a little apprehensive hitting that in one go on a rotary brooch. Had it been a spline with very little material being removed I might have given it a go.
Thanks for all the input, it is greatly appreciated! Thanks for watching 🙏
I have never seen an angle oriented m19, going to have to try that. I have 2 robodrills as well, but im curious how many other platforms will take it. I have a c- axis single point macro from a lathe, all you told it was how many sides, start diameter, end diameter, depth and feed. Worked great, but we went to wobble broach for the speed.
Thanks for watching the video! From my understanding most direct drive mills can index 1 degree at a time.
As I’m new to CNC machining, can someone explain why you would choose to broach instead of using a small endmill? I understand there’s more of a radius in the corner, but the nut also has a radius. Or is it more of a tool length issue? So much to learn….
You are spot on man. Do to the Z hight location of these and the very small end mill required to create this feature. Broaching is the most reliable/repeatable process. Especially when you stat getting into high quantity/lights out production. The more robust your process, the better odds of long night time runs.
This trade is a Marathon everyday you're going to learn something new. It takes a lifetime to become a well round Machinist. I myself have just scratched the surface of everything there is to know.
@@ConourManufacturing Thanks for taking the time to respond. Just found your channel and will go back to your earlier videos and get caught up!
Awesome post editing but i think you would save loads of time by using a rotary broach. Single point is good for prototyping because you don't need specific tools, but if you're doing production, rotary broach all the way. Each hole would be like 5 seconds
The only thing I could not do with a rotary broach was "clock" the hex. I had also read that there is more cutting pressure with a rotary, but I could not find hard evidence of that. Thanks for the feedback and thanks for watching!
@@ConourManufacturingThere are breaks that allow you to clock the broach.
Nice video! Have you checked the load support on the table when pushing? It is certainly possible, but with B swiveled 90 degrees it is not optimal in the long run.
There is no load registering on the control. The 4th and 5th are locked. I am only taking .001 per step over at 250 surface feed. I don't think I am hurting the machine, you can't even hear it cut😅
Edge precision has the best broaching video on youtube, but he's doing it in a macro. Haas have VPS templates for broaching, and some good videos on them.
I will definitely go check it out. Thanks for the lead!
Horn make nice single point hex broaches. Loads more reliable than a wobble broach. Used them on Swiss for years with a little macro I got off the internet
Write one line of code once in position and it will do what you need. 30 seconds work
Thanks for the recommendation! I have a few Horn tools that I use all the time. Thanks for watching!
They also make torx options as well
I use the same macro with a y offset to make ratchet rings for bike hubs. The y axis means you can use standard slotting broaches to make the profile rather than needing expensive custom tips
Loving the UberRobodrill.
horn tooling might have a broaching setup that may fit your requirement and then youd have inserts
I will definitely take a hard look at their offerings. Thanks for the advice!
clough42 did some broaching and macros
not worried about wearing your small taper precision spindle bearings by loading with zero RPM and lube?
It's only .001 depth of cut. No load registers on the control. Not overly worried about it.
Rotary broach has entered the chat…
I should have talked about rotary broaching in the video. I could not find one that would allow me to "clock" or orient the hexes the way they needed to be placed. I also read that there is a higher force on the BT30 over the single point cutting.
You da man Shawn!
Thanks friend! We need some content of you making chips.
You are telling us about the post property box but you don't show us
Ya, my bad. I thought I was screen recording but the program was not recording the dialogue boxes. That mistake will not happen again. Thanks for watching!
It looks to me like design for manufacturing has not found it's way yet. A lot of complicated procedures for simple feature. Can't you just press in nuts, or use serated inserts/cling nuts. Or could potentially just use normal nuts some simpler punch feature to deform once nut is in.
My client wanted to specifically be able to remove the nuts from the part, quickly and easily. I agree it's a tricky design that is definitely not a common feature. Thanks for watching!
Since this feature is for a nut, I would mill this hex and make my own nut to fit in there (or modify an existing one) . Way faster and cheaper. This just shows incompetence of design / construction.
How did you index the tool?
Was it as simple as index it in the holder, square to the drive lugs. M19 a normal m code for robodrills.? My post is the one that Nyccnc made + I modded it so it to G53 x y at the end of program. Now I need it to shut spindle off during Z G53 at end of program. Right now it'll be spinning up by the tool change relying on M30 to shut down
So the broach had a ground flat on it, that aligned it to the tip of the tool. The tool holder had it's set screw in the perfect location. When I M19 the machine. It is at "0 degrees" so I used all nominal numbers for indexing. Had it been of X amount of degrees I would have just taken that into consideration.
@@ConourManufacturing hey, got a potential job that requires broaching a hex with orientation like you are doing! Would you be willing to sell me your post?
@@RoboDriller you can purchase this post with something like 12 months of additional changes/modifications to it from DSI. I think it's $500 from them, it's well worth the money! Their link is in the video description. Let them know Conour Mfg sent you.
If you then have any questions or want to see an example program, just shoot me an email and I will help out!
@@ConourManufacturing today I emailed Dave about this stuff, no response yet. He's with cloudnc as well. I thought dsi made cloudnc but could be wrong
@@RoboDriller I don't believe so. If you click on the video description there is a link that will take you to the DSI website. You are using Fusion correct?