Soccer Ball CNC Machining
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- เผยแพร่เมื่อ 15 ก.ย. 2024
- This video is about CNC machining a Soccer Ball. This CNC machining test was carried out by OneCNC Research Department as an exercise to completely test the accuracy of an overall system. The Research department could have machined this part on a lathe but especially chose to make the soccer ball using a 5 axis machining centre to test the accuracy of the OneCNC database by creating segments and then copying and rotating them about the axis to form a soccer ball. The model was created from hexagonal and pentagon segments components to form a complete ball then CNC machined to prove overall the machining accuracy which also included machining the grooves between the segments as part of the finish toolpath. The completed CNC machined soccer ball as machined was then tested and proven to be within the accuracy of .004 mm. from the initial design shape. The original machining tolerance was .004 mm as set in the toolpath creation.
For more information please visit our website: www.onecnc.net
I going to call a baloney check on the final surface finish when its sitting on the CMM fixture. The video kind of implies this is the finish off the machine. Is that what you are claiming or were there some post machining finishing operations? Also if your trying to sell software you should state which version of OneCNC you programmed this with. You also state basically that there was no measurable error between the model geometry and the measured geometry. Are you stating that this sphere is within 4 microns of a sphere? I would have to question that as well. Seems like you are within the machine positioning accuracy and the perhaps the error bars of the CMM.
By the way I'm a OneCNC customer and not some troll calling you out. Been using OneCNC since the pre XR 2000 version.
Regards,
Tom
+oxtoolco Good questions there was minor hand finishing with 1200 paper before measuring which really only takes the final cusp of the machining off. This was also used for general cleaning after the machining prior to measurement. The software used was the OneCNC Mill Expert XR6 with the 5 axis positional and 5 axis simultaneous modules added. The CMM for measurement is a validated CMM and it does have Pcdmis cad++ software for checking the shape.
why didn't u record the machining process of cutting hexagon contours? I'd love to see it
Exactly.. that was what I was waiting to see too...
Others have also asked in a later video we will show that method
I was hard to include all facets of machining in reducing the time from many hours to just a few minutes.
Wow. The polygons magically appear. Quite the machine.
They were created as 1 polygon and then copied and rotated around the X0 Y0 Z0 position.
It was a joke. Machinists have no sense of humor. I do get it.
Haha good one!
the joke is the only thing we wanted to see were the polygons and you skip it over and show us the retarded stuff we all know already.
I have to agree with this. I really wanted to see the machining of the polygons.
why doesn't it show the cutting of the hexagons??
was hard to include all facets of machining in reducing the time from many hours to just a few minutes
Why not leave a boss rather than carve through the finished surface?
How did you time the c axis to match the hexagons and pentagons from 1st to 2nd op?
This was done by measurement and checkd with the Renishaw Probe in the machine.
OneCNC CAD/CAM I see, thanks for taking the time to reply!
I run XR6 Pro on my TM2P Haas . Very good for the money no complaints. Keep up the great work ONE CNC .
Thanks for your comments
I run XR6 Expert on my TM2P Haas.Same for me, software and machine are fantastic for the money.People who bitch about Haas never seem to grasp their affordability.Maybe there are better machines and software but I would never have been able to justify their cost.
OneCNC Has a considerable number of Haas CNC machine users and are all happily making parts
sorry if I sound dumb(im14) is a CNC lathe a thing and if it is would it be easier to make the sphere on it then machine the lines with something else
Not at all that is a valid question for sure, yes this could be machined in a multi function lathe gooves and all but for this exercise as mentioned in the published notes above we chose to use a 5 axis machining centre. The 5 axis machining centre was chosen to validate the modelling and the machining in a 5 axis machining centre environment.
thank you for answering my question and explaining it .
Frankie Pedraza there are Multi-Axis CNC machines that have a mill head and a lathe spindle all in one machine. Some even have a mill table that moves into place to be used with the mill head or out of the way for the lathe spindle. That way you can program the machine to make whatever the heck you want.
why do you like cutting air so much?
