We got some new contracts to come into the shop today, so I spent most of my time programming those. Super small and intricate square parts that I will be making on the 4th axis. None of them are bigger than a square inch and have some deep hard to clean pockets, which will be an enjoyable challenge. 

My boss has got an interesting technique for these, using bar stock and a double stick taping method to part them off. I'm honestly super excited for these as it requires a lot of small cutters and specific deburring methods that I haven't done a lot of before! I will also be using a slightly different programming method than previous contracts. I will be hand drawing and selecting pretty much all the toolpath parameters rather than relying on the 3D ones that take your model and program it for you. 

I won't show the entire process and techniques of making these parts, but I can take some specific instances and share those. 

It gets super cold in the early mornings here in the winter, and the heater takes several hours to heat the building, so my boss picked up an old large fan that I got to clean up and place upstairs to circulate the heat that rises and bring it down to the ground level.

I finished up the new truck program and got it running today! 

I'm honestly shocked how smoothly everything went; I only had to make a few minor changes before it was better than the previous programmed operation. I'm finding that it's not as complicated as I initially thought it would be to draw out most of the sketch references. I've got several instances in this disconnected sketch geometry program that makes up the entire finishing toolpath!

This whole program only took about 5 hours to put together completely from scratch compared to the accumulated almost 20-30 of the previous one. 

I haven't quite gotten the operation setup settings to where I want them yet as it still requires a body as a reference, but I'm toying with the idea of lying to it and just creating a bounding body around the 3D model. That way, I can get the benefits of the default height planes while not worrying about having all the toolpaths connected.

I'm also building a habit of always locking my toolpath once it's simulated and proof checked; that way, I can move on and not have to worry about it failing if I make a change to a previous one.

I also got to finish off one of the anodized setup trucks and cut the windows and engravings on it. I'm super pleased with the result, and the raw machine marks really catch the eye! Putting them back on the machine was actually not as difficult of a task as you might think. Using the cut-off stock from the first operation, I could locate the part on the 5-axis and only had a few minor tweaks to get it all aligned properly! 

I ran through the next batch of anodized rocket kits today and got those packaged up! I thought it'd be fun to take a short time-lapse of putting them all together :)

The anodized trucks came in the other day, and I was quite surprised at the different quality finishes on the raw machined vs. tumbled and bead blasting!

The raw machined parts came out best; they've got a really nice shine to them that the camera doesn't do credit to. Though you can still see the machine marks leftover from the endmills, it makes them much less noticeable.

The tumbled parts didn't turn out nearly as good and had a very rough texture to them. It seems like the anodizing was slightly splotchy with patches here and there that aren't as bold in color. The part I accidentally left in over the weekend was awful and had depressions, giving it a beat-up and rugged look. 

Out of all three, my favorite, though not the prettiest, is the bead blasted finish. It's completely matt but has an amazing feel to the touch. My boss is considering adding a clear coat to give it a shine.

The truck process's next step is to put them back on the 5-axis and remove the material from the windows and door highlights. I'm super excited to see how these turn out! The shine of the windows coupled with the deep blue should really make them catch the eye!

I've nearly finished re-programming the truck project, and I'm finding that it's actually quite a bit faster to manually draw and select features than working with Fusion360's automatic processes. 

Though I have to re-program this part, I am by no means regressing the progress I made before, and the small changes I made to the previous operation I can implement directly into the new. 

It's a little frustrating at times to be spending so much time working on one project, but I feel it is the best in the long term as I get to practice different machining strategies without having to worry about scrapping a client's work. I'm in a very fortunate situation where the shop has got a lot of downtimes, so I am able to dedicate it to learning and testing out different speeds and feeds. 

One of the biggest things I'm learning through this process of re-programming the truck is how much I relied on 3D adaptive toolpaths to do a lot of material removal. Apart from this new method is forcing me to realize that there are other methods that do take at first take a little longer to set up that have a much larger effect on removing material that is better for the tool and run time. 

I am quite enjoying thinking outside the box and made a major improvement by manually drawing out contour lines for my endmills to follow. I'm finding that in more complex geometry like 3D surfaces, you can quickly remove bulk material by hand drawing the toolpaths.

