Machining of Connectors

The equipment used for the machining of the connectors is KONDIA B-1000 Machining center. The requirements for machining are summarized in Table 3 for male connectors and in Table 4 for female connectors. The defined tolerances were 0.05 mm in XY and 0.1 mm in Z. The machining of male connectors was performed in three steps. In the first step, the rotation speed of the spindle was 5,000 rpm with a feed rate of 200 mm/rev, the plunge depth (Ap) of 2 mm, and pass width (Ae) of 0.375 mm. In the second step, the rotation speed of 6,500 rpm and a feed rate of 950 mm/rev have been used for bulk machining. Here, the conditions of Ap and Ae were 8 and 0.15 mm, respectively. In the last step, a finishing machining was executed with a rotation speed of 7,000 rpm, feed rate of 1,000 mm/rev, and with Ap and Ae of 2 and 0.12 mm, respectively. For female connectors, the rotation speed of the spindle for the external machining process was 1,200 rpm with a feed rate of 0.15 mm/rev. In the case of the internal machining process, the rotation speed was 900 m/min with a feed rate of 0.25 mm/rev. In both cases, Ap and Ae were 500 μm and 1.5 mm, respectively.

Machining requirements for Male connectors in Ertalyte.

Machining requirements for Female connectors in Ketron PEEK.