For production machining, the 3 setps were combined into a single program with a M00 pause to flip the part. Due to earlier tool breakages and poor surface finish, very conservative feed speed were used and the initial machining time was at 18 minute per piece. Gradually the machine time was reduced to 15 minutes per part. Vibratory tumbling will be used to radius the edges and if necessary, secondary polishing.

First batch of bottle opener ready for deburring

First three batches of bottle opener. Machined, deburred, burnished, and electrochemically marked.

A two way solenoid valve was installed to control the opening and closing of the Royal 5C pneumatic collet closer with machine M code. Inside the Haas TL-2 control cabinet there are a few spare M-relays that can be used.

For the M-relay, the user has the option to choose between a normally open or normally closed circuit. A normally open circuit was chosen. The solenoid has a similar logic and a when de-energized, the solenoid default state will close the 5C chuck.

In the original configuration, the foot pedal actuates a two way valve that will open and close the chuck. That opening and closing fucntion has been taken over by the solenoid valve. However, a roller lever switch was added to the foot control pedal, wired in parallel to the M-code relay. This restores the opening and closing function to the foot pedal.

Way covers on X, Y, and Z axis removed.

Close up of the rails and ball screw

Deburring with the ceramic media on the left will remove the burrs an slightly radius the edges. Burnishing with the porcelain media on right will brighten the surface dulled by the deburring process.

3/8-3/8 Ceramic Triangle & 3/16-3/8 Porcelain Cut Cylinders

The mouth lip was modified for better clearance and the center cavity was removed to help speed up the machining process and the logo were modified to reflect the coarser resolution of electrochemical etching. The height was also reduce to better fit the raw stock height.

The shallow mouth opening has too steep of an angle and tends to peal the cap back. The mouth opening was elongated to give better leverage to lift the cap.

Raw Stock, Machined, Deburred Burnished & Etched

The mouth of the bottle opener was based off the dimensions of the can opener tool on a Leatherman Sideclip. A few laser cut acrylic prototypes were made to test the mouth geometry for bottle cap engagement.

The bottle opener in the foreground was the very first prototype drawn with a commercial 3d cad before switching over to FreeCAD.

Op1 and Op2 Completed

Op3 Completed after numerous unsuccessful attempts in the background.

Modify radius and location of head and tail holes for fixturing with socket screw during op3, machining of the profile.