Tech Briefs Magazine - September 2024 - PIT-9
cept presentations. On his own time, Green continues to
broaden his knowledge, so he is ready if something breaks, especially
during the valuable observation time at night.
CFHT budgets approximately $25,000 for each night of operation.
" We do not lose nights of sky time for engineering
issues, " said Green. " We have weather issues infrequently, but
we can't control that. If something breaks, I have to either
replace that part or redesign it into something that we can
produce and get the thing back on the sky. I make crazy stuff
at night sometimes. "
One of the cylindrical parts of the telescope that was recently re-designed
using CAD tools. (Image: CNC Software)
tools. Green uses OptiRough, Pocket, Facing, Drill, and
Contour toolpaths. In one instance, he used Peel Mill to
create a tiny radiator part. Limited to a maximum spindle
speed of 8,000 rpm, a 3/32-inch end mill successfully machined
a channel in a pocket that was five times deeper
than the tool diameter.
The machine has an automatic tool changer with 21 slots
but is only loaded with the 18 tool holders available at the
machine shop. All the tools are frequently used and only
rarely changed out for different hole sizes. Establishing consistent
slots for each tool holder strategically allows programming
to become more routine and efficient. For every
job, CFHT purchases new indexable carbide tooling to ensure
high-precision results.
" I'm not concerned with material removal rate, I'm concerned
with surface finish, " said Green " Specifically, how do I
get a mirror finish out of this? "
Some parts will be located in a vacuum chamber, which is
incorporated within the instrument body to control temperature.
The surface finish must be impeccable for the part to
function properly.
Since each part is unique and Green is the only CFHT machinist,
simulation proves programming accuracy. " The Verify
feature in the software is priceless, " he said. " I know my post
that spits out the G-code is reliable and what I see on the screen
is what's going to happen on my machine, so I don't have to
scrap something that I've been working on for a month. "
One of the more challenging projects for Green was creating
the structural components for a small astrometric camera
that drives the big telescope, similar to a sight on a gun. Some
components were so large, they required four different machine
setups. Green added holes to the design, allowing him
to connect the part to a surface plate with dowel pins. He
then indexed the part on the fixture to access the different
areas for machining. The finished structure included carbon
fiber tubes bonded to an aluminum end and bolted to a semisphere
joint. The space frame cantilevers the camera into the
optical path. As the big telescope tilts during the night, the
carbon tubing is under tension or compression. The structure
has to be rigid enough to overcome the gravitational loads,
without flexing.
For other projects that require innovation or advanced solutions,
Green consults the Streamingteacher website. The resource
contains general training videos and more detailed conPhotonics
& Imaging Technology, September 2024
9
This article was written by Michelle McNulty, Copywriter
at Gorman Pompili Communications, on behalf of CNC
Software, LLC (Tolland, CT). For more information, visit
www.mastercam.com.
One night, Green designed and machined a part similar to a
Mason jar. Without a fourth axis, the equipment was unable to
spin the part to machine all the sides. Green created a custom
fixture with dowel pins and four holes. He programmed four
machine setups in Mastercam and manually rotated the part at
the different positions.
Green enjoys the variety at CFHT. At the most scientifically
productive site for astronomy on the planet, he has the
opportunity to machine parts that hold million-dollar chips,
all with a 23-year-old machine, CAD/CAM software, and creative
fixturing.
" This is the best job that I've ever had, " said Green. " The
benefits and location are amazing, and I never make two of the
same thing. "
http://www.mastercam.com
http://info.hotims.com/86259-703
Tech Briefs Magazine - September 2024
Table of Contents for the Digital Edition of Tech Briefs Magazine - September 2024
Tech Briefs Magazine - September 2024 - Intro
Tech Briefs Magazine - September 2024 - Sponsor
Tech Briefs Magazine - September 2024 - Cov1
Tech Briefs Magazine - September 2024 - Cov2
Tech Briefs Magazine - September 2024 - 1
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Tech Briefs Magazine - September 2024 - 16A
Tech Briefs Magazine - September 2024 - 16B
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Tech Briefs Magazine - September 2024 - Cov3
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Tech Briefs Magazine - September 2024 - PIT-Cov1
Tech Briefs Magazine - September 2024 - PIT-Cov2
Tech Briefs Magazine - September 2024 - PIT-1
Tech Briefs Magazine - September 2024 - PIT-2
Tech Briefs Magazine - September 2024 - PIT-3
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Tech Briefs Magazine - September 2024 - PIT-Cov4
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