Fair question but there is good reason we do that in development. It is quite easy with settings control to prevent lift in the 5 axis but in the job sheet of this part showed about 8 hours of cutting time and 7 min of non cutting time which is relatively small. In research we prefer to leave the lift settings more open it allows us to easily put the machining in pause so we can view the part with machine open then easily restart without using restart settings.
Killer work! Where did you mount the camera inside the machine to avoid getting it covered in coolant / swarf? I tried mounting a GoPro inside my Haas and it virtually instantly got covered! Thanks for sharing - great video.
Coolant sure is a problem to contend with. To assist we use GoPro at the highest resolution in the furthest away position in the machine. Then in the editing process we do the zoom in so that you get a closer view and this gives the appearance that the camera is close to the work when actually it is not as close as it appears. Unfortunately the coolant does still get on the camera occasionally but that is waterproof and the views that get affected from the coolant are then edited out. We do have to occasionally stop to clear the lens when it becomes bad in the preview as shown on the Iphone.
What software was that in the beginning?
The software used to create the solid model and then create the CNC files for the machine was OneCNCXR6 Mill Expert as you can find on www.onecnc.net
Was the part glued into the fixture?
+nhbb980 Not it was not glued it was held in with a singular 16 mm bolt
how did you manage to get the lines in the socer ball matched?
+Sorry my english is so suck Your English is fine. Actually using the software this was quite easy. You may notice that the top and bottom halves are symmetrical and rotating or turning the ball over the X axis allowed perfect alignment of the lines between the segments. This also allowed the perfect location of the 2 halves to match on the joint between the top and bottom halves.
+OneCNC CAD/CAM So did the machining fixture and the half finished ball have some kind of alignment part or key hole, so that when mounting the half finished soccer ball to vise you knew how it sat in relation with the machine axis.
+Sorry my english is so suck Thats a very valid question about the alignment the recess for the stand support also has a dowel pin which was drilled and accurately reamed with the correct alignment so when it was placed in the cradle it was correctly aligned. The part location was also checked with the Renishaw probe to micron accuracy
which model of Hermle CNC-mashine it is?
+EmericaRedHead It is a Hermle C400 machine
Very Impressive!!! but it would have been cooler had you shown the hexagon,pentagon patterns also being made on the machined surface. Is there any longer version of this video which includes the fine detailing of the soccer ball?
We do not a longer version available unfortunately. We had over 8 hours of movie to edit don to just a few minutes which did not allow a lot of time for fine detail. There will be more movies soon and one of those will have some similar fine detail.
Well it would have been nice to have some bits of it. Not all, the beginning of first line and the final line of it
we are doing more movies at the moment and will look at putting more detail in
How many hours of cycle time was that?
+gulch1969 Just over 8 hours total
you failed to show how you engraved the hexagon and Pentagon shapes. highly unsatisfying.
Sorry it is difficult to show all machining functions with just a few minutes of film compared to the many hours time involved
Are there any tutorials on how to place the hexagons around the axis and/or make the soccer ball on the design part of the process? And does this software offer free subscriptions for students?
We have many tutorials available not featuring this actual part but would show examples of moving and positioning. th-cam.com/channels/O0KRUp6HrF9ygzUysQGhgg.html
Here is another of our tutorial sites. th-cam.com/channels/iTvTUsvKuwvSlCHCvGiJVg.html
What oriented the ball in the support fixture? It was just a flat and a bolt right? What made the design line up with the second half?
+gredangeo Yes it was the flat location and singular bolt
+OneCNC CAD/CAM Thanks. Still unsure of what lined the design up though. The only thing I can think of is, you must have had the negative of the hexagons in the fixture.
+OneCNC CAD/CAM how do the grooves line up? are there grooves in the fixture?
+gredangeo Thats a very valid question about the alignment however because the design of a soccer ball is symetrical and you will notice the recess for the stand support also has a dowel pin which was drilled and accurately reamed with the correct alignment so when it was placed in the cradle it was correctly aligned. The part location was also checked with the Renishaw probe to micron accuracy.
