I've done some more work on the P228 solid model. I still have a little more work to do, and then I'll be ready to double check my work to insure everything is correct. I hope to start the machining in 3-4 weeks. I've uploaded a couple new pics of the work I've done lately...
I now have the P228 solid model nearly complete. I still have a few minor features to add to the model, and I will add new solid model pics once the model is 100% complete. Since there are only minor things left on the model, I was able to start the machining. I spent a full day just programming the 1st operation. This 1st operation ended up having 16 tools. After I finally got the program finished, I cut the stock for the frame and got the CNC setup to start the 1st operation. The stock I ended up using was 5 x 1.500 x 6.68 6061T6 aluminum. I probably could have used a smaller size, but that was the closest thing I could find without ordering special material. Here is a pic at the start of the 1st operation...
This is a pic I took as the 1/2 hog endmill was roughing the profile. You can see that it is starting to take shape...
And here is what it looked like after the 1/2 hog endmill was finished cutting...
This is a pic after the 1/4 carbide endmill made some clean up passes and milled some detailed areas...
I then used a 1/4 ball nose carbide endmill to 3-D profile the whole frame. I decided it would be easier to do this rather than trying to program all the curved surfaces and different step heights that the P228 has. Profiling the whole frame probably took a little longer to machine, but it gave the frame a nice even finish and I didn't have to worry about blending different tools in. Here is what it looked like after the profiling was finished...
I then started drilling all the holes. Come to find out, nearly every single hole on the frame is a different size. I was only able to use the same drill for 2 holes. Here is a pic after all the holes were drilled...
I then used some smaller endmills to machine some detailed areas and to cut the rails. This is a pic after all this was finished...
I then used a 1.5 x .375 woodruff cutter to mill the undercut area for the main spring seat. I had to make a special undercut tool (1/4 x 0.100) to mill the undercut inside the mag catch release hole. This undercut is what keeps the mag catch from coming out. The side of the mag catch has a detent, and this detent catches on the undercut. This is a bad picture, but maybe you can see the areas I'm talking about. You will be able to see these areas better in later pics...
I bead blasted one of the frames and took some good pics with a better digital camera. Here is how the frames compare...one is bead blasted and one is straight off the machine...
The next few pics are some better close up shots...
That is the end of the 1st operation. I will have to design a special fixture/jig to hold the frame for the 2nd operation. I'm going to try and get this fixture made this week, so I can start the 2nd operation next weekend. For the 2nd operation, I will be machining the right side of the frame. And for the 3rd operation, I'm thinking of machining the magazine well, since that area will still be solid and I won't have to worry about a drill "walking" off position. Then for the 4th operation, I'll be machining the top of the frame. There may have to be a 5th operation, but I'm not sure yet, it just depends on how much I can get machined on the 2nd operation.
