Fow Windows XP and later.

It has just been released.

Please test it out and tell me what you think!!!!!

Download it HERE http://zero-divide.net/index.php?page=FSWizard_SA

Here i will show you how to calculate Tool Engagement Angle using tool diameter and Width Of Cut (radial deopth of cut)

Lets first draw a pretty image that shows us everything we need.

Where:

• r: Radius of the cutter = Diamater /2
• a: TEA - Enagagement angle we are trying to find here
• WOC: Width of cut or RADIAL Depth of Cut
• r2: The difference between r and WOC, r=r2+WOC

Below we develop 2 formulas that allow us to find TEA and WOC

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Tired of printing out Operation lists and then wasting time adding setup information by hand?

There is a neat and easy way to replace standard Operations and Tooling lists with something very compact and usable.

Here are config files i use at my work to create Setup Sheets and tooling lists right from SurfCam.

1. First make sure you backup you Operations.cfg and Tooling.cfg files in case you want to go back (VERY NOT likely)
   Those can be found inside your V5 or V6\Config directory.
2. Unpack contents of the attached ZIP folder.
3. Copy .CFG files found within into your V5 or V6\Config folder.
4. Copy folder "images" into "C:\Surfcam" directory, if you want also tool images to show with tooling list.
5. Go to SurfCam Options and in section Setup Sheet select "Current" from several other choises.

Thats it!!

UPDATE!!!!!!

• Operations list NOW highlights table rows when you move the mouse over them.
• When you select ANY text on Operations List, the same text will be highlighted over the whole page!!!

Download current file below

Samples are below:

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Surfcam_custom_operations_cfg.zip Size:0.11 MB

Optimizing Peck Drilling for Deep Holes

Peck drilling is often necessary when machining deep holes. However, with the correct feed and speed settings, pecking is unnecessary for depths up to:

• 3× diameter for standard drills
• 5× diameter for high-performance parabolic drills

For deeper holes:

• Up to 10× diameter → Up to 5 pecks for regular drills, and up to 3 pecks for parabolic drills
• Beyond 10× diameter → Constant pecking is required:
  • 0.5–1× diameter per peck for regular drills
  • 1.5–2× diameter per peck for parabolic drills

Since programming requires specifying a peck amount, here are the recommended values:

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Here are some Okuma Captain 1200 program samples for work with live tooling.
Samples are quite big so READ full article

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Cycle Format:

G184 X Z C K (I) F Q E
OR
G184 X (Z) R C K (I) F Q E

G180 (Cancel)

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As part of FS Wizard's development. 2 drills were tested today on T6061 Aluminum.

0.312 Dia and 0.390 Dia Dormer A002 Drill Jobber Drill with TiN coated tip.

Helix:30Deg

Point:Split, 118Deg.

Hole depth for both was 3.0"".

Peck equaled 1xDia

Speeds and Feeds for 0.312 Dia drill were

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Tool:0.281 dia 0 helix TIN coated carbide drill

Recenty ordered a 3Flute High Performance End Mill From NIAGARA.
Was very glad and slightly surprised that when punched in all of the endmill's data into my Calculator nothing broke down.I had a rason: At 5000RPM and 3/8" Deep slot cut. The feed came to around 92.0IPM. Chips were making this nice ringing noise that sounds like money.

Setup:
HAAS VM-3
Hudrolic Tribos Holder
3/4" 45DegHelix 3Flute 1.625FluteLen, 2.375"Overhang TICN HP End mill

S:5000RPM
F:92.0IPM
DOC: 0.375" Slotting
Coolant:FLOOD

The calculation was pretty much dead on.

A need arouse to drill and tap lots of blind 1/4-20 holes in 3/4" thick hardox 45-50RC hard plate.

So if you ever need to do this use:

1) DRILL
Tap hole: >0.202" or bigger.  5/8 deep.
Drill used: Tialn coated carbide drill.
S=1418 RPM
F=2.6 IPM
NO Peck, No Coolant

2)TAP
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