Mike Michalowicz outlines how to find your QBR by looking at the big promise of your business. You can only make one big promise to a customer, and in combination with the delivery of the promise is your QBR.

I feel I did a poor job of explaining the problems I had yesterday.

For some of the more complex milling operations with many toolpaths in them, I've had some weird issues when I change one of the toolpaths. I can't put my finger on where the problem is coming from exactly, and there's no way of quite defining it. 

As I am putting together a large operation and I find I need to make a change to one of the initial toolpaths or model itself, it almost always causes something to change with the other parameters in the toolpaths that I've set up. The problems are never major and are almost always an easy fix, but most of the time, I don't catch it until it's too late. This has always been an issue since I got started using Fusion360 and became more prevalent in the complicated setups. 

For example, I could get one of the contouring toolpaths to leave a very nice surface finish, but later, when making changes to toolpaths behind it, I come back and find that it's now faceted. None of the settings have changed in the process, but there always seems to be some small deviation from the original toolpath. 

This isn't really an issue if you don't make any changes to your initial setup, but in my case, I have to play around and learn how to find the best machining methods, so I have a lot of small edits throughout the process. 

Thinking through the problem and talking it over with my boss, I think the problem traces back to Fusion360's linking setup, where the initial operation setup wants to link everything to the 3D model you're basing it off of. In contrast with Mastercam, which creates each toolpath independently from one another. In speed runs that don't require a lot of tweaking, Fusion is definitely superior, but making many small changes makes it more beneficial to have toolpaths not connected. 

One solution I'm working on today is breaking the 3D model down into surface planes instead of a solid model. This will allow me to create each toolpath independent of one another and make it easier for isolated changes. I'm also using a few new tips I got from my boss when it comes to sketching geometry, and I'm relying more on that than the hard boundaries of the 3D model itself. It's a bit of an outside box programming method, but I'm finding it's actually quite faster to do it this way. The downside to this method is that if any changes are made to the 3D model, everything must be updated manually, which isn't a problem as the geometry is fixed in contract jobs. 

Hey guys, I really need help with a weird 3D finishing toolpath problems.

One of the things that bugged me the most with the toolpaths I'm using is that I can never get spiral finishing passes to turn out very good.

It's hard to show on camera, but the surface the ball endmill cuts on leaves weird wrinkle lines from when the tool changes direction in a corner. From what I understand, when the ball endmill is changing directions suddenly, there is an ever so slight pause before it does so, and causes the endmill to cut into the material just a slight amount. And since I'm using a spiral or morphed spiral toolpath, it has consistent stepovers from itself, which means that the dwelling point would start from a center, then work its way out in 4 diagonal directions.

Previously, my solution was to use a parallel toolpath, but having a straight back and forth cut pattern doesn't work too well in more complicated 3D surfaces. I've played around a bit with the P1-3 machine smoothing settings, but I don't seem to get much of a change. I've also tried adding feed optimization, which slows the cutter down as it approaches sharp corners, but that doesn't stop it from dwelling in them. I'm sure some setting allows me to round the toolpath, so it is one consistent flow without stops, but I'm not sure how or where to adjust that.

If anyone has run into similar problems, what did you do to solve them?

I'm absolutely loving the surface finishes I'm getting on the underside of these trucks!

My thinking has changed quite a bit on speeds and feeds in general for machining, and though most of it makes intuitive sense, it is still a bit difficult to overcome sometimes. I'm finding that there are precise times and areas you want to use lower vs. higher RPMs and feedrates. And if a part is squealing, sometimes to fix that, you have to speed the machine up. 

There are particular kinds of chips I've found that seem always to produce amazing surface finishes. I'm not sure if it's entirely related, but whenever there are long, wispy strands of aluminum (similar in appearance to hair, just thinner), I've always gotten a very linear clean finish. 

Trying another form of after-machining finish on another truck, which is tumbling them in walnut shells. I didn't know this, but apparently, walnut shells have some quality that cleans up and shines certain metals. My boss had a bunch of dry finish shells leftover from a previous project where he said he could get a chrome finish on a stainless necklace for his wife. 

