This swimming pool filter clamp is no longer available. Instead of spending a small fortune and retrofitting a new filtration system the customer brought me the broken part to make one. With the cost of making the CAD model and the CNC programming was rolled into the first part the customer liked the reduced cost of a second part and elected to have us make him a spare.
Machined bosses and starting the through holes.
Quick blow off with compressed air to check progress.
Chamfering the bosses.
Hemstitching with .500 ball end mill.
Finishing the hemstitch.
Outer perimeter cut to leave a very thin attachment.
Finished part easily snaps out of the remaining material.
After some minimal deburr, another job is finished for a happy customer.
One part of a complex reverse engineering project.
A lot of as cast and machined surfaces to duplicate with a multitude of features all requiring accurately defined relationships to produce a good part.
There are a couple of 3D models to make; one for casting and one for machining.
The first step is to create the as machined model from the data gathered. It is important to identify the parting line and establish it as a datum to control the draft in opposing directions.
Creating an additional 3D Model for the casting pattern allows it to be CNC machined. Minor edits from the as machined model are required to add material in the areas to be machined; casting shrinkage can easily adjusted with a simple click of the mouse. The increased accuracy results in virtually no reworking of the pattern and no dimensional discrepancies in the castings.
Once the model is finished, shop drawings are produced and checked against the original part to validate the model. The shop drawings, once the model is validated, are used to machine the finished castings.