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The purpose of this project was to gain familiarity with a knee mill and its functionalities. A one inch diameter end mill was used throughout the process.
Stock high density foam was fixed onto mill. End mill position was zero'd with a .014" clearance from foam block using a business card as a feeler gauge.
Top surface of foam stock was machined to ensure surfaces were unifrom and flat before initial cuts.
Front view of surfacing
Surfacing the edges for uniformity
Fully surfaced foam block.
After the foam block was fully surfaced, the part was ready to be machined per the given part drawing. The end mill was repositioned to the new zero/ datums.
Side view of intial layer machining
Front view of intial layer machining.
Initial layer of stepped block completed. Layer depth was measured to ensure within spec.
Machining of final layer.
Final layer finished!
Fully completed and cleaned part!
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