I'm really interested to see what kind of a change it will do to these trucks and if it's possible to get anything close to a mirror finish. From what my boss tells me, it also takes quite a bit of time for them to run, so it may be a few days before I get a decent result, but I'm excited! 

Through my readings, I'm starting to come to realize what the greatest and hardest challenge in life is and it fits so perfectly into everything else it brings tears to my eyes. 

That one thing, the biggest challenge you could ever overcome is in fact, not a single thing. There is no one thing for anyone. Everyone has their own one thing which if you wanted to put it into words, it'd be perfection, or fully realized potential. I've come to realize though that literally every person is so different and unique it's quite amazing. 

God created this world and not one person is the same as the other. We all have different views, however slight, there is no two exactly alike. 

The only time we consider ourselves above someone else is when we compare, but comparing is imperfect as there are so many factors that come into play to the point where it's impossible to see the whole picture. We can only compare the result or outcome, but even that isn't a very good metric as two people may do the same action but have completely different motivations behind it. 

One son may do the dishes out of love, and the other may do it to avoid negative consequences. The outcome is the same in both instances and is difficult to tell the difference, but one is greater than the other. 

Books on actions don't always lead to the same results and so there is no single best action you can do to get the best results for everyone. Someone may get 90% to their full potential, while others doing the exact same thing only get 10%. 

I've come to realize that actions aren't hard, it's the reasons behind the actions that are the most difficult battles and achievements. Shaping your character is a long time and tedious task that never ends.

An economic principle that I've found applies nicely to the rest of life is that when you trade one item for another, they are not of equal value and the wealth of both parties is increased. Likewise, when you give someone more of something, this does not mean that you are giving less to another person. 

This world isn't composed of 100% where each person gets a portion of the pie, we all have our own pies and perceived values. In addition to that, there is more than one kind of pie, pecan, banana cream, apple, and many more, there is no limit to the kinds of pies. Some may like an apple more than a pecan, does that mean that Apple is better? The answer is both yes and no. Some may trade two pecan pies for one apple, but does that mean the individual trading the pecan pies has the short end of the stick?

“Teacher, which is the great commandment in the Law?” And he said to him, “You shall love the Lord your God with all your heart and with all your soul and with all your mind. This is the great and first commandment. And the second is like unto it. Thou shalt love thy neighbor as thyself. On these two commandments hang all the law and the prophets.

Agape love is the highest form of love. It's complete and selfless. There is no trade or bartering for it. This too has different meanings to different people. There is no 'one love' that you can show to everyone and get the same results. I was first put onto this by Gary Chapman in his book "The 5 Love Languages" where he spoke about how each person has a specific language that they feel especially loved in. He speaks in the context of marriage, but it fits nicely into the idea of everyone is unique and different. Though he divides it into 5 major catagories, he goes even further by saying that each person has thier own unique toung. Simlar to how there are many Indian languages all with similar charisteristics, but each with a different twist. 

Learning to observe and speak in other's love languages is difficult, as you have to set aside your own perceptions of what you think makes you feel loved the most, and actually find out what makes other's feel loved.

I've come to find that greatness, is not what I thought it was. The truly great people are very little known or observed. But the impact they have is enormous on the lives of those around them. Greatness is not made up of wealth, stature, position, or even how many people you know. True greatness is selflessness, living for others, actively seeking greater heights to bring more value to those around them. As it turns out, this is quite a difficult task. There is no earthly glory for this man, many people never recognize them for who they truly are. 

"Whoever exhalts himself will be humbled, and whoever humbles himself will be exhalted" Matt 32:12

In his book "Good to Great" James Collins spent a great deal of time and resources trying to find out what made the great companies truely great. He found that the businesses that out performed all the other's in their market were built on the foundation of what he called "level 5 leaders" which are induviduals with humility and great personal will to succeed. These level 5 leaders do not promote themselves, but work hard toward the goal and don't flaunt their achievements. 

It's facinating to see how God blesses the humble in the long run. Some may not see it in their lifetime, but He blesses their decendants. Likewise too, sometimes God curses an induvidual, not by taking away anything in thier earthly life, but rather the curse is on the generations following them. 

