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What Was Your Mentally Exhausting Program??

cheesiechanman
The reason I ask is because of the program I am working on right now. I have 3 fixtures with 4 parts that I have been working on. All of them have complicated Datums / Poor design. The fixture that holds two parts is the most complex of course. The gage is the only one built to hold the part vertically. It has a hole in the back of the gage to probe the bottom of the part through. So the part sits with the rear surface in the CMM's +x direction. The part sits on the net pads for datum A about 120mm from the back surface of the gage (where the hole is) There are 18 small clips spaced around the outside edge of the part that I need to touch in the -x direction. This means I need to articulate my probe to, at times, an angle of A-115B35. This shortens the distance from the end of the probe to the Z axis column. Most of the time I am less than 2mm from crashing into the gage.

The part also only has one tiny slot to control rotation on one side of the part. So when placing the part on the gage it can rock, roll and slide everywhere. So that means I need to create local alignments on each clip to ensure that they hit correctly which means dancing around that almost crashing point the entire time. And I need to create alignment after alignment to ensure that I am hitting it correctly and then be sure that I recall a fixture alignment before proceeding because if I forget to revert back to the fixture and the next part changes in size/ location/ rotation by a mm or 2 I am guaranteed to crash. And this doesn't include the complexity of some of the dimensions and the callouts. For example a profile without datums with a unequal tolerance called out..... or a position on a single plane.....

So with all that being said I have been programming these parts for a couple weeks now and my head at the end of the day is just mush. That's where the Forum comes in. So I want to thank all of you for giving me a source of relief from my mental torture chamber over here.

Also, What are you more exhausting program memories. What is that one job that really kicked your butt?


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  • I have worked on some big complicated parts with thousands of features to report, but really the most mentally exhausting thing I've had to program was a couple of relatively simple components for some high pressure valves. The prints were just so over toleranced that half the parts measured out of spec no matter what machining processes they tried. Unfortunately, some of the parts did not work when pressure tested even if they measured to print and each manager had different theories about what needed to be changed and could be changed. I had modified those CMM programs and the related inspection documents more times than I could count for all the special test runs and revisions that were made on those parts. I spent so many hundreds if not thousands of hours documenting nonconformities, attending design review meetings, and creating many different reports that no one bothered to read. Those parts and the company dysfunction surrounding them were the main reason I decided to leave that employer after having worked there for 16 years.
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  • I have worked on some big complicated parts with thousands of features to report, but really the most mentally exhausting thing I've had to program was a couple of relatively simple components for some high pressure valves. The prints were just so over toleranced that half the parts measured out of spec no matter what machining processes they tried. Unfortunately, some of the parts did not work when pressure tested even if they measured to print and each manager had different theories about what needed to be changed and could be changed. I had modified those CMM programs and the related inspection documents more times than I could count for all the special test runs and revisions that were made on those parts. I spent so many hundreds if not thousands of hours documenting nonconformities, attending design review meetings, and creating many different reports that no one bothered to read. Those parts and the company dysfunction surrounding them were the main reason I decided to leave that employer after having worked there for 16 years.
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