Introduction
How to Face a Work Piece
If you have access to a Haas machining center and a face milling cutter, this guide will step you through the actions for creating a flat face without using G-code programming.
Video Overview
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Load work part into table vise.
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At least 1/4" of work should be in contact with vise jaw.
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Ensure part sits flat on parallels or steps in vise jaws.
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A few taps with rubber mallet after initial clamping may help.
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LOAD CUTTER. Load cutter into spindle. Ensure proper orientation, with key from spindle chuck intersecting keyway on cutter body as shown in blown-up photo.
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On Haas machine with vertical tool changer, a LARGE TOOL designation should be made for the pocket with the 4-inch diameter cutter (page down under OFFSETS to see pocket designations).
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Tool Loading
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SET Z HEIGHT. Set the Z height in the POS-OPER coordinate system by jogging tool down to desired Z=0 position (or use touch-off block) and pressing "Origin."
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"Origin" is in the ZERO RET mode.
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SET/START SPINDLE. Set the spindle speed by entering S####; (with desired RPM) as the only command in the MDI screen, and then pressing Cycle Start (MDI mode). Nothing actually happens at the machine.
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Subsequently, spindle can be started or stopped at commanded RPM by using the SPINDLE CW (or CCW) or STOP buttons.
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Note Use RPM = 4V/D. V = 1500 fpm (carbide on Alum) or V = 500 fpm (carbide on steel).
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POSITION AND CUT. Jog cutter to desired Z-level position (Operator position system) and align it for the pass across the workpiece. Use appropriate jog speed and feed arrows to move cutter (AVOID Jog lock!).
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Recall: feed rate in IPM found from chip load (.001 to .005 ipr) multiplied by number of teeth and RPM.
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Feed rate overrides can be used with Handle Jog feeds to achieve almost any feed rate.
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Recall: Depth of cut should be no more than .050" (steel) or .100" (alum).
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