Originally Posted by
Michael82
.....I know there is a simple way to do this and its right under my nose can someone help????
Quite correct there is a simple way.
1; Grip your part in the chuck with the other end supported in a center.
2; Zero the 4th axis and take one or more passes with a face mill to remove slightly less half the difference between your starting bar diameter and the finished size of your hex.
3; Index the 4th axis 60 degrees and repeat 2;
4; Repeat 3; until all six sides are done.
5; Measure the size accurately and run through the sequence again taking off whatever is needed to get the finished size.
Depending on what the starting material is don't be surprised if it warps like crazy.
If your boss really insists on seeing what a long piece of hex bar looks like give him an Allen Key and a big magnifying glass.
An open mind is a virtue...so long as all the common sense has not leaked out.