These are some more recent projects.

These are some more recent projects.

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Here is a concept car grill we did recently. It was made in two parts, I did the outer section and another machinist did the inner section.

This is a side view of the grill. Chevrolet's proposed new SS model is the car this grill was made for. The SS was shown on the cover of the March 2003 issue of Motor Trend.

Here is a 124" X 38" X 2" thick plate (aerospace fixture) that I did in our 64" X 32" Haas mill. We had to take all the sheet metal off the Haas to even get the plate in the machine.

This is the 124" X 38" plate assembly with 2" X 2" stiffening rails top & bottom with hardware attached but without the hydraulic lines routed.

These are some satellite (test fixture?) parts that I've done out of Kovar (Iron, Nickel, Cobalt alloy), Silvar (Iron, Nickel, Silver alloy), and Copper/Tungsten. It's hard to see, but the top two parts have small pockets within the larger pockets with the depths + or - .0005.

Here are some misc. parts. Some medical, some computer related, some aerospace.

This is one of about 8 small cooling fan housings I did. This one is right off the machine before deburring and blending. It was quite the little project for such a simple looking item.

This is a little grinding fixture I made to help put angles on custom tools and such. You can set the angle you want with a protracter, I'm using it with a 5C collet block in this picture.

These are some motorcycle parts I did recently. They were based upon similar parts made by different manufacturers but I made some design changes with functional (diameters for bearings and such) and cosmetic differences (to make sure the customer's parts were sufficiently different to not be direct copies).

Here is the core and cavity for a simple silicon mold. It's hard to see but there are a couple of .015 holes in the "spoon" area that go through both the core and cavity to the outside surface.

This is the front view of a prototype Housing (Chassis) that I did recently. It measures 10.200" X 8.500" X 3.500. I roughed it with 3/4" Iscar inserted end mill at 7,500 RPM (our Haas max RPM) and 60 Inches Per Minute, with the depth of cut being .125 per pass. All the walls in all 6 sides plus all the bosses have a 2 degree draft angle with the top and bottom corner radii being the same.

This is the back view of the housing. I could have used 2 degree cutters and just blended the corners but I instead decided to 3D profile the whole thing. The large pocket was 1.890 deep and the vertical corner radius was .097 and base wall radius was .030. The resultant 3/16 end mill with a .030 tip/edge radius was run at 2250 and 35 IPM with a .020 step over.

bottlbob@earthlink.net

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