1.4" pulleys made using Mastercam, Lagunmatic CNC mill, and LeBlonde manual lathe
This pulley was a part I was making for a larger project that my professor was working on.  This will be a lab demo illustrating mechanical advantage and the design efficiencies of different pulley systems.
This was the first project I worked on with the CNC vertical mill where all the tool pathes where generated by Mastercam.
Original solid works 3D model of pulley imported into Mastercam
Generating tool pathes for machining operations (tool path lines in blue, rapid feed moves in yellow.)
Mastercam verification of center drill operation to accurately locate center of hole.
Mastercam verification of reaming operation to accurately create diameter of 0.125" center hole.
mastercam verification of final pass remachining using 1/16" carbide endmill bit.
Mastercam verification of drilling operation using #32 drill bit.
Mastercam verification of rough pass machining inside pockets using 1/8" H.S.S. endmill bit.
Mastercam verification of 2D contour mill operation for outer profile using 1/8" H.S.S. endmill bit.
Isometric view of part geometry and tool pathes.
Isometric view of solid model of pulley.
Lathe fixture for cutting the pulley groove.  This fixture was made to fit in a 1.0" 5C collet in order to obtain reproducible centering of the fixture in the lathe.
Fixture for mounting the brass blank stock in the vice for the CNC vertical milling operation.  The top cap is used for holding the brass blank down for the final operation of cutting the outside profile of the pulley.
Both the CNC vertical mill fixture and the lathe fixture use the same end cap to secure the pulley blank for different operations.
The final product.  The pulley in brass before polishing.  About thirty 1.4" diameter pulleys made in all.