To All:

	Here are a pair of alum. parts I finished Wednesday.

	I roughed the inner section of the chassis with a .375 two flute end mill 
running at 7,500 RPM and 60 IPM.  Finished the same inner section with a .1875 
four flute endmill 1.125" long (inner rad callouts were .094), running at 3,000 
and 20 IPM.  The cable socket shape on the front had a .020 radius callout for 
the corners (.380 deep), so I roughed it with a .0625 end mill then finished it 
with a relieved .040 end mill and ran it at 9,000 RPM at 10 IPM with .010 step 
downs.  I 3D profiled the "hinges" on the end and the two protruding bars on the
 front using a .1875 end mill with a .030 radius (a ball end mill with a dia. of 
..125 would have gouged the underlying surface).
	It took 5 setups and more than a carousel full of tools.  Oh yeah, had 
to manually tap the 2-56 holes on the inside bottom and the 4-40 cover holes at 
the top since the '85 Fadal was the only machine open at the time and it doesn't 
have rigid tapping.  By "manually tap" I mean using one of the "C" shaped tapping 
frames.
	
	The cover was no biggie, after doing the inside I flycut the back and cut 
the screw reliefs and top radius in it, then screwed it to a block so I could 3D 
profile the 34 degree angle around the perimeter with a .500 end mill that had a 
..020 edge/tip radius.
 


--
BottleBob
http://home.earthlink.net/~bottlbob