1. RFQ Cold model manufacture, June 2006 Peter Savage The Front End Test Stand Collaboration 1 OFC RFQ Cold Model Manufacture The first step is to convert the 3D parametric model into a 2D.iges file that the CAM software can read. The CAM software is then used offline to program the machining operations before finally being sent to the CNC controller.

2. RFQ Cold model manufacture, June 2006 Peter Savage The Front End Test Stand Collaboration 2 This screen snapshot shows the tool paths applied to the CAD model to create all the features on the outer face of the small quarter. The window to the right of the screen lists all the discreet operations required to machine the piece. OFC RFQ Cold Model Manufacture

3. RFQ Cold model manufacture, June 2006 Peter Savage The Front End Test Stand Collaboration 3 OFC RFQ Cold Model Manufacture The copper billet being prepared for machining. Here slots are being added to what will be the sides of the small quarter. These slots provide a clamping position that leaves the top surface unobstructed for machining.

4. RFQ Cold model manufacture, June 2006 Peter Savage The Front End Test Stand Collaboration 4 Outer face details of the small quarter have been completed. The end ports for RF coupling with their vacuum brazing slots can be seen. The edge pockets have been added to ease handling of this heavy but soft piece. OFC RFQ Cold Model Manufacture

5. RFQ Cold model manufacture, June 2006 Peter Savage The Front End Test Stand Collaboration 5 Overhead gantry crane being used to remove the small quarter from the CNC machine. At this stage the small quarter weighs approximately 50 kg. OFC RFQ Cold Model Manufacture

6. RFQ Cold model manufacture, June 2006 Peter Savage The Front End Test Stand Collaboration 6 End view showing the location of tool paths used to perform the vane roughing machining cycle on the small quarter. The tool used is an 80 mm diameter, carbide tipped shell mill. OFC RFQ Cold Model Manufacture

7. RFQ Cold model manufacture, June 2006 Peter Savage The Front End Test Stand Collaboration 7 Here the shell mill is being used to rapidly remove material to produce a stepped version of the final profile. The robust nature of this tool and the use of carbide tips allows for large depth of cuts and higher material removal rates. OFC RFQ Cold Model Manufacture

8. RFQ Cold model manufacture, June 2006 Peter Savage The Front End Test Stand Collaboration 8 End view showing the vane profile being machined on the small quarter using a 20mm diameter ball nose cutter. OFC RFQ Cold Model Manufacture

9. RFQ Cold model manufacture, June 2006 Peter Savage The Front End Test Stand Collaboration 9 Small quarter vane profiling nearing completion after a final machining pass with a depth of cut of 1mm, a step across distance of 0.2mm, a feed rate of 260mm/min - this complete cycle took a total of 32.5 hours. OFC RFQ Cold Model Manufacture

10. RFQ Cold model manufacture, June 2006 Peter Savage The Front End Test Stand Collaboration 10 The small quarter vane profile is complete. The next steps are to mill the braze slot and dowel holes and then finally to machine the vane end cutaways. OFC RFQ Cold Model Manufacture

11. RFQ Cold model manufacture, June 2006 Peter Savage The Front End Test Stand Collaboration 11 The completed tool paths shown here are for the machining of the large quarter side pockets. The blue lines represent the tool movement while cutting and the yellow lines represent rapid movement between cutting operations. This operation is large enough to require it’s own program file. OFC RFQ Cold Model Manufacture

12. RFQ Cold model manufacture, June 2006 Peter Savage The Front End Test Stand Collaboration 12 Outer face details of large quarter have been completed. The end ports are for RF coupling and the three holes around each RF port will lead to the cooling channels. The holes around the vacuum port are to accept a CF vacuum flange. OFC RFQ Cold Model Manufacture

13. RFQ Cold model manufacture, June 2006 Peter Savage The Front End Test Stand Collaboration 13 Rough profiling the large quarter has been completed. This involved two operations, first using the 80mm diameter shell mill to expose the tip of the vane, and second using a long series 25mm diameter carbide tipped tool to reach into the recesses. OFC RFQ Cold Model Manufacture

14. RFQ Cold model manufacture, June 2006 Peter Savage The Front End Test Stand Collaboration 14 Mid-way through the final vane profiling operation. The stripe to the left of the tool bears witness to the machining cycle being interrupted. This was caused by the PC automatically installing updates and forcing a restart while the code was being drip-fed to the CNC controller. OFC RFQ Cold Model Manufacture

15. RFQ Cold model manufacture, June 2006 Peter Savage The Front End Test Stand Collaboration 15 With vane profiling now complete, the quarters now require machining of the vane cutbacks that allow the RF current to re-circulate. OFC RFQ Cold Model Manufacture