It's not hard to build wealth, but building sustainable wealth is a different story. That's why you see many people rise to prominense only to stay there for a short period of time. True greatness is not social stature, it can't be measured by comparison to other's, but only by God's word and commandments. 

As people, we have a desire to become great. That's how Adam fell originally, he wanted to become like God and so ate the fruit. Pride and ego are the greatest enemies to who we are meant to become. Laying down our pride is difficult and there is no earthly glory in it. Announcing ourselves and our achievements is much easier and we get praise from those around us when we do. Truly dying to ourselves and living selflessly is the impossible task of greatness. 

It's difficult to not speak up and let other's know of our prouess. It's hard to let others talk and not throw in our two cents. It's almost impossible to live a life of starving your ego, but that is the greatest challange. Not telling a falsehood, when it's easier to do so. Being completely honest with all that you do and work toward is painful and we get no glory from man in doing so, but God sees all things. 

"For he looks to the ends of the earth and sees everything under the heavens" Job 28:24

Outward actions are only results of our inward selves. Shaping and molding your mind and heart is difficult. It too is a great challenge and is the bigger equation that you have to solve. There is no inner secret kept from our Lord, and God sees all things.

"Would not God discover this? For he knows the secrets of the heart." Psalm 44:21

Judging others is another interesting topic that I've struggled with. It is so easy to look down upon other's from their actions, not realizing the full story behind it. I've gone back and forth on whether it is right to judge a book by the cover, or by the meaning behind the cover. 

My current understanding on this is to judge neither result or meaning behind other's actions. If it affects me, then I am commanded to forgive. But if it is not toward me, then I have no right to judge another's actions. This is not an easy task as I've had to struggle with not holding their actions against them and looking at them in a different light. When I judge other's it becomes a sin on my part and now I have to seek repentance. This doesn't mean you lay aide the actions done by others, and if you see your brother sinning it is your duty to bring him back, if not you are aiding in the sin by not opising it. But it means that you love the sinner and hate the sin. Going with gentleness to them and not by way of shaming. 

I've come to realize that to genuinly influence and aid someone you have to love them enough to lay down your pride and walk. I given into the temptation of 'stating the facts' or 'being honest' when attempting to help someone, only for them to lash out in anger. They see it as an attack on them as a person, and not the sin within them. We are to be prudent and tread carefully. I've found that when it comes to influencing another induvidual listening is the biggest way you can help them. Too often we want to get our thoughts and opinions across, and not often enough do we shut our mouths and listen with full focus. 

The key thing I've come to realize when you do listen to others is that they will now observe your actions and listen to your ideas. This is both a good and bad thing as if you are not doing the right actions then you are influencing them negativly. On the other hand, if you model good works, then you can influence them posativly. 

I decided to test this idea out, of actually listening to people by way of influencing them posativly and I am honestly shocked by how far it goes. It's brought me to tears on more than one ocasion the past few weeks that I'm writing this seeing how just listening and showing that I am listening changes people. At first those around me were suspicious, as if I was trying to get something out of them, but once they found there was no hidden objective behind it, they started wanting to spend more time sharing thoughts and ideas. And they make very subtle changes to their actions that imulate and model my own, to the point where my little sister went out of her way to setup a show and gave me a shoulder massage. I couldn't have payed her to do that, but she decided to do it on her own without my saying a word. Even my youngest sibling (5) would remind her older sister to remember to pray before eating because she saw me do that. Those are only two small instances of the impact and many other subtle ones that would be hard to determine the exact origins from.

Taking listening to another level is combining it with Gary Chapman's love languages, and observing how those around you feel most loved and loving them in thier languages has huge impact! I find it super interesting and weird in some ways how 'easy' it is to influence people and develop deep relationships in such a short period of time. More times than I can count have I seen my thoughts come to fruition. It's almost as if those around me are able to read my thoughts and take action on them. 

In some ways it feels like manipulation, but the weird thing is, it only seems to work to the good. The bad habits that I have don't seem to influence those around me like I expected. It only seems to allow the good through and not the evil.