OVERVIEW:

The part consists of a rectangular outer profile with filleted corners and a stepped internal pocket. Four counterbored mounting holes are positioned near the corners, indicating mechanical fastening to another assembly. Within the main pocket are two raised rectangular islands, likely serving as mounting bosses or datum surfaces, along with a central circular feature.

Most features are constant-depth prismatic geometry, making them well-suited for 2.5D milling. Smooth blends and vertical transitions are incorporated where internal walls and islands meet the pocket floor.

Machining Operations Performed

All machining operations were programmed using Mastercam 2026, with a focus on proper sequencing, tool selection, and surface finish quality.

1. Drill / Counterbore Operations

• Used to machine the corner mounting holes
• Counterbores provide flat seating surfaces for socket head cap screws
• Ensures accurate hole location and consistent fastener depth

2. 2D Contour Operations

• Defines the outer profile of the part
• Used on vertical walls and perimeters
• Applied multiple contour passes to control wall finish and dimensional accuracy

3. Pocket (Standard)

• Removes material from the internal cavity
• Creates the recessed pocket while leaving raised island features intact
• Efficient roughing strategy with controlled step-downs

4. Drill / Counterbore (Internal Features)

• Applied to internal circular features
• Maintains positional accuracy relative to the main pocket geometry

5. 3D High Speed – Waterline

• Used to finish vertical and near-vertical surfaces
• Produces consistent surface finish on pocket walls and island sides
• Ideal for complex geometries where traditional 2D finishing is insufficient

HOW THIS CAN BE FURTHER IMPROVED: This project poses many unique milling operation steps in order to achieve the wanted part. I was particularly challenged in the pocketing operation to first define the depth and had to go back to the setup to properly define the wireframe so that I can get the depth values. Furthermore the actual part, consist of a slotted feature at its edges and therefore I need to perform a contour mill with a slotted endmill to perform the endded feature. Better ways to reduce time can be optimized but that depends on how the operator will perform the programmed NC code in actual machine!