+Limosical A machining setup of a component such as this there are no second chances. Using the procedure such as we did in OneCNC combined with the work datum point as set in the software it proved to be very accurate. The correct alignment was one of the main features of our testing procedure in determining the accuracy ability.
How many hours did this take?
+joe Shirley The total machining time was just over 8 hours.
@Onecnc how did you match the lower and upper part ?
Check down in the earlier replies where we described how we did that.
What is the file size of that program?
About 60meg
how does the fixture for the second side work?
The fixture was machined to the exact radius of the ball and one central 16mm cap head bolt was used to secure the ball into the fixture, What was more important was the rotation to ensure that the grooves lined up correctly. This was done in the fixture and ball by having a 10mm dowel pin to ensure that the rotation angle was correct.
Was a ballnose endmill used for the finish pass
Yes we used ball mill for the finish passes
what was the total cycle time?
+Limosical I was just over 8 hours total
I like how this video only showed the rough stock removal. No one wants to see the fine detail of milling the soccer ball pattern and the final finishing.
We thank for your comments. It is difficult to show 8 hours of video in a 5 minute video. If you check the time periods between 1.21 to 1.50 and 3.49 to 4.30 it shows parts of the the final machining finish of both of the halves.
Could you cnc a snake out of aluminum
+Vdog Vman Well as long as it was not coiled up I guess it would be possible.
is this the hermle c52u?
It is a Hermle and here is a link to the actual machine www.hermlemachine.com/cms/en/products/product_overview/bearbeitungszentrum_c400/
after every step tool going to zero. why u choise this strategy? why not spiral?
Spiral method is not as easy to get excellent finish on a spherical part. Right on the top area we used spiral
Are you using the standard carbine tip?
Yes we used standard solid carbide tools
Lilly Wood
From which manufacturer is the Maschine? Hermle?
safe or DMG
It is a Hermle and here is a link to the actual machine www.hermlemachine.com/cms/en/products/product_overview/bearbeitungszentrum_c400/
probably the heaviest soccer ball ever
Would be hard on toes for sure.
How many kidneys would this marvelous machine cost? (I did already spend my soul for something else.)
Hahaha jk, it was pure pornography and very satisfying to watch :)
+thaGkillah We enjoyed making it too.
hell I'd be happy with a big golf ball like that!!! i want one.
That's another idea for a project.
Yep! Fire it up.
excellent processing
The machines are very good and our OneCNC is tuned to run them very well.
Hermle c400u?
It is a Hermle and here is a link to the actual machine www.hermlemachine.com/cms/en/products/product_overview/bearbeitungszentrum_c400/
really? 1/2" depth per cut on alu? I would go 2" right away even with a lyndex not the strongest rego-fix.
Good point you raise. This particular project was not about speed it was all about accuracy. We needed to check for alignment of the 2 halves of the sphere surface finish and dimensional accuracy of the spherical shape including the alignment of all the panels. For this we chose not to preload the tools so as not to create variables that could have an affect on any of these important parts of our research and test.
Hmm... I would say if you run any simultaneous 5-axis toolpath, you already lost that .004mm tolerance. Actually you did. If you worried about the vibration of machining, large depth of cut but less stepover is not worse than small depth but bigger stepover, specially on the top of the second operation.
Great machine. How much is it?
In Australian Dollars it is about $400,000 for the machine. Then i requires tooling and all the HSK holders which is another $60,000 or more.
too expensive
I guess its all relative but this machine has excellent accuracy excellent performance and excellent long term volume production ability
song bob dont know but ask the manufacture
its a "hermle" from gossheim in germany and the modell looks like "c30u"
maybe it is expansive but rly worth
in our company shes the one with lowest repair kost producing constantly
new subscriber ❤ Awsome channel
Thanks we are making some new ones covering new functionality in our development program
Is this ball made for playing soccer or just showing how to waste iron?
If you want to break your toe, sure. Also Im pretty sure this is alu, and it is perfect for a soccer cup, even tho casting and then engraving it would be a much faster/efficient method.
It was made to test the accuracy of the OneCNC CNC dabase output
When you’re spoiled with 5th axi machines
It certainly helps when you have one of the best 5 axis machines available
why hide the bottom of it in that base? EXPOSE as much as possible, the base is 'overwhelming' the primary object here....also why not sand cast it then polish: then you wouldn't have the mating line in the middle...
The Ball required a rigid fixture to guarantee the accuracy
video cut everytime it gets interesting. wtf
Sorry it is difficult to show all machining functions with just a few minutes of film compared to the many hours time involved
What if someone kicks it thinking it is real?
They would find it very hard!
Well, It is Real...
What gave the final golden color?
After completion and cleaning we had the ball and the supporting stand anodised at our local facility. The ball was anodised gold and the stand was anodised clear.
Here is a link to the anodise website they also explains the treatment www.agradeanodising.com.au/
Hey thanks a lot for your answer, very interesting this anodising stuff !!! Great link as well, cheers ;)
Tamás Rajna it also looks like a rendering. I would have also like to see machining the grooves!
I think it got anodized, like the stand as well.
sorry for my bad english
Yes it was anodized with a gold colour on the ball and clear on the stand
I liked the part when you showed none of the interesting bit
Sorry we could not have all the parts due to such a limited view of the many hours of machining.
do lime I do when people are out to screw you just buy the equipment and one of their products and reverse engineer it. make it yourself and sell it cheaper thus putting them out of buisness . because greed causes people to do things like mass produced their products. so they can get rich. instead of being happy providing hand made stuff at a higher price. Tom lipton has a great TH-cam channel and is also a great teacher.
just wow
so clean.....
We are pleased that you like it.
OneCNC CAD/CAM i do, last time i saw a machine that clean was in school haha
The machine is actually very easy to keep clean because it has a high pressure jet coolant that we run at the end of the finished part and that deposits all the swarf into the conveyor at the base of the machine and as well washes the inside of the front door screens.
That wasn't a machine finish, and you ruined a beautiful piece with that nasty orange paint...
It was anodized to preserve the surfaces of the ball and stand.
We bjust anodised it to keep it as permanent display of the accuracy and prevent it oxidising over time.
Enjoyed the video - very impressive.
Actually saw this after watching a guy machine a potato on a Bridgeport:
th-cam.com/video/SzgPOJPTo_A/w-d-xo.html
...so I was sorta expecting something different!
+ogenmatic Well yes this is a bit different than machining potatoes.
Работал я на этом станке, Hermle C42.
They are a fine machine I guess you liked working on it.
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You bet next time i have half a million for a 5ax laying around i will be sure to make a ball with your' software .
+doug wotton Ha Ha yes the machine is quite expensive but absolutely the best 5 axis we have used.
hurco?
No it is a Hermle f5 axis simultaneous from Germany
Mit drehen wäre man ein bischen schneller 🤔
aber würde ja keinen sinn machen als hersteller eines 5axs Cad/Cam programms. zudem soll das einfach nur nach was aussehen und weniger Produktiv sein
Yes turning would be a bit faster but in this case we were testing the machining centre method using OneCNC
ok lets play football
+BRIAN QUINTONFLYER I think it would be a little tough on the toes and head.
bye a lathe
Certainly could do it on a multi -function lathe but it is also fin on the machining centre that we were testing the OneCNC Database output on.
We also have a lathe in our technical centre however this exercise was for testing the OneCNC Database accuracy on the machining centre.
I'll be blunt, I'm not impressed. it's a basic job and not using any impressive strategies. I wouldn't show this to anyone to showcase my skill set.
Sure we have more impressive strategies for products too and we understand what you say. The main objective with this part was to test the accuracy of the whole of manufacture starting from the construction of all the segments placing them into position completely machining the ball then measuring the overall accuracy and alignment. We accomplished what we set out to do and achieved the results of both accuracy and perfect alignment.
Gezz, chill out mate. :/
I was going to thumb down simply for calling it a soccer ball, it's a football, you kick the ball with your foot, hence football!
1987safc I agree. It was always football.
ah but you wear socks on your feet, hence the soccer. for real idk why america changed it.
Hermle C400?
Yes it is a Hermle from Germany
Yes yo picked it correctly